Web 00ELB0011
Web 00ELB0011
Web 00ELB0011
Shop Manual
chassis
GROUP INDEX
GENERAL ........................................ 00
CLUTCH ........................................... 21
MANUAL TRANSMISSION ............. 22
(EURO 3)
PROPELLER SHAFT....................... 25
Shop Manual FRONT AXLE................................... 26
REAR AXLE ..................................... 27
chassis WHEEL, TIRE................................... 31
FRONT SUSPENSION..................... 33
REAR SUSPENSION ...................... 34
FOREWORD BRAKE ............................................ 35
This Shop Manual is published for the information and
PARKING BRAKE ........................... 36
guidance of personnel responsible for maintenance of
Mitsubishi Fuso ROSA series buses, and includes proce- STEERING ....................................... 37
dures 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
FRAME ............................................. 41
HEATER, AIR-CONDITIONER,
no wastage. VENTILATION .................................. 55
For more details, please consult your nearest authorized
Mitsubishi Fuso dealer or distributors.
BODY ............................................... 63
Kindly note that the specifications and maintenance ser-
vice figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.
FEBRUARY 2013
Applicable models
BE
DIAGNOSIS CODES
1. Diagnosis Codes ........................................................................ 00-28
2. Access and Clearing of Stored Diagnosis Code.......................... 00-28
00-1
VEHICLE MODEL CODING SYSTEM
1 2 3 4 5 6 7 8 9 10 11
B E 6 3 D J L M S H
00-2
EQUIPMENT TYPE CODES LIST 00
Component Name plate marking Code description
Engine
4M50T7 4 M 5 0 T 7
Disc OD
Facing material (W: Woven)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the clutch
Transmission
M036S6 M 036 S 6
Forward speeds
Type of mesh (S: Synchromesh)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the transmission
Propeller shaft
P3 P 3
00-3
POWER TRAIN TABLE
Propeller Reduction &
Vehicle model Engine Clutch Transmission Front axle Rear axle
shaft Differential
BE63DJLMSHNF 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DELSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DGLSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DJLMSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
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
Service procedures
• Procedures for servicing components and parts off the vehicle are described centering on key points in their re-
moval, 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:
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 de-
struction of equipment or parts.
Standard value
• Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-
ance 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
Metric unit
SI unit
00-7
HOW TO READ THIS MANUAL
Illustrated Parts Breakdown and Service Procedures
Symbol Denotation Application Remarks
Specified values shown in table
Parts not tightened to standard torques
See Table of Standard Tightening Torques for
Tightening torque (standard torques specified where neces-
parts for which no tightening torques are speci-
sary for servicing)
fied.
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or Parts to be coated with lubricant or sealant Necessary lubricant and/or sealant, quantity re-
sealant for assembly or installation quired, etc. are specified in table.
Parts for which special tools are required for Tool name/shape and part number are shown in
Special tool
service operation table.
Parts associated with those removed/disas-
*a Associated part
sembled for servicing
00-8
00
00-9
HOW TO READ THIS MANUAL
How to Read Circuits (Electrical)
00-10
00
1.1 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.
1.2 Key number: A01 to Z99
• Key numbers indicate electrical equipment installation locations. The installation location of an electrical equip-
ment 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.
1.3 Part name
1.4 Connector type (type indication)
• A list of the connectors used is included in Gr54-14.
1.5 Connector terminal number
00-11
HOW TO READ THIS MANUAL
Wire color
Wire color Base color + tracer
Black/ Black/ Black/ Black/ Black/
BW BY BR Black/red BG BL BO
white yellow green blue orange
B Black
Black/ Black/ Black/
BP BV B Br
pink violet brown
Brown/ Brown/ Brown/ Brown/ Brown/ Brown/
BrW BrB BrY BrR BrG BrL
white black yellow red green blue
Br Brown
Brown/ Brown/
BrGr BrV
gray Violet
Green/ Green/ Green/ Green/ Green/ Green/
GW GR GY GB GL GO
white red yellow black blue orange
G Green
Green/ Green/ Green/
GGr GBr GV
gray brown violet
GrL, Gray/ GrR, Gray/ GrB, Gray/ GrG, Gray/ GrW, Gray/ Gray/
GrY
Gr, GyL blue GyR red GyB black GyG green GyW white yellow
Gray
Gy Gray/ Gray/
GrG GrBr
green brown
Blue/ Blue/ Blue/ Blue/ Blue/
LW LR Blue/red LY LB LO LG
white yellow black orange green
L Blue
Blue/
LGr Blue/gray LBr
brown
Light Light Light Light
Light
Lg LgR green/ LgY green/ LgB green/ LgW green/
green
red yellow black white
Orange/ Orange/ Orange/
O Orange OL OB OG
blue black green
Pink/ Pink/ Pink/ Pink/ Pink/
P Pink PB PG PL PW PGr Pink/gray PV
black green blue white violet
Pu Purple
Red/ Red/ Red/ Red/ Red/
RW RB RY RG RL Red/blue RO
white black yellow green orange
R Red
Red/ Red/
RBr Rgr
brown Gray
Sb Sky blue
Violet/yel- Violet/ Violet/ Violet/ Violet/
V Violet VY VW VR Violet/red VG VGr VB
low white green gray black
White/ White/ White/ White/ White/ White/
WR WB WL WG WO WV
red black blue green orange violet
W White
White/ White/
WBr WY
brown yellow
Yellow/ Yellow/ Yellow/ Yellow/ Yellow/ Yellow/
YR YB YG YL YW YO
red black green blue white orange
Y Yellow
Yellow/ Yellow/ Yellow/ Yellow/
YP YV YGr YBr
pink violet gray brown
00-12
00
M E M O
00-13
CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE
• Serial chassis (vehicle identification) and engine numbers are assigned to the vehicles and engines in manufac-
turing sequence. Every vehicle and engine has its own number. These numbers are required for registration and
related inspection of the vehicle.
• Chassis number <Type A>
J L B B E 6 3 D J C R
00-14
00
• Name plate contains the following information.
• MODEL
• CHASSIS No. <Type A>
• Engine model
• Vehicle identification number (VIN) <Type B>
00-15
PRECAUTIONS FOR MAINTENANCE OPERATION
1. General Precautions
• Before performing service operations, inquire into the customer’s complaints and ascertain the condition by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
on 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 dis-
assembled. Then, follow the service procedure given in this
manual.
• Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this man-
ual. Do not attempt to use other tools since they could
cause injuries and/or vehicle damage.
• Identify the weight of the item being lifted. Use the cable that
is strong enough to support the weight.
• If lifting eyes are not provided on the item being lifted, tie a ca-
ble around the item taking into account the item’s center of
gravity.
00-16
00
• Do not allow anyone to pass or stay under a lifted item which
may possibly fall.
• Inspect for oil leakage etc. before washing the vehicle. If the or-
der is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
• 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.
00-17
PRECAUTIONS FOR MAINTENANCE OPERATION
• When disassembling parts, visually check them for wear, cracks,
damage, deformation, deterioration, rust, corrosion, defective ro-
tation, fatigue, clogging and any other possible defect.
• 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 in-
spection or replacement. Immediately wipe away any excess oil
or grease with a rag.
00-18
00
2. Handling of Battery
2.1 Handling of battery cable
• Before working on the electrical system, disconnect the (–) bat-
tery cable 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 (–) termi-
nal 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.
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 op-
erate on the battery voltage.
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 circuit-
ry.
00-21
PRECAUTIONS FOR MAINTENANCE OPERATION
• Check for defective connections caused by loose terminals, by
rust on terminals, or by contamination of terminals by foreign
substances.
00-22
00
5. 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.
00-23
PRECAUTIONS FOR MAINTENANCE OPERATION
• Disconnect the battery cables before quick-charging the battery
with a quick charger.
Unless the battery cables are disconnected, quick-charging can
damage the diodes and regulator.
6. 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 re-
produced by performing the following checks on individual con-
nectors 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.
00-24
00
7. Precautions for Arc Welding
• When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless ap-
propriate 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 (–) cable of the welder is connected, might be
largely damaged.
7.2 Procedure
• Turn the starter switch to the LOCK position.
• Disconnect the battery’s (–) cable.
• Cover all parts of the vehicle that may be damaged by welding
sparks.
• Connect the welder’s (–) cable to the vehicle as close as possi-
ble to the area being welded. Do not connect the welder’s (–) ca-
ble to the cab if the frame is being welded, and vice versa.
• Set the welding current in accordance with the part being weld-
ed.
8. Precautions When Repainting
• When repainting, cover the following electronic control components with a masking material. If paint get on these
components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal
circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti-
lation holes.
• Engine electronic control unit and other electronic control units
• Sensors
00-25
JACKING UP THE VEHICLE
<Front of Vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Jack up the front of the vehicle with a bottle jack or garage jack.
3 Support the front of the vehicle frame on jack stands.
WARNING
• Chock the wheels firmly to prevent the vehicle from rolling away.
• Do not attempt to remove the chocks until the operation is completed.
• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the front of the vehicle frame on jack stands.
• Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed.
00-26
00
<Rear of Vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Jack up the rear of the vehicle using a bottle jack or garage jack as illustrated above.
3 Support the vehicle frame on jack stands on both sides.
WARNING
• Chock the wheels firmly to prevent the vehicle from rolling away.
• Do not attempt to remove the chocks until the operation is completed.
• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the vehicle frame on jack stands on both sides.
• Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed.
00-27
DIAGNOSIS CODES
1. Diagnosis Codes
• The diagnosis code indicates the faulty location(s) of the vehicle.
• Reading the diagnosis code(s) and performing the corresponding remedy (troubleshooting) repairs the faulty lo-
cation(s).
• Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to
be diagnosed.
• Using a Multi-Use Tester
• Flashing of warning on meter cluster
• The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in-
dividual systems.
FMS-E12-3 or
higher (Multi- Data transmission between V.C.I. and
PC
Use Tester-III PC
version)
00-28
00
Mark Tool name and shape Part No. Application
00-29
DIAGNOSIS CODES
(1.2) Inspection using the drive recorder function
• Move the starter switch to the LOCK position.
• Connect installed PC, , -A, -B and as
illustrated.
• Connect the cigarette lighter plug of -C with the cigarette
lighter socket.
• Connect the Multi-Use Tester connector with the connector of
-B.
00-30
00
2.2 Use of Warning Display for Diagnosis Code
(1) Engine control
• Using the diagnosis and memory clear switches, display diagnosis codes.
CAUTION
• Opening the memory clear switch followed by its reconnection will erase the stored diagnosis codes from
the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure de-
scribed below before handling diagnosis codes.
00-31
DIAGNOSIS CODES
(1.2) Present diagnosis codes
• Turn the starter switch ON.
• Open the diagnosis switch.
• Present diagnosis codes will be displayed by flashing of the
warning.
• When the diagnosis switch is connected, electronic control unit
will stop (terminate) displaying diagnosis codes.
00-32
00
M E M O
00-33
TABLE OF STANDARD TIGHTENING TORQUES
1. Tightening Torques
• Tightening torques are roughly classified into the following two categories:
Availability of
How to determine tightening
Tightening torque Definition torque specifica-
torque
tions in text
Locate a bolt or nut correspond-
Standard tightening Tightening torque determined according to thread
None ing to actual part in the following
torque size and material of bolts and nuts
standard tightening torque table.
Tightening torque of bolts and nuts other than those
Specified tightening Tightening torque is shown in
defined in “Standard tightening torque”, or that of Provided
torque the text.
bolts and nuts not identified in the following tables
• Fasteners used in a location denoted by “wet” should always be tightened in a wet condition (lubricated with en-
gine oil or grease). Any other fasteners than those so specified should be tightened in a dry condition.
(1) Hexagon head bolts and stud bolts (Unit: N·m {kgf·m})
Strength
4T 7T 8T
00-34
00
Strength
8.8 (Nut 4T) 8.8 (Nut 6T)
Strength
8.8 (Nut 4T) 8.8
00-35
TABLE OF STANDARD TIGHTENING TORQUES
(3) Hexagon nuts (Unit: N·m {kgf·m})
Strength
4T 6T (Bolt 7T) 6T (Bolt 8T)
00-36
00
(6) Tightening torques of nylon tubes for general air piping (DIN) (Unit: N·m {kgf·m})
Nominal diameter
6×1 10 × 1.25 12 × 1.5 15 × 1.5
× wall thickness mm
+6 +0.6 +10 +1.0 +10 +1.0 +5 +0.5
Tightening torque 20 0 {2.0 0 } 34 0 {3.5 0 } 49 0 {5.0 0 } 54 0 {5.5 0 }
(7) Tightening torques of nylon tubes for general air piping (SAE) (Unit: N·m {kgf·m})
Nominal diameter in. 1/4 3/8 1/2 5/8
+4 +0.4 +5 +0.5 +5 +0.5 +5 +0.5
Tightening torque 13 0 {1.3 0 } 29 0 {3.0 0 } 49 0 {5.0 0 } 64 0 {6.5 0 }
00-37
GROUP 21 CLUTCH
SPECIFICATIONS............................................................................... 21-2
TROUBLESHOOTING .......................................................................21-11
21-1
SPECIFICATIONS
Item Specifications
Clutch model C5W33
Drive type Strap drive
Clutch disc type Dry, single plate type
Pressure plate type Diaphragm spring type
Control system Fluid and vacuum pressure type
Clutch master cylinder manufacturer NISSIN KOGYO
Clutch booster Bosch
Direct power cylinder manufacturer NISSIN KOGYO
21-2
STRUCTURE AND OPERATION 21
1. Clutch Control
21-3
STRUCTURE AND OPERATION
2. Clutch Booster and Clutch Master Cylinder
2.1 Clutch booster
• The clutch booster magnifies the stepping force applied onto the clutch pedal (therefore reduces the operator’s
pedal effort) through the utilization of pressure difference between the vacuum it generates and the atmospheric
pressure.
21-4
21
(1) When clutch pedal is depressed
• With the clutch pedal released and no
stepping force applied to the clutch
pedal, the operating rod and the valve
plunger are held to the left by the force
of the valve return spring. The atmo-
spheric pressure valve remains closed
while the vacuum valve remains open.
• The vacuum pump creates vacuum in
chamber A. As the atmospheric pres-
sure valve is closed, no outside air
flows into chamber B. Instead, vacu-
um in chamber A flows through the air
passage and into chamber B. Cham-
bers A and B are both filled with vacu-
um, and there is no pressure
difference between the chambers. No
boosting occurs.
21-5
STRUCTURE AND OPERATION
(2) When clutch pedal is released
• With the clutch pedal depressed,
chamber A is filled with vacuum gener-
ated by the vacuum pump while cham-
ber B is open to the atmosphere.
When the clutch 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.
21-6
21
2.2 Clutch master cylinder
21-7
STRUCTURE AND OPERATION
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.
21-8
21
3.1 When clutch pedal is released
or engaging the clutch
• There is no 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.
21-9
STRUCTURE AND OPERATION
3.3 When clutch disc wear limit
• As the clutch disc approaches to its
wear limit, the release bearing is
pushed by the inner edge of the dia-
phragm spring in the direction of the
arrow shown in the illustration.
• The wear limit will be reached when
the flanged section of the release
bearing comes in contact with the
stepped section of the rod.
21-10
TROUBLESHOOTING 21
Symptoms
Clutch slips
Possible causes
Diaphragm spring heights uneven O O O O
Diaphragm spring fatigued O O
Clutch cover Pressure plate warped or faulty O O O O
Loose rivets O O O
Strap plate bent O O O O
Disc deformed O O O
Disc rivets loose O O
Disc torsion spring fatigued or damaged O
Spline worn O O O
Clutch disc
Spline rusted O O O
Facing worn O
Facing surface hardened O O O
Facing oily or greasy O O
Pedal free play insufficient O O
Pedal free play excessive O O
Clutch pedal
Pedal stroke insufficient O
Pedal sliding part faulty O O O
Spring fatigued O
Brake fluid passage port clogged O O O
Clutch booster
Vacuum pressure reduced O
Malfunction O
Piston and pressure cup sliding movement
O O O O
faulty
Clutch master cylinder
Spring fatigued O
Brake fluid passage port clogged O O O O
Piston and piston cup sliding movement
O O O O
faulty
Direct power cylinder
Brake fluid passage port clogged O O O O
Release bearing faulty O O O
Transmission drive pinion spline worn O O Gr22
Engine idling speed too low O O Gr13
Engine mounting fatigued O
Flywheel warped, deformed or worn forming steps O O O O Gr11
Flywheel pilot bearing faulty O
Air mixed in clutch hydraulic system O
Clutch hydraulic system leaking O
21-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Brake Fluid Level
• Check that brake fluid level in the brake fluid tank is between
“MAX” and “MIN”.
• If the fluid level is lower than “MIN”, replenish the brake fluid.
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 dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter 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 prop-
erties or mineral oil enter into the system.
21-12
21
2.1 Work before replacement
• Start the engine and keep it running at idle until finishing the re-
placement to ensure that vacuum booster functions properly.
• Install one end of a vinyl pipe onto the bleeder screw. Place the
loose end into a container.
21-13
ON-VEHICLE INSPECTION AND ADJUSTMENT
2.2 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.
Finish
21-14
21
3. 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 proce-
dures for the brake system (See Gr35.)
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 dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter 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 prop-
erties or mineral oil enter into the system.
21-15
ON-VEHICLE INSPECTION AND ADJUSTMENT
3.2 Air bleeding of brake fluid
• Bleed the air in the following sequence.
Finish
21-16
21
4. Inspection of Clutch Booster
4.1 Operation
• Depress the clutch pedal several times. Make negative pressure
be zero.
• Start the engine and keep it running at idle with depressing the
pedal slightly.
A little while later, check the pedal sinks slightly.
• If the pedal doesn’t sink, replace the clutch booster.
21-17
ON-VEHICLE INSPECTION AND ADJUSTMENT
6. Inspection and Adjustment of Clutch Pedal
• Perform inspection and adjustment of clutch pedal after finishing air bleeding in clutch system.
[Adjustment]
• Loosen the lock nut of the clutch booster operating rod and turn
the rod to adjust the installed height of the clutch pedal.
• Retighten the lock nut to the specified torque.
• After tightening the lock nut, inspect the clutch pedal play and
the clearance between the clutch switch and clutch pedal.
21-18
21
M E M O
21-19
CLUTCH PEDAL
Disassembly sequence
1 Fluid hose 8 Collar
2 Pipe 9 Bushing
3 Vacuum hose 10 Bushing
4 Clevis pin 11 Pedal pad
5 Clutch booster and clutch master cylinder 12 Clutch pedal
(See later section.) 13 Clutch pedal support
6 Clutch switch
7 Return spring : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
• Perform inspection and adjustment of clutch pedal after installation. (See “ON-VEHICLE INSPECTION AND AD-
JUSTMENT”.)
21-20
21
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Clevis pin Chassis grease
As required
Inner surface of collar [NLGI No. 1 (Li soap)]
21-21
CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER
Disassembly sequence
1 Piston
2 Clip
3 Packing
4 Union collar
5 Cylinder body
6 Clutch booster
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.
Removal procedure
Removal: Piston
• Close the opening A and cover with a cloth the cylinder bore end
from which the piston is to be removed.
• Apply compressed air to the cylinder while slowly increasing its
pressure from 0 kPa {0 kgf/cm2} to force out the piston.
WARNING
• Do not apply high-pressure compressed air suddenly. Oth-
erwise, the piston will fly out with full force.
21-22
21
Installation: Clutch master cylinder and clutch booster
• Measure the indicated dimensions A and B on the clutch master
cylinder.
• After the adjustment, apply grease to the push rod end and
sealed portion of clutch booster.
21-23
CLUTCH HOSE
Removal sequence
1 Eyebolt
2 Clutch hose
*a: Connector
*b:: Clutch housing
Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
Cap nut
Prevention of brake fluid leakage
A B ME538216
when removing brake hose
16 M12 × 1.25
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 when loosening the eyebolt.
Otherwise, the connection between the connector and the
clutch direct power cylinder may loosen.
21-24
21
• Release the clutch hose together with the eyebolt and the gas-
kets from the connector, quickly fit to the eyebolt, and tight-
en it so that the brake fluid would not leak from this end. The
fluid leak from the connector is ignorable, so just receive it by the
container.
CAUTION
• Loosening the eyebolt causes the brake fluid to leak. Work
quickly.
Installation procedure
Installation: Clutch hose
• Install the clutch hose by following the removal procedure in re-
verse. (See “ Removal: Clutch hose”.)
• After the 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 ten-
sion to or twist it.
21-25
CLUTCH PROPER
Removal sequence
1 Clutch cover
2 Clutch disc
*a: 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.
21-26
21
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
Sleeve
Checking diaphragm spring for in-
A B MH061425
stalled height
φ45 φ28.94
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 straight edge 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 mea-
sured.
• If the flatness does not conform to the standard value, replace
the clutch cover.
21-27
CLUTCH PROPER
(2) Inspection of diaphragm spring
• Inspect the diaphragm spring for play.
• If the spring has play, the clutch cover needs to be replaced.
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.
21-28
21
M E M O
21-29
CLUTCH CONTROL
Removal sequence
1 Connector 6 Oil seal
2 Grommet 7 Dust plug
3 Bleeder cap 8 Bracket
4 Bleeder screw
5 Direct power cylinder
(See later section.)
*a:: Clutch housing
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.
21-30
21
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Connector 40 {4.1} –
Nut (bleeder hose mounting) 51 to 60 {5.0 to 5.9} –
Bolt (direct power cylinder mounting) 44.5 {4.5} –
Bleeder screw 6.8 to 8.8 {0.7 to 0.9} –
Nut (bracket mounting) 38 to 54 {3.9 to 5.5} –
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.
21-31
CLUTCH CONTROL
Direct Power Cylinder
Disassembly sequence
1 Snap ring 10 Outer cup
2 Release bearing 11 Piston
3 Oil seal 12 Bleeder
4 Rear spring stopper 13 Rod
5 Front spring stopper 14 Cylinder body A
6 Boots 15 O-ring
7 Spring 16 Cylinder body B
8 Front inner cup
9 Rear inner cup : Non-reusable parts
CAUTION
• Remove the bleeder only when cylinder body A is being replaced. Because removing the bleeder may
cause the thread deformation of the cylinder body A. Therefore you must replace the cylinder body A
when removing the bleeder once. Reusing the body causes oil leak.
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 dis-
lodged. An incorrectly installed piston causes brake fluid leakage and clutch drag.
21-32
21
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (cylinder bodies A, B and rod mounting) 6.8 to 8.8 {0.7 to 0.9} –
Bleeder hose 15.7 to 17.6 {1.6 to 1.8} –
Removal procedure
Removal: Piston
• With the bleeder hose 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.
21-33
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 cor-
rectly, 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.
21-34
GROUP 22 MANUAL TRANSMISSION
MAINSHAFT......................................... 22-50
22-1
SPECIFICATIONS
Item Specifications
Transmission model M036S6 (5.175/0.669)
1st 5.175
2nd 2.913
3rd 1.682
Gear ratio 4th 1.000
5th 0.793
6th 0.669
Rev 5.175
Gear oil API GL-3, GL-4
Classification
Engine oil API CC
GL-3
General 80
GL-4
Transmission Viscosity (applica-
oil Warm GL-3 90
tion/SAE viscosi-
ty number) Tropical GL-4 90
Long period
CC 30 or 40
of high-speed
Quantity dm3 {L} Approx. 4.4 {4.4}
Mass kg Approx. 100
Mode of control Floor shift remote control
• Transmission oil depends on the driving conditions.
22-2
STRUCTURE AND OPERATION 22
1. Transmission
• The transmission changes revolution and torque generated by the engine into those that match the vehicle’s pow-
er requirement (driving force). The power requirement (driving force) is increased or decreased by making a se-
lection from several sets of engaged gears.
• 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 Reverse, 1st, 4th, 5th, 6th
Triple cone type 2nd, 3rd
• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the syn-
chronizer 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 the
protrusions of the synchronizer rings.
• Synchronizer rings rotate relative to the synchronizer sleeve by the amount of play (width difference).
• 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 synchro-
nous 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).
22-4
22
2.2 Triple cone type
The following descriptions are for 3rd 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 syn-
chronizer 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 syn-
chronizer 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 the 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 addi-
tion, 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 synchro-
nous 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
Identification
A B C D L E F G
mark
Number of
15 16 17 18 19 20 21 22
teeth
Gear ratio 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4
22-6
TROUBLESHOOTING 22
Symptoms
Possible causes
Mainshaft rear lock nut loose O O
Mainshaft thrust washer worn O O
Mainshaft bearing worn or damaged O O
Synchronizer ring and synchronizer sleeve spline worn O
Synchronizer ring and gears taper cone area worn O
Mainshaft pilot bearing worn or damaged O O
Transmission Drive pinion bearing worn or damaged O
body faulty Countershaft bearing worn or damaged O
Needle bearings of gears worn or damaged O O
Mainshaft and countershaft gears worn or damaged O
Mainshaft and countershaft gears backlash excessive O
Spline of gears worn O
Gears damaged O
Transmission oil insufficient O
Clutch disengagement faulty O O Gr21
Clutch faulty
Clutch pedal play faulty O
Contacting surface of synchronizer
Single cone type O O
ring and gear taper cone worn
Contacting surface of synchronizer in-
ner and outer rings and center cone O O
Triple cone type worn
Synchronizer Contacting surface of synchronizer in-
O O
faulty ner ring and gear taper cone worn
Synchronizer ring spline chamfer worn O
Shifting key worn O
Shifting key spring deteriorated or damaged O
Synchronizer sleeve worn or damaged O O
Control rod joint play O O
Control rod joint lubricated in insufficiently O
Control rod length adjusted incorrectly O
Control rod bent O
Control mecha- Bushings worn O O
nisms faulty Steel ball and groove of shift rail worn O
Poppet spring of shift rail fatigued or damaged O
Shift rail sliding movement faulty O
Shift fork jaws worn O
Shift fork bent O
22-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection of Transmission Oil Leakage
1.1 Inspection of oil leakage at each part of transmis-
sion body
• Check the oil leakage at each part of transmission body in visu-
al. If the oil leakage is found, replace the defective part.
22-8
22
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
mainshaft.
• If excessive play is detected, remove the propeller shaft, then
check the lock nut for looseness and the splines on companion
flange and mainshaft for abnormalities. If any part is found de-
fective, replace the part. (See “EXTENSION HOUSING AND
PARKING BRAKE”.)
22-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
4. Inspection and Replacement of Transmission Oil
WARNING
• Temperature of transmission oil is high immediately after driving. Perform work when oil is cold.
[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.
[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.
22-10
22
M E M O
22-11
REMOVAL AND INSTALLATION OF TRANSMISSION
Removal sequence
1 Engine speed sensor
2 O-ring
3 Propeller shaft (See Gr25.)
4 Parking brake cable (See Gr36.)
5 Transmission
6 U-bracket
7 Insulator
8 Transmission mounting bracket
: Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
22-12
22
Removal procedure
Removal: Transmission
• Support the transmission on the transmission jack.
• Ensure that the harnesses, piping and other relevant parts have
been disconnected.
• Remove transmission mounting bolts.
Installation procedure
Installation: Insulator
• Install the insulator on the transmission mounting bracket in the
illustrated direction.
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 can drip and cause clutch
slip.
22-13
REMOVAL AND INSTALLATION OF TRANSMISSION
[Applying sealant]
• Apply sealant to the clutch housing side of the transmission
while observing the following cautions and then engage the
transmission with the engine.
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 ex-
tremely different at each part.
• The applied sealant has some breaks.
• The applied sealant covers the bleeding hole of the
clutch housing and engine parts.
[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 trans-
mission.
• When loosening or removing transmission mounting bolts, be
sure to reapply the sealant.
22-14
22
M E M O
22-15
GEAR SHIFTER UPPER
Removal sequence
1 Gear shifter upper
(See later section.)
2 Poppet spring plate
3 Poppet spring <Except 4th and
5th>
4 Poppet spring <4th and 5th>
5 Steel ball
6 Backup lamp switch
7 Torque limit switch
8 Stopper plate
9 Interlock plate
Installation sequence
Follow the removal sequence in reverse.
22-16
22
Installation procedure
Installation: Gear shifter upper
[Applying sealant]
• Apply sealant to the transmission case side while observing the
following cautions and then engage the gear shifter upper with
the transmission.
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 ex-
tremely different at each part.
• The applied sealant has some breaks.
[Installation]
• After applying the sealant, install the gear shifter upper before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• 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.
22-17
GEAR SHIFTER UPPER
Gear Shifter Upper
Disassembly sequence
1 Air breather 9 Spring retainer 17 Oil seal
2 Neutral switch 10 Gear shift sliding lever 18 Bushing
3 Spring pin 11 Spring retainer 19 Oil seal
4 Torsion shaft 12 Return spring 20 Selector lever case
5 Steel ball 13 Lock pin
6 Poppet spring 14 Gear selector lever : Non-reusable parts
7 Return spring 15 Washer
8 Return spring 16 Gear selector lever
NOTE
• Do not remove bushing except for replacement.
Assembly sequence
Follow the disassembly sequence in reverse.
22-18
22
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Poppet spring installed load 20 ± 1 N 14 N
6 Replace
(installed length 14) {2.08 ± 0.1 kgf} {1.5 kgf}
Return spring installed load 31 ± 1.6 N 22N
7 Replace
(installed length 16.7) {3.2 ± 0.16 kgf} {2.2 kgf}
Return spring installed load 38.1 ± 1.9 N 27 N
8 Replace
(installed length 16.7) {3.9 ± 0.2 kgf} {2.7 kgf}
Return spring installed load 80.5 ± 4.0 N 56 N
12 Replace
(installed length 27) {8.2 ± 0.4 kgf} {5.7 kgf}
A MH062445
M12 × 1.25
A 03726-82000
M12 × 1.25
22-19
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.
Removal: Bushing
• Remove the bushing using a screwdriver.
CAUTION
• Be careful not to damage the selector lever case.
22-20
22
Installation procedure
Installation: Bushing
• Clean the bushing and bushing mounting surface of the selector
lever case.
• Apply grease to the inner surface of the bushing and sealant to
its outer surface.
NOTE
• Do not allow sealant to adhere to the inner surface of the
bushing.
22-21
EXTENSION HOUSING AND PARKING BRAKE
Disassembly sequence
1 Drain plug 9 L-joint 18 Speedometer worm
2 O-ring 10 Spring pin 19 Bearing
3 Dust plug 11 Speedometer gear 20 Bearing retainer
4 Parking brake drum 12 O-ring 21 Distance pipe
(See Gr36.) 13 Oil seal
5 Companion flange 14 Speedometer gear bushing : Locating pin
6 Reamer bolt 15 Lever set bolt : Non-reusable parts
7 Parking brake (See Gr36.) 16 Oil seal
8 Vehicle speed sensor 17 Extension housing
Assembly sequence
Follow the disassembly sequence in reverse.
22-22
22
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Lock nut 245 to 343 {25 to 35} –
Reamer bolt 52 to 66.7 {5.3 to 6.8} –
Vehicle speed sensor 14.7 to 29.4 {1.5 to 3.0} –
L-joint 34 to 39 {3.5 to 4.0} –
Bolt (speedometer gear bushing mounting) 23.5 {2.4} –
Bolt (extension housing mounting) 44.5 {4.5} –
Lever set bolt 160 {16.3} Sealant
Drain plug 68.6 ± 14.7 {7.0 ± 1.5} Sealant
Flange puller
22-23
EXTENSION HOUSING AND PARKING BRAKE
Removal procedure
Removal: 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 measured value exceeds the limit, replace the 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 extension housing in the illustrated di-
rection.
• After installation, apply grease to the lip area of the oil seal.
22-24
22
Installation: Extension housing
[Applying sealant]
• Apply sealant while observing the following cautions and then
engage the extension housing with the transmission.
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 ex-
tremely different at each part.
• The applied sealant has some breaks.
[Installation]
• After applying the sealant, install the extension housing before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the exten-
sion housing.
• When loosening or removing extension housing mounting bolts,
be sure to reapply the sealant.
22-25
EXTENSION HOUSING AND PARKING BRAKE
Installation: Spring pin
• Install the spring pin in the illustrated direction to prevent the
speedometer gear from slipping off.
22-26
22
M E M O
22-27
REVERSE IDLER GEAR
Disassembly sequence
1 Power take-off cover 5 Side washer
2 Reverse idler gear shaft
3 Side washer
*a: Transmission case
4 Reverse idler gear : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
22-28
22
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
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.
22-29
REVERSE IDLER GEAR
Installation procedure
Installation: Power take-off cover
[Applying sealant]
• Apply sealant to the transmission case side while observing the
following cautions and then engage the power take-off cover
with the transmission.
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 ex-
tremely different at each part.
• The applied sealant has some breaks.
[Installation]
• After applying the sealant, install the power take-off cover before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• 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.
22-30
22
M E M O
22-31
6TH GEAR
Disassembly sequence
1 Spring pin 8 Shifting plunger 15 Snap ring
2 6th shift rail jaw B 9 Shifting plunger spring 16 Countershaft rear bearing
3 6th reverse lever 10 Synchronizer hub 17 Mainshaft 6th gear
4 Gear shift fork piece 11 Countershaft 6th gear
5 Shifting key retainer 12 Needle bearing
*a: Countershaft
6 Synchronizer ring 13 Countershaft 6th gear sleeve : Non-reusable parts
7 Synchronizer sleeve 14 Thrust washer
Assembly sequence
Follow the disassembly sequence in reverse.
22-32
22
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
End play of countershaft 6th gear 0.25 to 0.35 0.7 Replace
–
Play of countershaft 6th gear in diameter direction 0.08 to 0.14 0.2 Replace
Clearance between 6th gear shift fork piece and syn-
4, 7 0.3 to 0.6 1.0 Replace
chronizer sleeve
Clearance between protrusion of synchronizer ring and
6, 10 3.0 to 3.3 4.0 Replace
synchronizer hub groove
Clearance between synchronizer ring and countershaft
6, 11 1.23 to 1.47 0.5 Replace
6th gear
MH062696
Bearing puller and in-
staller
Installation of countershaft 6th gear
A B C sleeve
φ80 φ56 φ45.5
22-33
6TH GEAR
Inspection: Play of countershaft 6th gear in diameter direc-
tion
• If the measurement exceeds the limit, replace defective parts.
Removal procedure
Removal: Countershaft 6th gear sleeve, thrust washer and
countershaft rear bearing
• Remove the countershaft rear bearing together with the sleeve
and washer.
Inspection procedure
Inspection: Clearance between gear shift fork piece and
synchronizer sleeve of mainshaft
• If the measurement exceeds the limit, replace defective parts.
22-34
22
Inspection: Clearance between synchronizer ring and syn-
chronizer hub
• If the clearance exceeds the limit, replace defective parts.
Installation procedure
Installation: Countershaft rear bearing
• Install the countershaft rear bearing on the countershaft in the il-
lustrated direction.
22-35
6TH GEAR
Installation: Gear shift fork piece
• Install the gear shift fork piece on the reverse lever as shown in
the illustration after checking that its shaft diameter is appropri-
ate.
CAUTION
• Never fail to check the shaft diameter of the gear shift fork
piece. Installation of any gear shift fork piece with a smaller
diameter shaft is possible but not permitted.
22-36
22
M E M O
22-37
TRANSMISSION BODY
Disassembly sequence
1 Inspection plug 10 Shift rail and shift fork (See later section.)
2 Drain plug 11 Countershaft (See later section.)
3 Direct power cylinder (See Gr21.) 12 Drive pinion (See later section.)
4 Lever set bolt 13 Mainshaft (See later section.)
5 Rear bearing retainer 14 Clutch housing
6 Snap ring
7 Mainshaft rear bearing : Locating pin
8 Transmission case : Non-reusable parts
9 Bearing retainer
NOTE
• After removing direct power cylinder, perform work with the transmission body laid vertically on its clutch
housing side.
• If the countershaft, drive pinion and mainshaft are not disassembled, the shift rail and shift fork can be
disassembled on its own while mounted on the clutch housing.
22-38
22
Assembly sequence
Follow the disassembly sequence in reverse.
22-39
TRANSMISSION BODY
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
MH062697
Bearing puller and in-
staller
φ94 φ48
Eyebolt
Eye nut
A MH063308
M24 × 1.5
Synchromesh guard
A B
For preventing synchromesh from
98 30.9 MH062889
sticking when mainshaft is driven
22-40
22
Removal procedure
Removal: Mainshaft rear bearing
• Secure the countershaft and the 2nd gear area of the mainshaft
with for safety. Be sure to tighten enough to prevent it
from coming undone, but not excessively.
22-41
TRANSMISSION BODY
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 hit-
ting 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 pin-
ion and mainshaft
• When driving in the drive pinion, mainshaft and countershaft, in-
stall 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.
22-42
22
[Installation]
• After applying the sealant, install the transmission case before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the trans-
mission case.
• When loosening or removing transmission case mounting bolts,
be sure to reapply the sealant.
22-43
TRANSMISSION BODY
Shift Rail and Shift Fork
Disassembly sequence
1 Spring pin 10 Gear shift fork piece 19 4th and 5th shift jaw B
2 6th shift jaw 11 Spring pin 20 4th and 5th shift rail
3 6th shift rail 12 Spring pin 21 4th and 5th reverse lever
4 Spring pin 13 2nd and 3rd shift jaw 22 Gear shift fork piece
5 Spring pin 14 2nd and 3rd shift fork
6
7
1st and reverse shift jaw B
1st and reverse shift jaw A
15
16
2nd and 3rd shift rail
Spring pin
*a: Mainshaft (Synchronizer
sleeve)
8 1st and reverse shift rail 17 Spring pin : Non-reusable parts
9 1st and reverse lever 18 4th and 5th shift jaw A
Assembly sequence
Follow the disassembly sequence in reverse.
22-44
22
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
3, 8, 15, Correct or
Bend of shift rail 0 to 0.04 0.05
20 replace
10, 22, Clearance between gear shift fork piece and synchro-
0.3 to 0.6 1.0 Replace
*a nizer sleeve
14 Tilt of 2nd and 3rd gear shift fork claw 0 to 0.1 0.2 Replace
Clearance between 2nd and 3rd gear shift fork and syn-
*
14, a
chronizer sleeve of mainshaft
0.3 to 0.6 1.0 Replace
Inspection procedure
Inspection: Bend of gear shift rail
• Measure the extent of bending at the middle of each of gear shift
rail.
• While rotating the gear shift rail by one revolution, read how
much the dial gauge needle will move. A half of the reading ob-
served represents the bend, if any, of the shaft.
• If the measurement exceeds the limit, replace the gear shift rail.
22-45
TRANSMISSION BODY
Installation procedure
Installation: Gear shift fork piece
• Install the gear shift fork piece on the reverse lever as shown in
the illustration after checking that its shaft diameter is appropri-
ate.
Shaft portion diameter (mm)
1st & Rev 10
4th & 5th 15
CAUTION
• Never fail to check the shaft diameter of the gear shift fork
piece. Installation of any gear shift fork piece with a smaller
diameter shaft is possible but not permitted.
Installation: 1st and reverse lever, 4th and 5th reverse lever
• Place the synchronizer sleeve of mainshaft in neutral position
before installing the reverse lever on the mainshaft.
22-46
22
M E M O
22-47
DRIVE PINION
Disassembly sequence
1 Snap ring
2 Drive pinion bearing
3 Drive pinion
Assembly sequence
Follow the disassembly sequence in re-
verse.
MH062697
φ94 φ48
22-48
22
Removal procedure
Removal: Drive pinion bearing
Installation procedure
Installation: Drive pinion bearing
• Install the drive pinion bearing, facing the grooved side in the il-
lustrated direction.
22-49
MAINSHAFT
Disassembly sequence
1 1st gear thrust washer 13 Needle bearing
2 1st gear 14 Snap ring
3 Needle bearing 15 3rd gear thrust washer
4 Snap ring 16 3rd gear
5 1st and reverse synchronizer (See later section.) 17 Needle bearing
6 Reverse gear 18 Snap ring
7 Needle bearing 19 2nd and 3rd synchronizer (See later section.)
8 Snap ring 20 2nd gear
9 Pilot bearing 21 Needle bearing
10 Snap ring 22 Mainshaft
11 4th and 5th synchronizer (See later section.)
12 5th gear
*a: Drive pinion
Assembly sequence
Follow the disassembly sequence in reverse.
22-50
22
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
1st gear 0.15 to 0.46 0.7
2nd gear 0.15 to 0.61 0.8
– End play 3rd gear 0.15 to 0.46 0.7 Replace
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
Play in the diameter
– 3rd gear 0.02 to 0.06 0.12 Replace
direction
5th gear 0.05 to 0.09 0.2
Reverse gear 0.04 to 0.07 0.12
1st gear and synchronizer ring of
1.23 to 1.47 0.5 Replace
1st and reverse synchronizer
Reverse gear and synchronizer
ring of 1st and reverse synchro- 1.23 to 1.47 0.5 Replace
nizer
Clearance 5th gear and synchronizer ring of
1.23 to 1.47 0.5 Replace
– between gear and 4th and 5th synchronizer
synchronizer ring Drive pinion and synchronizer ring
1.23 to 1.47 0.5 Replace
of 4th and 5th synchronizer
3rd gear and synchronizer ring of
0.96 to 1.54 0.5 Replace
2nd and 3rd synchronizer
2nd gear and synchronizer ring of
0.96 to 1.54 0.5 Replace
2nd and 3rd synchronizer
9 Play of pilot bearing in the diameter direction 0.04 to 0.08 0.12 Replace
Special tools
Mark Tool name and shape Part No. Application
22-51
MAINSHAFT
Inspection: Play in diameter direction of each gears
• If the measurement exceeds the limit, replace defective parts.
Inspection procedure
Inspection: Clearance between gear and synchronizer ring
of synchronizer
<Triple cone type>
• When measuring the clearance, press the ring and the center
cone evenly against the gear and measure all around the cir-
cumference.
• If the measurement is less than the limit, replace the ring and
gear or the drive pinion.
22-52
22
M E M O
22-53
MAINSHAFT
2nd and 3rd Synchronizer
Disassembly sequence
1 Synchronizer inner ring
2 Synchronizer center cone
3 Synchronizer outer ring
4 Synchronizer sleeve
5 Shifting plunger
6 Shifting plunger spring
7 Synchronizer hub
Assembly sequence
Follow the disassembly sequence in re-
verse.
Inspection procedure
Inspection: Clearance between synchronizer outer ring pro-
trusion and synchronizer hub groove
• If the clearance exceeds the limit, replace defective parts.
22-54
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.
22-55
MAINSHAFT
1st and Reverse, 4th and 5th Synchronizer
Disassembly sequence
1 Synchronizer ring
2 Synchronizer sleeve
3 Shifting plunger
4 Shifting plunger spring
5 Synchronizer hub
Assembly sequence
Follow the disassembly sequence in re-
verse.
Inspection procedure
Inspection: Clearance between synchronizer ring protru-
sion and synchronizer hub groove
• If the clearance exceeds the limit, replace defective parts.
22-56
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.
22-57
COUNTERSHAFT
Disassembly sequence
1 Snap ring
2 Countershaft front bearing
3 Countershaft gear
Assembly sequence
Follow the disassembly sequence in re-
verse.
MH062696
Bearing puller and in-
staller
Installation of countershaft front bear-
A B ing
φ80 φ42
22-58
22
Removal procedure
Removal: Countershaft front bearing
Installation procedure
Installation: Countershaft front bearing
• Install the countershaft front bearing on the countershaft in the il-
lustrated direction.
22-59
TRANSMISSION CONTROL
Removal sequence
1 Gear shift lever cover 13 Lever (See later section.) 24 No. 2 select lever
2 Gear shift lever knob 14 Select rod No. 3 (See later section.)
3 Gear shift lever boot 15 Spacer 25 No. 3 select lever
4 Bracket 16 Bushing (See later section.)
5 Ball joint 17 Select rod No. 4 26 Cross shaft bushing
6 Grommet 18 Spacer 27 Cross shaft boot
7 Gear shift lever 19 Bushing 28 Cross shaft
(See later section.) 20 Shift rod No. 3 29 Cross shaft bracket
8 Hose 21 Spacer
9 Select rod No. 1 22 Bushing
*a: Torsion shaft
10 Shift rod No. 1 23 No. 2 shift lever
*b: Gear select lever
11 Shift rod No. 2 (See later section.) : Non-reusable parts
12 Select rod No. 2
22-60
22
Installation sequence
Follow the removal sequence in reverse.
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.
22-61
TRANSMISSION CONTROL
Installation: Shift rod No. 1 and No. 2 and select rod No. 1
and No. 2
• Install each shift rod and select rod with the dimension shown in
the drawing.
• Position the ball joints on both ends so that their relative installa-
tion angle become as shown in the table below.
Shift rod No. 1 180° ± 2°
Shift rod No. 2 0° ± 2°
Select rod No. 1 90° ± 2°
Select rod No. 2 180° ± 2°
22-62
22
Work after installation
Inspection: Gear shift lever
[Inspection]
• With the gearshift lever in the neutral position, check that the dis-
tances specified below meet the standard values in the following
table.
Fore-and-aft direction C : Distance from instrument panel
Right-and-left direction D: Distance from the center of the
steering wheel:
To the 4th-5th line on the gear shift le-
ver knob
[Adjustment]
• With the torsion shaft of transmission and gear select lever in
their neutral positions, adjust the shift rod No. 3 and select rod
No. 4 using the turnbuckles on the transmission side so that
neutral position of gear shift lever is as specified below.
• Make sure to operate the gear shift lever that it shifts smoothly
and selects each position.
22-63
TRANSMISSION CONTROL
Gear Shift Lever
Disassembly sequence
1 Shift lever
2 Spacer
3 Wave washer
4 Collar
5 Bushing
6 Spacer
7 Return spring
8 Collar
9 Bushing
10 Cross sleeve
11 Plate
Assembly sequence
Follow the disassembly sequence in re-
verse.
Installation procedure
Installation: Cross sleeve
• Assemble the cross sleeve and plate and tighten the nut to the
specified value. Measure the clearance between the cross
sleeve and plate. If the measurement is out of the dimension
shown in the drawing, adjust by spacer.
• After installation, make sure that the shift lever operates smooth-
ly without hesitation.
Spacer thickness: 0.3 mm and 0.5 mm (2 types)
22-64
22
Installation: Shift lever
• Temporarily assemble the shift lever and cross sleeve with no
wave washers and tighten the nut to the specified torque. Mea-
sure the clearance between the shift lever and cross sleeve. Se-
lect an appropriate spacer to make the clearance to the
dimension shown in the drawing. Reassemble the shift lever and
cross sleeve with the selected spacer and two wave washers in-
stalled.
Spacer thickness: 0.3 mm and 0.5 mm (2 types)
22-65
TRANSMISSION CONTROL
Lever
Disassembly sequence
1 Return spring
2 Lever bracket A
3 Lever bracket B
4 Bushing
5 Dust boot
6 Cover
7 Lock pin
8 Lever
9 Spacer
10 Bushing
11 No. 1 lever B
12 No. 1 lever A
Assembly sequence
Follow the disassembly sequence in re-
verse.
22-66
22
Installation procedure
Installation: Lever
• While applying a force of 98 N {10 kgf} on the lever around No. 1
lever A as shown in the drawing, align the lever and the groove
on No. 1 lever A. Then insert the lock pin with its tapered side to-
ward the shaft and tighten it with a nut.
• With the nut tightened to the specified torque, check that the
clearance between No. 1 lever A and No. 1 lever B meets the di-
mension shown in the drawing. If the measurement is out of the
specified value, adjust using spacer.
• After installation, check that the lever, No. 1 lever B and No. 1 le-
ver A moves smoothly without hesitation.
Spacer thickness: 0.3 mm and 0.5 mm (2 types)
22-67
TRANSMISSION CONTROL
No. 2 Shift Lever
Disassembly sequence
1 Bushing
2 No. 2 shift lever
3 Spacer
4 No. 2 shift lever bracket
Assembly sequence
Follow the disassembly sequence in re-
verse.
Installation procedure
Installation: Spacer
• Assemble the No. 2 shift lever and No. 2 shift bracket and tight-
en the nut to the specified value. Measure the clearance be-
tween the No. 2 shift lever and No. 2 shift bracket. If the
measurement is out of the dimension shown in the drawing, ad-
just by spacer.
• After installation, make sure that the No. 2 shift lever operates
smoothly without hesitation.
Spacer thickness: 0.3 mm and 0.5 mm (2 types)
22-68
22
No. 2 Select Lever
Disassembly sequence
1 Bushing
2 No. 2 select lever
3 Spacer
4 No. 2 select lever bracket
Assembly sequence
Follow the disassembly sequence in re-
verse.
Installation procedure
Installation: Spacer
• Assemble the No. 2 select lever and No. 2 select lever bracket
and tighten the nut to the specified value. Measure the clear-
ance between the No. 2 select lever and No. 2 select lever
bracket. If the measurement is out of the dimension shown in the
drawing, adjust by spacer.
• After installation, make sure that the No. 2 select lever operates
smoothly without hesitation.
Spacer thickness: 0.3 mm and 0.5 mm (2 types)
22-69
TRANSMISSION CONTROL
No. 3 Select Lever
Disassembly sequence
1 Bushing
2 No. 3 select lever
3 Spacer
4 No. 3 select lever bracket
Assembly sequence
Follow the disassembly sequence in re-
verse.
Installation procedure
Installation: Spacer
• Assemble the No. 3 select lever and No. 3 select lever bracket
and tighten the nut to the specified value. Measure the clear-
ance between the No. 3 select lever and No. 3 select lever
bracket. If the measurement is out of the dimension shown in the
drawing, adjust by spacer.
• After installation, make sure that the No. 3 select lever operates
smoothly without hesitation.
Spacer thickness: 0.3 mm and 0.5 mm (2 types)
22-70
BEARING PULLER AND INSTALLER 22
• Bearing pullers and installers are special tools used for removing and installing the bearings listed in the table be-
low and used in this group.
• For each puller (for removing) and each installer (for installing), use the components of the bearing pullers and in-
stallers in combination.
Application
22-71
GROUP 25 PROPELLER SHAFT
SPECIFICATIONS............................................................................... 25-2
25-1
SPECIFICATIONS
Item Specifications
<Without center bearing> P3 (straight type, swage type)
Propeller shaft Model
<With center bearing> P3
25-2
STRUCTURE AND OPERATION 25
1. Configuration of Propeller Shaft Connection
2. Propeller Shaft
25-3
STRUCTURE AND OPERATION
• There are two types of propeller shaft: the straight type (stan-
dard) and swage type.
25-4
TROUBLESHOOTING 25
Symptoms Propeller shaft vi- Abnormal noise
brates from propeller shaft
zero or at coasting
Possible causes
Wrong combination of flange yoke directions O
Insufficient grease O
Slip yoke joint
Excessive play at spline O O
Excessive clearance in axial direction of spider shaft O O
Universal joint Insufficient needle bearing greasing O
Worn out needle bearing O O O
Insufficient grease O
Seizure, wear or improper rotation O O
Center bearing
Deteriorated or deformed cushion rubber O
Loose hanger mounting bolt O
Loose mounting bolts O O
Propeller shaft Bent O
Dynamic balance improper O
Transmission in high speed gear O
25-5
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection of Propeller Shaft Joint Fasteners for Looseness
• Check the bolts and nuts of the following components for loose-
ness.
• Flange yokes
• Front propeller shaft hanger
• Tighten loose fasteners, if any, to the specified torques. (See
“REMOVAL AND INSTALLATION OF PROPELLER SHAFT”.)
25-6
25
M E M O
25-7
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.)
3 Rubber bushing
4 Spacer
: 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.
25-8
25
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Nut (propeller shaft mounting) 100 to 120 {10 to 12} –
Nut (propeller shaft hanger mounting) 73 to 92 {7.4 to 9.4} –
Nut (propeller shaft hanger mounting) 47 to 65 {4.8 to 6.6} –
25-9
PROPELLER SHAFT
<Without Center Bearing>
Disassembly sequence
1 Snap ring 6 Grease nipple 11 Shield packing
2 Needle bearing 7 Spider 12 Propeller shaft
3 Flange yoke 8 Grease nipple
4 Snap ring 9 Slip yoke joint : Non-reusable parts
5 Needle bearing 10 Retainer packing
Assembly sequence
Follow the disassembly sequence in reverse, excepting:
12→10→11→9
25-10
25
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Supply through grease nipple Wheel bearing grease
As required
Shield packing lips [NLGI No. 2 (Li soap)]
25-11
PROPELLER SHAFT
Removal procedure
Removal: Needle bearing
• Fit -C into -A from outside.
• Applying -B to the spider, operate -A to force out the
spider and remove the needle bearing.
Inspection procedure
Inspection: Clearance between needle bearing and spider
• If the measurement exceeds the limit, replace the spider and
bearings with the universal joint spider kit.
25-12
25
Installation procedure
Installation: Retainer packing
• Hold retainer packing against slip yoke joint and caulk tabs (at
eight places).
Installation: Spider
• Fit the grease nipple to the spider facing it in the illustrated direc-
tion.
25-13
PROPELLER SHAFT
Inspection: Propeller shaft
[Inspection]
• Measure the amount of imbalance (dynamic imbalance) of com-
pleted propeller shaft assembly on a balancing machine.
• If measured value exceeds the standard value, make adjust-
ment as follows.
[Adjustment]
• Attach appropriate balance pieces at the illustrated points so
that the amount of imbalance comes within the specified stan-
dard value.
• Maximum balance piece allowance for one point is 100 g.
• Use a combination that keeps the number of balance pieces to a
minimum.
25-14
25
M E M O
25-15
PROPELLER SHAFT
<With Center Bearing>
Disassembly sequence
1 Snap ring 7 Spider 13 Center bearing
2 Needle bearing 8 Disc spring 14 Propeller shaft
3 Flange yoke 9 Companion flange
4 Snap ring 10 Holder : Non-reusable parts
5 Needle bearing 11 Hanger
6 Grease nipple 12 Cushion rubber
Assembly sequence
Follow the disassembly sequence in reverse.
25-16
25
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Wheel bearing grease
Supply through grease nipple As required
[NLGI No. 2 (Li soap)]
70 to 100% of
Fill space in center bearing housing Heat-resisting grease space capacity
[NLGI No. 3] (20 to 29 g)
Center bearing seal lips As required
25-17
PROPELLER SHAFT
Removal procedure
Removal: Needle bearing
• Fit -C into -A from outside.
• Applying -B to the spider, operate -A to force out the
spider and remove the needle bearing.
Inspection procedure
Inspection: Clearance between needle bearing and spider
• If the measurement exceeds the limit, replace the spider and
bearings with the universal joint spider kit.
25-18
25
Installation procedure
Installation: Grease nipple
• Fit the grease nipple to the spider facing in the illustrated direc-
tion.
[Adjustment]
• Attach appropriate balance pieces at the illustrated points so
that the amount of imbalance comes within the specified stan-
dard value.
• Maximum balance piece allowance for one point is 100 g.
• Use a combination that keeps the number of balance pieces to a
minimum.
25-19
PROPELLER SHAFT
Available balance pieces
Mass
2g
4g
6g
8g
10 g
12 g
16 g
24 g
25-20
GROUP 26 FRONT AXLE
SPECIFICATIONS............................................................................... 26-2
26-1
SPECIFICATIONS
Item Specifications
Model F020B
Front axle
Type Reverse Elliot, “I” beam
Kingpin outer diameter × length mm 28 × 180
Tread (dimension notified to the
1655
authorities) mm
Approx. 140 <Drum brake type>
Mass kg
Approx. 145 <Disc brake type>
26-2
STRUCTURE AND OPERATION 26
1. Wheel Hub and Rotor
• The brake pad wear indicator is installed in both the right and left wheels.
26-3
STRUCTURE AND OPERATION
3. Knuckle and Kingpin, Front Axle
26-4
TROUBLESHOOTING 26
Symptoms
26-5
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection and Adjustment of Wheel Alignment
Because the value of wheel alignment is related to the side slip amount, both wheel alignment and the side slip
amount must conform to the standard values.
Perform the following before carrying out inspection and adjustment of wheel alignment.
• Park the unloaded vehicle on a level surface.
• Check that the tire sizes are appropriate.
• If the wear conditions of the right and left tires are remarkably different, replace them.
• Adjust the tire pressure to the specified value.
• If the vehicle is tilted due to faulty suspension, repair it.
• Adjust the front axle to eliminate the following conditions.
• Play at or loose kingpin
• Loose front wheel hub
• Loose securing bolts for the tie rod arm, knuckle arm and tie rod
• Bent knuckle and front axle
• Adjust the play of the steering wheel.
• 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.
Hubcap wrench
Alignment gauge
adapter
Measurement of camber, caster and
MH063428
kingpin inclination angle
A B C D
φ80 M24 × 1.5 φ45 69
26-6
26
1.1 Inspection and adjustment of toe-in
[Inspection]
• Direct the front wheels straight ahead.
• Put a mark at the front center of each front tire.
• Align the needle tips of the toe-in gauge with the marks on the
tires to measure distance A between the marks.
[Adjustment]
• Loosen the clamp nuts on the right and left.
• Turn the tie rod with a pipe wrench to adjust the toe-in.
C: Toe-out direction
D: Toe-in direction
• After the 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 straight ahead so that both the right and
left tie rod ends are in contact with the ball studs. 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 straight ahead.
• Remove the hubcap with .
• Wipe off grease from the knuckle end, attach and tighten
the knuckle to the specified torque.
• Attach the camber/caster/kingpin gauge.
• Unlock the turning radius gauges and set the scale to 0 degrees.
• In the same manner as “1.2 Inspection of camber”, attach the
camber/caster/kingpin gauge and adjust the level so that the
bubble staying in the middle.
26-8
26
• Depress the brake pedal. With brake applied to the front wheels,
turn the steering wheel slowly, to the right when inspecting the
right wheel and left when inspecting the left wheel, until the scale
of the turning radius gauge moves from 0 to 20 degrees.
NOTE
• If brake is not applied, the wheel may turn slightly, resulting
in an inaccurate measurement.
• With the wheel turned 20 degrees, turn the adjuster to set the
center of the bubbles in the caster scale and kingpin scale to 0
degrees.
NOTE
• There are two kingpin scales, right and left. Be sure to use
the right kingpin scale to inspect the right front wheel and
left to inspect the left front wheel.
• Slowly turn the steering wheel in reverse until the turning radius
gauge indicates 20 degrees of the reverse direction.
• Read the centers of the bubbles in the caster scale and kingpin
scale in this condition to obtain the caster and kingpin inclination
angles.
• If the measured value deviates from the standard value, check
the kingpin and kingpin bushing for wear, the wheel bearing for
looseness, and the knuckle and front axle for distortion. Replace
defective parts.
• After the inspection, install the lock nut and measure the starting
torque of the wheel hub bearing. (See later section.)
• If the measured value deviates from the standard value, check
the wheel bearing and adjust the starting torque. (See later sec-
tion.)
• Fill the lock nut mounting potion of the wheel hub with the speci-
fied amount of grease with the grease pump nozzle so that the
outer bearing surface is covered with the grease. Then, install a
new hubcap. (See later section.)
26-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
2. Inspection and Adjustment of Steering Angle
• Perform steering angle inspection and adjustment only after inspection and adjustment of wheel alignment have
been completed.
Service standards
Location Maintenance item Standard value Limit Remedy
Inside (outside steering angle is only 0°
– Steering angle 47° (35°) – Adjust
for reference) –2°
• Prepare the turning radius gauge and a platform under the vehi-
cle in the same manner as “1.3 Inspection of caster and kingpin
inclination angle”.
• With the turning radius gauge set to 0 degrees, fully turn the
steering wheel right or left, and read the scale of the turning radi-
us gauge to obtain the steering angle.
• If the measured value deviates from the standard value, adjust
the steering angle with the knuckle stopper bolt and tighten the
lock nut to the specified torque.
26-10
26
3. Inspection of Side Slip
• Perform side slip inspection only after inspection and adjustment of wheel alignment have been completed.
• Because the value of the side slip amount is related to wheel alignment, both the side slip amount and wheel
alignment must conform to the standard values.
• If feeling play with your hand, replace the tie rod end of the tie
rod.
26-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
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 il-
lustrated directions to inspect the wheel bearing for play.
• If play is found with the feel of hands, repeat the inspection pro-
cedure while having the brake pedal depressed by another per-
sonnel. When the play is removed by operating the brake pedal,
the symptom indicates that there is play in the wheel bearing.
Then inspect the turning torque of the wheel bearing and adjust
it as required. (See “WHEEL HUB AND ROTOR” and “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 RO-
TOR” and “WHEEL HUB AND BRAKE DRUM”.)
26-12
26
M E M O
26-13
WHEEL HUB AND ROTOR
Disassembly sequence
1 Brake pipe 12 Inner bearing outer race
2 Brake hose 13 Outer bearing outer race
3 Eyebolt 14 Disc rotor (See Gr35.)
4 Brake hose 15 Hub bolt
5 Front disc brake (See Gr35.) 16 Wheel hub
6 Hubcap 17 Bracket
7 Lock nut 18 Adapter
8 Lock washer 19 Dust shield
9 Outer bearing inner race 20 Spacer
10 Oil seal
11 Inner bearing inner race : Non-reusable parts
• Plug the brake hoses that have been removed to prevent the ingress of dust and other contaminants.
Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION
• Make sure that the disc rotor surface and the pad surface of the front disc brake are free from grease to
avoid malfunction of brakes.
• Make sure that the brake hose is not twisted when installing it.
• After assembly, check the drag torque of the disc brake. (See Gr35.)
• After assembly, bleed air in the brake system. (See Gr35.)
26-14
26
Service standards
Location Maintenance item Standard value Limit Remedy
1 to 3.5 N·m
Starting torque of wheel hub bearing {0.1 to 3.5 kgf·m}
– – Adjust or replace
(tangential force at hub bolt with oil seal installed) (tangential force: 9.6 to
33.6 N {1 to 3.4 kgf})
Hubcap wrench
Bearing installer
Installation of oil seal (to be used in
A B C MB999069
combination)
φ94.5 φ60 φ92.5
26-15
WHEEL HUB AND ROTOR
Mark Tool name and shape Part No. Application
Bearing installer
A B MB999100
φ70 φ57
A B C MB999099
φ88.5 φ51 φ71
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: Hubcap
26-16
26
Removal: Outer bearing outer race
• Through the notches (three locations) in the wheel hub, tap the
outer bearing outer race evenly to remove it.
Inspection procedure
Inspection: Outer bearing inner race
• Clean the bearing to remove the grease before inspecting the
outer bearing inner race.
• Replace the outer bearing inner race if it has cracks or other
damage, or defective rotation.
• The inner race and outer race should be replaced as a set.
26-17
WHEEL HUB AND ROTOR
(3) Crack check
• Check that there is no crack on the entire rounded corner on the
root of the flange on the brake drum side of the wheel hub by a
magnetic inspection or liquid penetrant testing.
• If a crack is found on the wheel hub bolt, replace it.
Installation procedure
Installation: Outer bearing outer race
26-18
26
Installation: Oil seal
• Apply grease to the lip area of the oil seal and install it in the
wheel hub in the illustrated direction while aligning the end sur-
faces of the oil seal and wheel hub.
• As shown in the illustration, fill the hub body with grease in such
a manner that grease covers the outer races of the outer bearing
and inner bearing. Make sure that the grease reaches the outer
bearing and inner bearing.
26-19
WHEEL HUB AND ROTOR
Adjustment: Starting torque of wheel hub bearing
CAUTION
• Unless this procedure is performed, seizure of the wheel
hub bearing may result.
[Adjustment]
• Tighten the lock nut to the specified torque (primary tightening)
while turning the wheel hub and rotor. Then, fully loosen the lock
nut.
• See the movement 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).
• Loosen the lock nut approximately 45 degrees (1/8 turn) and se-
cure it with the split pin. If the pin cannot be inserted due to the
position of the pin hole, loosen the lock nut until the position of
the hole becomes appropriate. Make sure that there is no play in
the axial direction.
[Inspection]
• Perform the following inspections after installing the lock nut.
• Measure the tangential force at hub bolt with a spring scale.
• If the tangential force is within the specified value, the starting
torque conforms to the standard value.
If the measured value is within the specified value, install the
split pin in either of the ways shown in the illustration.
• If the measured value deviates from the specified value, the ad-
justment of the lock nut may be inadequate. Perform adjustment
again.
• If the abnormality still remains, replace the outer and inner bear-
ings.
• After installing lock nut, fill the outside of the outer bearing with
the specified amount of grease using a grease pump nozzle so
as to make a grease wall.
CAUTION
• Do not pile grease in the hubcap. Otherwise, grease may
not reach the outer bearing, causing poor lubrication of the
bearing.
26-20
26
Installation: Brake hose
• To install the brake hose, follow the removal procedure in re-
verse. (See “ Removal: Brake hose”.)
• After installing, make sure that the brake hose does not interfere
in the peripheral parts.
CAUTION
• Make sure that the brake hose is not twisted when you in-
stall it.
26-21
WHEEL HUB AND BRAKE DRUM
Disassembly sequence
1 Brake pipe 10 Outer bearing outer race
2 Brake hose 11 Brake drum (See Gr35.)
3 Hubcap 12 Hub bolt
4 Lock nut 13 Wheel hub
5 Lock washer 14 Front drum brake (See Gr35.)
6 Outer bearing inner race 15 Spacer
7 Oil seal
8 Inner bearing inner race : Non-reusable parts
9 Inner bearing outer race
• Plug the brake hoses that have been removed to prevent the ingress of dust and other contaminants.
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 installing it.
26-22
26
Service standards
Location Maintenance item Standard value Limit Remedy
1.5 N·m
Starting torque of wheel hub bearing (tangential force at {0.15 kgf·m} or less
– – Adjust or replace
hub bolt with oil seal installed) (tangential force: 14 N
{1.4 kgf} or less)
Hubcap wrench
A B MB999097
φ84 φ70
Bearing installer
A B C MB999069
φ94.5 φ60 φ92.5
26-23
WHEEL HUB AND BRAKE DRUM
Mark Tool name and shape Part No. Application
Bearing installer
A B MB999100
φ70 φ57
A B C MB999099
φ88.5 φ51 φ71
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: Hubcap
26-24
26
Removal: Inner bearing outer race
• Through the notches (three locations) in the wheel hub, tap the
inner bearing outer race evenly to remove it.
Inspection procedure
Inspection: Outer bearing inner race
• Clean the bearing to remove the grease before inspecting the
outer bearing inner race.
• Replace the outer bearing inner race if it has cracks or other
damage, or defective rotation.
• The inner race and outer race should be replaced as a set.
26-25
WHEEL HUB AND BRAKE DRUM
Inspection: Wheel hub
(1) Visual inspection
• Check the disc wheel mounting surface of the wheel hub visually
and by hand. If there is any damage or crack, replace the wheel
hub.
• Check that there is not rust, dust, paint or foreign matter on the
disc wheel mounting surface to prevent the wheel nut from loos-
ening.
• If any abnormality is found, remove it with sandpaper.
26-26
26
• Assemble the brake drum and wheel hub with the hub bolt. After
tightening the nut to the specified torque, caulk it with a punch.
26-27
WHEEL HUB AND BRAKE DRUM
Installation: Packing grease in outer bearing inner race
• Follow the same procedure as for the inner bearing inner race.
(See “ Installation: Packing grease in inner bearing inner
race”.)
• As shown in the illustration, fill the hub body with grease in such
a manner that grease covers the outer races of the outer bearing
and inner bearing. Make sure that the grease reaches the outer
bearing and inner bearing.
[Adjustment]
• Tighten the lock nut to the specified torque (primary tightening)
while turning the wheel hub and brake drum. Then, fully loosen
the lock nut.
• See the movement 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 tighten-
ing).
• Loosen the lock nut approximately 45 degrees (1/8 turn) and se-
cure it with the split pin. If the pin cannot be inserted due to the
position of the pin hole, loosen the lock nut until the position of
the hole becomes appropriate. Make sure that there is no play in
the axial direction.
26-28
26
[Inspection]
• Perform the following inspections after installing the lock nut.
• Measure the tangential force at hub bolt with a spring scale.
• If the tangential force is within the specified value, the starting
torque conforms to the standard value.
If the measured value is within the specified value, install the
split pin in either of the ways shown in the illustration.
• If the measured value deviates from the specified value, the ad-
justment of the lock nut may be inadequate. Perform adjustment
again.
• If the abnormality still remains, replace the outer and inner bear-
ings.
• After installing lock nut, fill the outside of the outer bearing with
the specified amount of grease using a grease pump nozzle so
as to make a grease wall.
CAUTION
• Do not pile grease in the hubcap. Otherwise, grease may
not reach the outer bearing, causing poor lubrication of the
bearing.
26-29
KNUCKLE AND KINGPIN, FRONT AXLE
Disassembly sequence
1 Tie rod (See later section.) 10 Grease nipple 19 U-bolt
2 Key 11 Plug 20 Stud bolt
3 Knuckle arm 12 Dust seal 21 Front axle
4 Key 13 Bushing
5 Tie rod arm 14 Knuckle stopper bolt
*b:
a: Drag link (See Gr37.)
6 Dust plug 15 Lock nut
* Shock absorber
7
8
Dust cap
Lock pin
16
17
Knuckle
Thrust bearing
*c:: Stabilizer
Non-reusable parts
9 Kingpin 18 Kingpin shim
CAUTION
• When removing the tie rod, take care not to damage the dust cover. It may cause ingress of water in the
ball joint, resulting in its premature wear.
Assembly sequence
Follow the disassembly sequence in reverse.
• After assembly, check and adjust toe-in. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
26-30
26
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
9 Outer diameter of kingpin 27.947 to 27.980 27.9 Replace
9, 13 Clearance between kingpin and bushing 0.020 to 0.086 0.15 Replace
9, 21 Clearance between kingpin and front axle 0.02 to 0.074 0.1 Replace
Inner diameter of bushing (after having been pressed
13 28.000 to 28.033 – Replace
into knuckle)
16, 21 Vertical clearance between knuckle and front axle 0.02 to 0.10 0.20 Adjust
Longitudinal bend – 2
21 Front axle Vertical bend – 2 Replace
Kingpin inclination angle 8° ± 10’ –
26-31
KNUCKLE AND KINGPIN, FRONT AXLE
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
Kingpin puller
A: Pipe MB999013
B: Bolt A: MB999014
C: Cap B: MB999015 Removal of kingpin
D: Nut C: MB999016
D: MB999017
E
φ47
Bushing installer
C D E F G
φ25 φ30 φ28 φ25 φ32.8
Removal procedure
Removal: Lock pin
• Remove the nut, spring washer and washer.
• Screw the nut into the lock pin again until just before they be-
come flush. Then, lightly tap the nut to loosen the lock pin.
• Remove the nut, apply a pin punch to the lock pin and lightly tap
it to remove the lock pin.
Removal: Kingpin
• Screw -B into the kingpin threads to remove the kingpin.
26-32
26
Inspection procedure
Inspection: Outer diameter of kingpin
• Measure at a total of four levels of the kingpin: two levels for the
axle fitting portion and the other two levels for the upper and low-
er knuckle fitting portions.
• If the measured value is under the limit, replace the kingpin.
Replacement of bushing
[Removal]
• Remove the bushing and the dust seal at the same time using
.
[Installation]
• Install the bushing using so that a step height between the
bushing and the 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.
26-33
KNUCKLE AND KINGPIN, FRONT AXLE
• Apply grease to the dust seal lip before installing it in the knuck-
le. Be sure to face the dust seal as shown in the illustration.
26-34
26
(3) Clearance between kingpin and front axle
• Measure the inner diameter of the axle’s hole for kingpin inser-
tion with a cylinder gauge and obtain the clearance by deducting
the outer diameter of the kingpin from it. If the clearance ex-
ceeds the limit, replace the axle or the kingpin.
Installation procedure
Installation: Stud bolt
• Apply Loctite to the front axle mounting threads of the stud bolt.
• Install the stud bolt with the dimension in the illustration.
Installation: Plug
• After installing the plug, caulk the knuckle at three evenly spaced
points of the plug circumference avoiding the previously caulked
points.
Installation: Knuckle
• After temporarily assembling the thrust bearing, knuckle and
kingpin into the front axle, move the knuckle a few times to
smooth its operation.
• Measure the clearance between the front axle top face and the
knuckle bottom.
26-35
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.
• 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 sur-
faces 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 sur-
faces 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.
26-36
26
Installation: Knuckle arm and knuckle
(1) When one or both the knuckle arm and knuckle need reas-
sembly, making use of existing parts
• Polish the entire tapered surfaces of the knuckle arm and knuck-
le evenly by means of sand paper #120 or higher until sand pa-
per 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.
26-37
TIE ROD
Disassembly sequence
1 Tie rod end
2 Tie rod
Assembly sequence
Follow the disassembly sequence in re-
verse.
Inspection procedure
Inspection: Tie rod end
(1) Play
• Fix the tie rod end with a vise.
CAUTION
• Take care not to damage the dust cover when fixing it with a
vise.
26-38
26
(2) Rotation torque of ball joint
• Install the tie rod mounting nut in the tie rod end.
• Install the socket, adapter and torque wrench and measure the
rotation torque.
• If the measured value deviates from the standard value, replace
the tie rod end.
Installation procedure
Installation: Tie rod end
• Screw in the tie rod end so that the difference of dimension A be-
tween the tie rod end and the clamp is within 1.5 mm between
right and left.
A: Approximately 74 mm
CAUTION
• Ensure that the difference of the amount of screwing in the
tie rod end between right and left is within one turn.
• Secure the tie rod ends so that the illustrated axis B-B on
the right is parallel to that on the left.
26-39
GROUP 27 REAR AXLE
SPECIFICATIONS............................................................................... 27-2
27-1
SPECIFICATIONS
Item Specifications
Model R033B
Rear axle
Type Axle pipe type, full floating
Model D033H
Reduction Type Single-reduction hypoid gear
Gear ratio 4.875
Differential Tooth shape Straight bevel gear
Gear oil:
Normal: Maximum air temperature during operation below 40°C
API GL-5
Grade SAE90
Gear oil Hot area: Maximum air temperature during operation above 40°C
*API GL-5
*SAE140
Quantity
4.5 {4.5}
dm3 {L}
Mass kg 190 to 220 (approx.)
* Use this oil 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.
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
Symptoms Power transmission in-
sufficient
27-6
27
Symptoms Power transmission in-
sufficient
27-7
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection and Replacement of Differential Oil
WARNING
• The oil temperature is high immediately after the vehicle has stopped, so take care not to scald yourself.
* Use this oil 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.
[Replacement]
• Remove the drain plug to drain differential oil. Drainage can be
made quickly with the inspection plug removed.
• As the drain plug (magnet type) is a magnet, clean it before in-
stallation.
• Fill the specified quantity of differential oil from the inspection
plug hole.
• After filling, check that oil is filled up to the neck. If oil is not suffi-
cient, replenish it.
27-8
27
2. Inspection of Wheel Bearing for Play
• Jack up the vehicle and 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 pro-
cedure while having the brake pedal depressed by another per-
sonnel. 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
starting torque of the wheel bearing and adjust it as required.
(See “WHEEL HUB AND BRAKE DRUM”.)
• If the starting 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 Brake pipe 10 Outer bearing outer race
2 Axle shaft 11 Brake drum (See Gr35.)
3 Outer oil seal 12 Hub bolt
4 Lock washer 13 Wheel hub
5 Lock nut 14 Rear drum brake (See Gr35.)
6 Outer bearing inner race
7 Oil seal : Locating pin
8 Inner bearing inner race : Non-reusable parts
9 Inner bearing outer race
• Plug the brake pipe that has been removed to prevent the ingress of dust and other contaminants.
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.
27-10
27
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
2.0 to 3.9 N·m
Starting torque of wheel hub bearing (tangential force at {0.2 to 0.4 kgf·m}
– – Adjust or replace
hub bolt position with oil seal assembled) (tangential force: 17.6 to
34.4 N {1.8 to 3.5 kgf})
Bend at center 0 to 1 2
2 Axle shaft Replace
Lateral runout at flange face 0 to 0.03 0.05
27-11
WHEEL HUB AND BRAKE DRUM
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
A B
MB999150 Removal and installation of lock nut
70 12.7
A B MB999097
φ84 φ70
A B C MB999098
φ109 φ99 φ77
Removal procedure
Removal: Axle shaft
• Screw two axle shaft mounting bolts evenly into the axle shaft
removal screw holes to remove the axle shaft.
27-12
27
Removal: Outer oil seal
• To remove the outer oil seal, pull protrusions on the outer periph-
ery of the outer oil seal evenly around the whole circumference
with pliers.
27-13
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.
Inspection procedure
Inspection: Axle shaft
• Perform the following inspection. If the measurement exceeds
the limit, 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.
27-14
27
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.
27-15
WHEEL HUB AND BRAKE DRUM
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.
27-16
27
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.
27-17
WHEEL HUB AND BRAKE DRUM
Installation: 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 turn-
ing the wheel hub and brake drum several times, and then tight-
en the lock nut to the specified torque (secondary tightening).
• Insert the flat area of the lock washer, 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 wash-
er, 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 balance.
• 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 Inspection plug 9 Connector
2 Drain plug 10 Axle housing
3 Reduction and differential (See later sections.)
4 Brake pipe
*b:
a: Propeller shaft
5 Brake hose
* Shock absorber
6
7
Vent plug
U-bolt
*c:: Leaf spring
Non-reusable parts
8 Brake pipe
CAUTION
• Plug the brake hose and the brake pipe to prevent entry of dust and dirt after they have been removed.
• Be careful not to damage the brake hose, brake pipe and sensor harness when removing and installing
the axle housing.
• When removing the axle housing, the suspension parts around the axle housing must be removed. (See Gr34.)
Installation sequence
Follow the removal sequence in reverse.
27-20
27
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Inspection plug
98 to 120 {10 to 12} –
Drain plug
Nut (propeller shaft mounting) 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} Sealant
Brake hose 14 to 17 {1.4 to 1.7} –
Nut (U-bolt mounting) 127.5 to 166.7 {13 to 17} Wet
Differential carrier
base
Removal and installation of reduction
MB999102
A and differential
φ28
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 (M12 × 1.25 mm) evenly into the reduction and
differential removal screw holes to remove the reduction and dif-
ferential.
27-21
AXLE HOUSING
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 measured value exceeds
the limit, replace the axle housing.
(1) Runout at outer bearing portion
• Apply a dial gauge to the outer bearing fitting and turn it 360 de-
grees to measure runout.
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 Lock plate 6 Differential (See later sections.)
2 Side bearing nut 7 Pinion (See later sections.)
3 Bearing cap 8 Shim
4 Side bearing outer race 9 Differential carrier
5 Side bearing inner race
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.
27-24
27
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (lock plate mounting) 20 to 26 {2.0 to 2.7} –
Bolt (bearing cap mounting) 200 {20.5} –
Bolt (pinion mounting) 67 to 90 {6.8 to 9.2} –
Differential working
base assembly
H J K L
11 20 40 φ11
Workbench for reduction and differen-
tial
Component Part No. MB999034
Flange stopper to be used for remov-
Attachment – al and installation of companion
A RA F G – flange
R158 30° φ13 MH064132 (MB999040)
B Holder MH064130 (MB999036)
C Holder MH064131 (MB999037)
D Working base MH064129 (MB999035)
E Flange stopper MH064137 (MB999096)
Adapter
Removal of side bearing inner race
A B MB999076 (to be used in combination with com-
mercial bearing puller)
φ45 φ59
Bearing installer
A B C D
85 18 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 .
Removal procedure
Removal: Side bearing inner race
Removal: Pinion
• Screw two bolts evenly into the pinion removal screw holes to re-
move 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 assembly and
differential carrier.
• Formula: Shim thickness = 0.5 – a + b + 0.2
a: 1/100 of numeral stamped on outer periphery of flange of dif-
ferential 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 differ-
ential carrier.
27-27
REDUCTION AND DIFFERENTIAL
Installation: Side bearing inner race
27-28
27
[Adjustment]
• Optimize tooth contact by increasing or decreasing rear bearing
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 re-
place both the reduction gear and reduction pinion as a re-
duction gear set.
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 the starting torque of the pinion assembly using a
torque wrench and calculate the starting torque of the side bear-
ing using the following formula.
Pinion bearing starting torque is the value obtained at earlier
measurement of pinion bearing starting torque.
[Adjustment]
• Adjust by means of the right- and left-hand adjusting screws.
• Always adjust both adjusting screws by the same amount.
27-30
27
Differential
Disassembly sequence
1 Reduction gear
2 Differential case right-hand
3 Side gear washer
4 Side gear
5 Pinion washer
6 Differential pinion
7 Pinion spider
8 Differential case left-hand
CAUTION
• Be sure to replace the differential
case right-hand and the differential
case left-hand 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 re-
verse.
27-31
REDUCTION AND DIFFERENTIAL
Work before removal
Alignment marks: Reduction gear and differential case left-
hand
• Put alignment marks on the reduction gear and differential case
left-hand.
Inspection procedure
Inspection: Backlash between side gear and axle shaft
• If the measured value exceeds the limit, replace defective parts.
Installation procedure
Installation: Differential case right-hand and differential
case left-hand
• Apply rust preventive to the entire surface of the bolt. After ap-
plying 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 run-
ning 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 hard-
en.
27-32
27
Installation: Reduction gear and differential case left-hand
• Apply rust preventive to the entire surface of the bolt. After ap-
plying 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 left-hand.
• 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 run-
ning 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 hard-
en.
27-33
REDUCTION AND DIFFERENTIAL
Pinion
Disassembly sequence
1 Lock nut
2 Companion flange
3 Dust cover
4 Collar
5 Rear bearing inner race
6 Lock ring
7 Pinion pilot bearing
8 Reduction pinion
9 Oil seal
10 Front bearing inner race
11 Front bearing outer race
12 Rear bearing outer race
13 Bearing retainer
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.
Service standards
Location Maintenance item Standard value Limit Remedy
2.0 to 2.9 N·m
When new bear- {0.20 to 0.30 kgf·m}
– Adjust
ing is used (tangential force: 34 to
Starting torque of pinion bearing 52 N {3.5 to 5.3 kgf})
– (tangential force at outer periphery
point of bearing retainer) 1.6 to 2.4 N·m
When old bearing {0.16 to 0.24 kgf·m}
– Adjust
is reused (tangential force: 27 to
41 N {2.8 to 4.2 kgf})
27-34
27
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
27-35
REDUCTION AND DIFFERENTIAL
Removal procedure
Removal: Reduction pinion
27-36
27
Installation procedure
Installation: Rear bearing outer race
27-37
REDUCTION AND DIFFERENTIAL
Work after installation
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 bear-
ing retainer using a spring balancer.
CAUTION
• Securely fix the companion flange to measure.
• Do not assemble the oil seal when measuring the tangential
force.
27-38
GROUP 31 WHEEL, TIRE
SPECIFICATIONS............................................................................... 31-2
31-1
SPECIFICATIONS
Tire size Wheel type
205/80R17.5 120/118L 17.5 × 5.25-115-8
• Tire pressures specified for each tire size are shown on the tire pressure label.
31-2
TROUBLESHOOTING 31
Symptoms Tire tread wear
Worn in serration
Outside worn
Center worn
Inside worn
out
Possible causes
in
Overload O
Too low O O O O O
Tire pressure
Too high O
Excessive O O
Toe-in
Insufficient O
Excessive O
Wheel alignment Camber
Insufficient O
Gr26
Excessive toe-out O O
Multiple misalignment O O O O O O O O
Knuckle arm bent O O O O
Left and right tie-rods different in length O
Wheels out of balance O O O O
Wheel bearing loose O O O O Gr26, 27
Tie-rod end loose O Gr26
Brake drum eccentrically mounted <Drum brake> O O Gr27
Axle bent O O Gr27
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 Wheel Nuts for Looseness
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> 4 Tire <Double tire> (See later section.)
Wheel nut (outer) <Double tire>
2 Tire (See later section.)
3 Wheel nut (inner) <Double tire>
*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 genuine wheel nuts and tighten them to the specified torque, otherwise damage to hub
bolts and looseness of wheel nuts can be caused.
31-6
31
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Wheel nut 490 ± 49 {50 ± 5} –
[Correction]
• Mark the tire, disc wheel, and one of the hub bolts in the illustrat-
ed locations.
• Remove the tire from the disc wheel.
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
31-8
31
M E M O
31-9
WHEEL, TIRE
Tire
Disassembly sequence
1 Tire
2 Air valve
3 Disc wheel
Assembly sequence
Follow the disassembly sequence in re-
verse.
31-10
31
Inspection procedure
Inspection: Disc wheel
(1) Visual inspection
• Visually inspect the disc wheel for deformation, crack, deteriora-
tion, damage, corrosion or 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 circumferences of
hub bolt holes in the disc wheel.
• If the measured value is equal to or exceeds 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
<Tire with no red mark>
• Install the tire such that the yellow mark (light point mark) on the
tire is aligned with the air valve on the disc wheel.
31-11
WHEEL, TIRE
<Tire with red mark>
• Install the tire such that the red mark (max. radial runout mark)
on the tire is aligned with mark A or B on the disc wheel.
A: Front face of disc wheel
B: Back face of disc wheel
31-12
GROUP 33 FRONT SUSPENSION
STABILIZER........................................................................................ 33-6
33-1
STRUCTURE AND OPERATION
1. Front Suspension Elements
• The front suspension shown above uses a spring shackle connected to the rear end of the leaf spring (shackle-
link type suspension).
• The stabilizer prevents the vehicle from pitching during turning.
33-2
TROUBLESHOOTING 33
Symptoms
Feels as if floating
Tends to be noisy
Poor linearity
Heavy rolling
Vehicle tilted
Possible causes
Deformed stabilizer bar or worn bushing O
Substantial loss of oil and damping
O
capacity
Shock absorber
Rubber bushing worn O
Loose fitting O
Cracks or other damage O O
Broken O O
Leaf spring
Loose U-bolt O O
Rubber bushing worn O O
Uneven wear O O
Tire Tire and wheel needs balancing O O Gr31
Excessive tire pressure O
Wheels out of alignment O Gr26
33-3
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection of Leaf Springs for Damage
• Check the leaf spring visually for cracks and breakage.
• If there is any crack or breakage, replace the leaf spring.
(See “LEAF SPRING”.)
2. Inspection of Suspension Mounting Points and Joints for Looseness and Dam-
age
• Check the mounting points and joints of the leaf spring, shock
absorber, stabilizer, spring hanger and other components for
looseness.
• If there is any looseness, tighten the loose parts to the specified
torque. (See later sections.)
• Check the leaf spring, shock absorber, stabilizer, spring hanger
and other components and their mounting points and joints visu-
ally for damage.
• If there is any damage, replace the damaged parts. (See later
sections.)
33-4
33
M E M O
33-5
STABILIZER
Removal sequence
1 Washer 7 Stabilizer hanger
2 Rubber bushing 8 Rubber bushing
3 Washer 9 Stabilizer bracket
4 Washer 10 Stabilizer bushing
5 Rubber bushing 11 Stabilizer bar
6 Washer 12 Stabilizer hanger bracket
Installation sequence
Follow the removal sequence in reverse.
33-7
SHOCK ABSORBER
Removal sequence
1 Washer 6 Washer
2 Rubber bushing 7 Rubber bushing
3 Rubber bushing 8 Shock absorber
4 Washer
5 Washer : Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
33-8
33
Installation procedure
Installation: Rubber bushing
• Tighten the nut until the rubber bushing is squeezed to the illus-
trated dimension. Align the groove of the lock nut with the pin
hole in the front axle. The adjustment must be finished by tight-
ening the nut.
• Install the split pin as shown in the illustration.
33-9
LEAF SPRING
Removal sequence
1 U-bolt 5 Shackle plate 9 Front bump stopper
2 Front spring clamp 6 Spring shackle
3
4
Spring pin
Rubber bushing
7
8
Rubber bushing
Leaf spring (See later section.)
*a: Front spring hanger
Installation sequence
Follow the removal sequence in reverse.
NOTE
• The right-hand and left-hand leaf spring assemblies have different cambers from each other. Ensure that
both assemblies are installed correctly. Reversed installation results in a slanted vehicle.
33-10
33
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Clearance between spring pin and rubber bushing in ra-
3, 4 0 to 0.04 – Replace
dial direction
Clearance between rubber bushing and front spring
*
4, a
hanger in axial direction
0 0.5 Replace
33-11
LEAF SPRING
Inspection procedure
Inspection: Spring shackle
• Check the pins of the spring shackle for wear and damage.
• If there is any abnormality, replace the spring shackle.
Installation procedure
Installation: Spring pin
• Install the spring pin by aligning the concave on the pin with the
convex on the frame.
33-12
33
M E M O
33-13
LEAF SPRING
Leaf Spring <Except Multi-leaf Spring>
Disassembly sequence
1 Spacer (thickness: 6 mm) 8 Rivet
2 Spacer (thickness: 0.5 mm) 9 Clip
3 Collar 10 Leaf spring (No. 3)
4 Leaf spring (No. 1) 11 Spacer (thickness: 1 mm) <Wheelbase J, LH>
5 Leaf spring (No. 2) 12 Caster shim
6 Spacer (thickness: 0.5 mm)
7 Silencer : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
33-14
33
Removal procedure
Compression: Leaf spring
• Compress the leaf spring using a press to prepare for the subse-
quent operations.
• Raise the bent portions of the clip with a chisel.
Removal: Clip
• Cut the flattened head of the rivet with a drill and remove the clip
from the leaf spring (No. 3).
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
• Flatten the rivet with a riveting machine and install the clip.
33-15
LEAF SPRING
Leaf Spring <Multi-leaf Spring>
Disassembly sequence
1 Collar 8 Rivet
2 Leaf spring (No. 1) 9 Clip
3 Leaf spring (No. 2) 10 Leaf spring (No. 5)
4 Rivet 11 Leaf spring (No. 6)
5 Clip 12 Caster shim
6 Leaf spring (No. 3)
7 Leaf spring (No. 4) : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
33-16
33
Removal procedure
Compression: Leaf spring
• Compress the leaf spring using a press to prepare for the subse-
quent operations.
• Raise the bent portions of the clip with a chisel.
Removal: Clip
• Cut the flattened head of the rivet with a drill and remove the clip
from the leaf spring (No. 3 and No. 5).
Installation procedure
Installation: Clip
• Flatten the rivet with a riveting machine and install the clip.
33-17
GROUP 34 REAR SUSPENSION
STABILIZER........................................................................................ 34-6
34-1
STRUCTURE AND OPERATION
1. Structure of Rear Suspension
• The rear suspension use a spring shackle at the rear end of the leaf spring (shackle-link type suspension).
• The stabilizer bar reduces the roll of the body during cornering.
34-2
TROUBLESHOOTING 34
Symptoms
Feels as if floating
Tends to be noisy
Heavy rolling
Possible causes
Stabilizer deformed, bushing worn O
Cracks or other damage O
Broken O
Leaf spring
Loose U-bolt O
Rubber bushing worn O
Spacer or bump stopper damaged or broken O
Spring pin over-tightened O
Substantial loss of oil and damping capacity O
Shock absorber Rubber bushing worn O
Loose fitting O
Tire and wheel unbalanced O
Tire Gr31
Excessive tire pressure O
34-3
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Checking Leaf Spring for Damage
• Visually check the leaf springs for cracks and breaks.
• If any crack or break is found, replace the leaf spring. (See
“LEAF SPRING”.)
34-4
34
M E M O
34-5
STABILIZER
Removal sequence
1 Washer 7 Stabilizer clamp
2 Rubber bushing 8 Stabilizer bushing
3 Rubber bushing 9 Stabilizer bushing
4 Washer 10 Stabilizer bar
5 Stabilizer retainer 11 Stabilizer bracket
6 Stabilizer hanger 12 Stabilizer hanger bracket
Installation sequence
Follow the removal sequence in reverse.
34-6
34
Installation procedure
Installation: Stabilizer clamp and bushing
• Mount stabilizer bushings with their end surfaces aligned with
marks on stabilizer bar and fix them with stabilizer clamps.
34-7
SHOCK ABSORBER
Removal sequence
1 Washer
2 Washer
3 Rubber bushing
4 Rubber bushing
5 Shock absorber
6 Washer
7 Washer
Installation sequence
Follow the removal sequence in reverse.
34-8
34
M E M O
34-9
LEAF SPRING
Removal sequence
1 U-bolt seat 8 Bushing
2 U-bolt 9 Leaf spring (See later section.)
3 Bump stopper 10 Spacer (8 mm)
4 Spring pin
5 Bushing
*b:
a: Rear spring hanger
6 Spring shackle
* Rear shackle hanger
7 Shackle plate
*c: Rear axle
Installation sequence
Follow the removal sequence in reverse.
34-10
34
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
4, 5 Radial clearance between spring pin and bushing 0 to 0.04 – Replace
Axial clearance between bushing and rear spring hang-
*
5, a
er
0 0.5 Replace
34-11
LEAF SPRING
Inspection: Clearance between leaf spring and frame
• Measure the clearance between the leaf spring and frame. If the
measurement exceeds the limit, replace the bushings.
Inspection procedure
Inspection: Spring shackle
• Check the pins of the spring shackle for wear and damage.
• If any abnormality is found, replace the spring shackle.
Installation procedure
Installation: Spring pin
• Install the spring pin while aligning its concave section with the
convex section on the rear spring hanger.
34-12
34
M E M O
34-13
LEAF SPRING
Leaf Spring <Except Multi-leaf Spring>
• The above drawing shows an example. The number of leaf springs and the components of the leaf spring assem-
bly may differ depending on the vehicle model.
Disassembly sequence
1 Spacer 7 Silencer
2 Spacer 8 Rivet
3 Collar 9 Clip
4 Leaf spring (No. 1) 10 Leaf spring (No. 3)
5 Leaf spring (No. 2)
6 Spacer : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
34-14
34
Removal procedure
Compression: Leaf spring
• Using a press, compress the leaf spring as illustrated for subse-
quent operations.
• Using a chisel or the like, open the bent ends of the clip.
Removal: Clip
• Using a drill, break the flattened head of the rivet and remove
the clip from the leaf spring (No. 3).
Installation procedure
Installation: Clip
• Using a riveting machine, rivet a clip onto the leaf spring.
34-15
LEAF SPRING
Leaf Spring <Multi-leaf Spring>
Disassembly sequence
1 Leaf spring (No. 6) 11 Leaf spring (No. 3)
2 Center spacer 12 Center spacer
3 Leaf spring (No. 5) 13 Rivet
4 Center spacer 14 Clip
5 Pipe 15 Leaf spring (No. 4)
6 Collar 16 Center spacer
7 Leaf spring (No. 1) 17 Spacer
8 Center spacer
9 Leaf spring (No. 2) : Non-reusable parts
10 Center spacer
Assembly sequence
Follow the disassembly sequence in reverse.
34-16
34
Removal procedure
Compression: Leaf spring
• Using a press, compress the leaf spring as illustrated for subse-
quent operations.
Removal: Clip
• Using a drill, break the flattened head of the rivet and remove
the clip from the leaf spring (No. 4).
Installation procedure
Installation: Clip
• Using a riveting machine, rivet a clip onto the leaf spring.
34-17
GROUP 35 BRAKE
35-1
SPECIFICATIONS
Vacuum Booster and Brake Master Cylinder
Item Specifications
Boosting type Vacuum tandem type
Vacuum booster Diaphragm diameter inch φ9 + φ10
Manufacturer Bosch
Inner diameter mm φ31.75
Brake master Front mm 16.0
Stroke
cylinder Rear mm 16.0
Manufacturer Bosch
Vacuum Pump
Item Specifications
Type Vane type
3
Output cm {mL} 60 {60}
Manufacturer MITSUBISHI ELECTRIC
35-2
35
M E M O
35-3
STRUCTURE AND OPERATION
1. Brake System
1.1 Brake fluid line
• 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.
35-4
35
1.2 Vacuum booster line
35-5
STRUCTURE AND OPERATION
2. Vacuum Pump
• The vacuum pump is mounted onto the front case of engine, and is driven by the timing gear.
• The check valve is provided to ensure that no air or engine oil flow back from the vacuum pump to the vacuum
tank when the engine is stopped.
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 wall
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 com-
pressed air is returned through the pump outlet and into the oil
pan.
35-6
35
3. Vacuum Booster and Brake Master Cylinder
• The vacuum booster magnifies the stepping force applied onto the brake pedal through the utilization of pressure
difference between the vacuum it generates and the atmospheric pressure to reduce the operator’s pedal effort.
The system is of a tandem type and has 2 vacuum chambers, achieving size reduction while offering a great ca-
pacity 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, therefore, stopping power can still be provided
by the system that is intact.
35-7
STRUCTURE AND OPERATION
(1) When brake pedal is depressed
(1.1) 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 re-
mains open.
• The vacuum pump creates vacuum in
chamber A. As the atmospheric pres-
sure valve is closed, no outside air
flows into chamber B. Instead, vacu-
um in chamber A flows through the air
passage and into chamber B. Cham-
bers A and B are both filled with vacu-
um, 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 de-
pressed further, the valve plunger sep-
arates from the poppet. This opens the
atmospheric pressure valve, allowing
outside air flow into chamber B. There
is now a pressure difference between
chambers A and B.
• The stepping force, boosted as a re-
sult of the pressure difference be-
tween chambers A and B, overcomes
the force of the diaphragm plate
spring, pushing the front and rear dia-
phragms and the push rod to operate
the brake master cylinder.
(1.2) Brake master cylinder operation
• As the push rod pushes the primary
piston, the return port is closed by the
packing cup. Fluid pressure now
builds up in chamber C.
• The pressure is sent to the front brake
system and at the same time pushes
the secondary piston.
• In the same manner as in chamber C,
fluid pressure builds up in chamber D
in front of the secondary piston. The
pressure is sent to the rear brake sys-
tem.
35-8
35
(2) Fluid leakage in front brake sys-
tem
• 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 fur-
ther, 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.
35-9
STRUCTURE AND OPERATION
(4) When brake pedal is released
(4.1) Vacuum booster operation
• With the brake pedal depressed,
chamber A is filled with vacuum gener-
ated by the vacuum pump while cham-
ber 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.
35-10
35
• The secondary piston goes back to its
original position, making the fluid pres-
sures in chambers C and D the same.
The packing cup restores its original
shape, blocking the orifices. The fluid
pressure in the brake pipe now returns
to the brake fluid tank through the re-
turn port.
35-11
STRUCTURE AND OPERATION
4.1 Wheel cylinder
• The wheel cylinder is equipped with a
self-adjusting mechanism to compen-
sate for lining wear and maintain the
correct clearance between the lining
and the drum. The adjustment is made
each time braking is performed.
35-12
35
• As the brake drum-to-lining clearance
grows, the amount of piston travel,
and therefore the amount of lever trav-
el, becomes greater.
• When the lever travels far enough to
turn the adjuster, the threads on the
adjuster causes the adjusting screw to
advance. As a result, the brake shoe
extends.
35-13
STRUCTURE AND OPERATION
5. Front Disc Brake
• The front disc brake uses twin floating-
type calipers.
• The caliper houses one each of cylin-
der and piston. Stopping power is gen-
erated by squeezing the disc rotor
between the pads, with the outer pad
pressed against the disc rotor by reac-
tion.
• The inner pad is equipped with wear
indicator which serves to indicate re-
placement timing for both the inner
and outer pads.
• The front disc brake is equipped with
self-adjusting mechanism to compen-
sate for pad wear and maintain the
correct clearances between the disc
rotor and the inner and outer pads.
The adjustment is made each time
braking is performed.
35-14
35
6. Rear Drum Brake
• The rear drum brake is of a dual 2-
leading type.
• Double-acting wheel cylinders activate
both brake shoes as a leading shoe in
forward- and rearward-travel braking.
By self-servo effect, both leading
shoes generate great stopping power.
35-15
TROUBLESHOOTING
Wheel Brake
Symptoms Noise and shock
Uneven braking when brake ped-
al depressed
vehicle
speed)
Other
Other
Possible causes
Surface of the ledge of the backing plate is
O O
rough
Backing plate deformed or incorrectly installed O
Lubricant or moisture on brake pad or lining
O O
surface
Deterioration or incorrect material used for
O
brake pad or lining
Brake pad or lining unevenly worn or with
O
rough surface
Fade (brake pad or lining surface deteriora-
O
tion)
Brake pad or lining worn to limit O
Incorrect contact of brake pad or lining O O O
Brake lining radius uneven O
Wheel brake
Wheel cylinder malfunction O O O O
Shoe return spring fatigued or broken O O
Disc rotor or brake drum worn unevenly O
Disc rotor or brake drum deformed O
Disc rotor or brake drum worn O
Disc rotor or brake drum surface rough O
Disc rotor or brake drum inaccurately ma-
O
chined
Brake drum cracked O
Foreign matter in brake drum O
Brake shoe deformed or damaged O
Shoe hold cup broken O
Movable parts insufficiently lubricated O
35-16
35
Symptoms Noise and shock
Uneven braking when brake ped-
al depressed
vehicle
speed)
Other
Other
Possible causes
Incorrect pedal travel O
Brake pedal
Incorrectly adjusted, too much play O
Fluid level low O
Fluid leakage O
Brake fluid
Air ingress O
Vapor lock O
Vacuum system Vacuum drop O
Vacuum booster Faulty vacuum booster O O
Tire pressure uneven between wheels O
Tire Gr31
Different tire sizes from left to right O
Wheel hub bearing incorrectly adjusted O O
Gr26, 27
Axle Wheelbase different from left to right O
Incorrect wheel alignment O Gr26
35-17
TROUBLESHOOTING
Symptoms Brake drum
Brake noise
overheating
lining replacement
Brake drag
Judder
Other
Possible causes
Rough ledge surface of backing plate O
Shoe trapped on backing plate ledge surface O
Backing plate deformed or incorrectly installed O
Fading of brake pad or lining (deterioration of sur-
O
face material)
Wear powder attached on brake pad or lining O
Brake pad or lining worn O
Incorrect contact of brake pad or lining O
Wheel brake
Wheel cylinder malfunction O O
Faulty wheel cylinder piston cup O O
Shoe return spring fatigued or broken O O
Disc rotor or brake drum glazed O
Brake drum deformed or center deviation O
Uneven disc rotor thickness O
Brake shoe deformed or damaged O
Brake shoe twisted or sagged O
Abnormal pedal return O
Pedal play insufficient O
Brake pedal Linkage rusted or deformed O
Return spring fatigued or broken O
Vacuum booster operating rod thrust O
Brake fluid Poor fluid return due to over-tightened brake pipes O
Vacuum booster Faulty vacuum booster O
Brake master Faulty piston cup O
cylinder Clogged return port O
Wheel hub bearing incorrectly adjusted O O O Gr26, 27
Axle
King pin bushing worn O Gr26
35-18
35
M E M O
35-19
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Fluid Leaks from the Brake System
• Check the hose and pipe connections for fluid leak, and check the hose for blister, damage and cracked.
• If any fluid leak is found, check the connections for looseness or replace the faulty part.
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 prop-
erties 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.
35-20
35
3. 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. For the air bleeding of clutch system, see Gr21.
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 prop-
erties 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.
35-21
ON-VEHICLE INSPECTION AND ADJUSTMENT
With the brake pedal still depressed, allow the brake fluid
to drain.
35-22
35
4. Inspection of Fluid Level in Fluid Tank
• Check that the fluid level is between the “MAX” and “MIN”
marks.
• If the fluid level is lower than “MIN”, add the brake fluid.
[Adjustment]
• Loosen the lock nut and turn the operating rod to adjust the in-
stalled height of the brake pedal to the standard value.
• Tighten the lock nut to the specified torque.
• After tightening the lock nut, inspect the pedal-to-floor clearance
when the brake pedal is depressed and brake pedal play.
• After adjustment, check the clearance between the brake pedal
and the thread end of the stop lamp switch.
CAUTION
• When the brake pedal is fully depressed, the vacuum boost-
er operating rod functions as a stopper for the brake pedal.
35-23
ON-VEHICLE INSPECTION AND ADJUSTMENT
5.2 Brake pedal-to-floor clearance when the brake pedal
is depressed
[Inspection]
• Fold the floor mat aside for measurement.
• With the engine idling, depress the brake pedal by 490 N {50
kgf} and measure the pedal-to-floor clearance.
• If the measurement is out of the standard value, adjust the in-
stalled height of the brake pedal.
[Adjustment]
• See “5.1 Installed height of brake pedal”.
[Adjustment]
• See “5.1 Installed height of brake pedal”.
35-24
35
6. Inspection of Brake Master Cylinder, Wheel Cylinder and Caliper for Function,
Wear and Damage
• Perform the following inspections and, if any abnormality is
found, replace the faulty part(s).
(1) Brake master cylinder
• Visually check the brake master cylinder for damage and fluid
leak.
35-25
ON-VEHICLE INSPECTION AND ADJUSTMENT
7. Inspection and Replacement of Disc Brake Pad
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
– Thickness of outer/inner pad 14 4 Replace
Piston expander
[Inspection]
• When a brake pad has worn down to a thickness of approxi-
mately 4 mm, the pad wear indicator contacts the disc rotor. This
breaks the circuit, illuminating the disc brake warning lamp on
the meter cluster to tell the operator that the brake pads need re-
placement.
35-26
35
[Replacement]
• Remove the lower slide pin. Flip the caliper upwards and sus-
pend it in place using a wire or the like.
CAUTION
• The caliper needs to be suspended firmly in place so that it
does not drop, without stretching, squeezing or otherwise
forcing the brake hosing or harness.
• The slide pin is coated with grease. Do not wipe off this
grease and keep it away from dust.
• Inspect the piston for fluid leakage. Inspect the piston boots for
damage. Faulty parts must be replaced.
• Install a pad wear indicator onto the inner pad (included in the
pad kit) using a clip (included in the pad wear indicator kit).
35-27
ON-VEHICLE INSPECTION AND ADJUSTMENT
• Using , screw in the piston of the caliper until it bottoms on
the back of the caliper.
• Move the caliper back to the original place while taking care not
to damage the piston boots.
• Bleed the pin boots of air.
• Ensure that the pin boots are firmly attached into the groove on
the slide pin.
• Tighten the slide pin to the specified torque.
• Correctly route the harness(es) for the pad wear indicator(s).
• Measure the drag torque of the disc brake.
• Cycle the brake pedal several times, and check the brake fluid
level in the tank. The fluid level should be at the “MAX” mark on
the tank. Add brake fluid as required.
• Ensure that the starting torque of the wheel hub bearings con-
forms to the standard value.
• Using a spring balance, measure the tangential force at the hub
bolts.
• If the measured tangential force conforms to the specified value,
this means that the drag torque of the disc brake conforms to the
standard value.
• If the measured value does not conform to the specified torque,
check the sliding portions of the piston and piston seal.
35-28
35
10.Inspection of Drum Brake Lining Thickness
CAUTION
• To ensure correct operation of the brakes, be sure to inspect both linings on each wheel.
• Remove the inspection hole plug from the inspection hole in the
backing plate. Through the inspection hole, measure the thick-
ness of the brake lining.
• If any lining is worn down to the step on the side, replace all lin-
ings or shoes on that axle.
• After the inspection, be sure to install the plug onto the inspec-
tion hole.
[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]
• Jack up the wheel being adjusted. Ensure that the wheel hub
bearings are not loose.
• With a 0.3 mm feeler gauge inserted through the inspection
hole, adjust the drum-to-lining clearance in the following man-
ners such that the gauge can be inserted and out with slight re-
sistance.
• If the feeler gauge can be inserted and out with no resistance,
turn the adjuster through the inspection hole in the direction of
the arrow on the backing plate.
35-29
ON-VEHICLE INSPECTION AND ADJUSTMENT
• If the clearance is too small to insert the feeler gauge or there is
considerable resistance when inserting the gauge, remove the
cover and insert a φ2 mm wire through the hole to lift the adjust
lever for the wheel cylinder. Then, through the inspection hole
turn the adjuster in the direction opposite to the arrow on the
backing plate to increase the clearance between the brake drum
and shoe.
• Then, cycle the brake pedal a couple of times. This will automat-
ically bring the brake drum-to-shoe clearance to 0.2 mm.
• Insert a 0.2 mm feeler gauge between the brake drum and lin-
ing. It should be able to be inserted and out with slight resis-
tance.
• Check the disc brake for normal operation. If faulty, disassemble
and inspect the wheel cylinders.
35-30
35
• Install a vacuum gauge between the vacuum tank and the vacu-
um pump.
• Start the engine and measure the time taken to reach the speci-
fied degree of vacuum.
• If the measured time does not conform to the standard value,
disassemble and service the vacuum pump.
Service standards
Location Maintenance item Standard value Limit Remedy
Airtightness inspection (vacuum loss) (vacuum of 3.3 kPa {25 mmHg} or
– – Replace
67 kPa {500 mmHg}, 15 sec. after engine stop) less
3920 kPa {40 kgf/cm2}
(pedal depressed with a –
force of 98 N {10 kgf})
– Fluid pressure at vacuum of 67 kPa {500 mmHg} Replace
8820 kPa {90 kgf/cm2}
(pedal depressed with a –
force of 295 N {30 kgf})
196 kPa {2 kgf/cm2}
(pedal depressed with a –
force of 98 N {10 kgf})
– Fluid pressure at vacuum of 0 kPa {0 mmHg} Replace
140 kPa {15 kgf/cm2}
(pedal depressed with a –
force of 295 N {30 kgf})
• 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 be closed, prevent-
ing the breath from passing it.
• Suck on the hose and depress the brake pedal. The check valve
should be opened immediately, allowing air to pass.
• If any fault is encountered during the above inspections, replace
the vacuum hose with check valve.
35-31
ON-VEHICLE INSPECTION AND ADJUSTMENT
14.2 Operational check of vacuum booster
CAUTION
• The vacuum booster operational checks described below
are only of summary nature. If the vacuum booster contin-
ues to malfunction, perform a bench test specified by a ser-
vice 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 spec-
ified testing, ask the service station of the manufacturer for
repair.
[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 approxi-
mately 30 seconds.
35-32
35
(2) Operational check with a simplified tester
(2.1) Airtightness check
• Inspect the check valve in the vacuum hose for normal opera-
tion.
• Remove the vacuum hose from the vacuum booster and con-
nect 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 illus-
trated. 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 read-
ing 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 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.
35-33
ON-VEHICLE INSPECTION AND ADJUSTMENT
35-34
VACUUM PUMP 35
Disassembly sequence
1 Check valve
2 Cylinder
3 O-ring
4 Vane
5 Rotor
6 Housing
: Locating pin
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.
35-35
BRAKE MASTER CYLINDER
Disassembly sequence
1 Bracket 6 Connector
2 Retaining ring 7 Clamp
3 Primary piston 8 Cylinder body
4 Set bolt
5 Secondary piston : Non-reusable parts
CAUTION
• To clean the parts, use brake fluid.
Assembly sequence
Follow the disassembly sequence in reverse.
35-36
35
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Distance from the end of brake pedal and brake booster 0
– 8.25 – Adjust
to the end of push rod –0.25
35-37
BRAKE MASTER CYLINDER
Special tools (Unit: mm)
Mark Tool name and shape Part No. Application
Support tool
MK528895
A B
No. of splines: 23 30
Measurement support
tool
Adjustment of vacuum booster push
MK528896
A B rod
36 φ11.5
Box spanner
MB999062
A B C
Width across flats: 8 120 120
Removal procedure
Removal: Secondary piston
• While pushing the secondary piston with a rod, loosen the bolt to
remove the piston.
35-38
35
Installation procedure
Installation: Secondary piston
• While pushing the secondary piston with a rod, tighten the bolt to
the specified torque.
• If the secondary piston groove does not align with the set pin in-
sertion hole, rotate the piston to align them.
[Inspection]
• Remove the vacuum hose from the brake pedal & vacuum
booster to fill the vacuum booster with the atmospheric pres-
sure.
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 & vacuum booster.
[Adjustment]
• Set the distance to the specified value by turning the push rod in
or out.
35-39
BRAKE PEDAL AND VACUUM BOOSTER
Disassembly sequence
1 Clevis pin 7 Brake pedal
2 Vacuum booster 8 Stop lamp switch
3 Return spring 9 Brake pedal support
4 Collar
5 Pedal pad : Non-reusable parts
6 Bushing
CAUTION
• Do not attempt to disassemble the vacuum booster.
Assembly sequence
Follow the disassembly sequence in reverse.
• After installation, inspect and adjust the brake pedal. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
35-40
35
M E M O
35-41
FRONT DRUM BRAKE
Disassembly sequence
1 Return spring 8 Brake lining 14 Cover
2 Shoe hold-down cup 9 Brake pipe 15 Cover
3 Shoe hold-down spring 10 Spacer 16 Backing plate
4 Shoe hold-down cup 11 Connector
5 Shoe hold-down pin 12 Wheel cylinder
*a: Brake drum
6 Rivet (See later section.) : Non-reusable parts
7 Brake shoe 13 Cover
• For removal and installation procedures of the rear drum brake, see Gr26.
Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION
• Do not smear the surface of the brake lining with lubricant. Otherwise, braking performance will drop se-
riously.
• When replacing the brake shoe, 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 ADJUST-
MENT”.)
35-42
35
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
215 ± 22 N 175 N
1 Return spring load (installed length: 190) Replace
{22 ± 2.2 kgf} {18.0 kgf}
4.0
(Side shoul-
7 Brake lining thickness 10.4 Replace
der means
wear limit.)
Inner diameter 320 322 ( 321)
*a Brake drum
Cylindricity 0.05 0.20
Repair or replace
: Repair limit
Removal procedure
Removal: Return spring
• Using a flat-blade 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 screwdriv-
er with the spring hook and pry away the spring.
35-43
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.
Installation procedure
Installation: Backing plate
• Grease the backing plate at the illustrated locations.
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. Then 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 spec-
ifications.
• Around the rivets: 0.05 mm or less
• Along the shoe/lining sides:
0.3 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
• Brake linings used on the same axle should be in the same
size and have the same identification mark. Otherwise, un-
even braking will occur.
35-45
FRONT DRUM BRAKE
Wheel Cylinder
Disassembly sequence
1 Spring 6 Washer 11 Air bleeder
2 Spring & fitting 7 Washer 12 Body
3 Lever 8 Piston
4 Adjust screw 9 Piston cup : Non-reusable parts
5 Adjuster 10 Boot
Assembly sequence
Follow the disassembly sequence in reverse.
35-46
35
M E M O
35-47
FRONT DISC BRAKE
Disassembly sequence
1 Slide pin 13 Inner pad
2 Piston boot 14 Pad liner A
3 Piston 15 Pad liner B
4 Piston seal 16 Pad liner C
5 Air bleeder 17 Pad liner D
6 Caliper 18 Pin boot
7 Outer shim 19 Bushing
8 Outer pad 20 Torque member
9 Inner shim A
10 Inner shim B
*a: Disc rotor
11 Clip : Non-reusable parts
12 Pad wear indicator
• For removal and installation procedures of the front disc brake and disc rotor, see Gr26.
Assembly sequence
Follow the disassembly sequence in reverse.
35-48
35
CAUTION
• Rubber parts that are disassembled must be replaced with the ones in the seal kit.
• Items included in the seal kit must be lubricated with grease supplied with the kit before installation.
• Do not smear the surfaces of outer and inner pads with lubricant. Otherwise, braking performance will
drop seriously.
• After installation, inspect the disc brake drag torque. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
Inspection procedure
Inspection: Disc rotor
(1) Visual inspection
• If abnormal wear or damage is found on the disc rotor, replace
the disc rotor.
(2) Thickness
• If the measured value is lower than the limit, replace the disc ro-
tor.
Installation procedure
Installation: Slide pin, bushing, and torque member
• Using a rod with φ8 mm outer diameter, install the bushings into
the torque member.
• Apply grease to the entire inner periphery of bushing and the
connecting section with slide pin.
• Apply grease to the outer periphery of slide pin and connecting
section with bushing, then install the slide pins.
• Confirm that the sealing section of bushing is attached to the
bushing mating portion of the slide pin.
35-49
FRONT DISC BRAKE
Installation: Slide pin, pin boot, and torque member
• Apply grease to the pin boot mounting groove and entire periph-
ery of guide hole of the torque member.
• Apply grease to the outer periphery of slide pin and mating sec-
tion with slide pin on pin boot, then install the pin boot.
• Apply grease to the outer periphery of slide pin and mating sec-
tion with bushing, then install the slide pin.
• Confirm that the sealing section of pin boot is fitted to the pin
boot mating portion of the slide pin.
Installation: Shim
• Install the shims to the pads in the directions shown in the draw-
ing.
35-50
35
M E M O
35-51
REAR DRUM BRAKE
Disassembly sequence
1 Return spring 8 Brake lining 14 Cover
2 Shoe hold-down cup 9 Brake pipe 15 Backing plate
3 Shoe hold-down spring 10 Spacer
4
5
Shoe hold-down cup
Shoe hold-down pin
11 Wheel cylinder
(See later section.)
*a:: Brake drum
Non-reusable parts
6 Rivet 12 Cover
7 Brake shoe 13 Cover
• For removal and installation procedures of the rear drum brake, see Gr27.
Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION
• Do not smear the surface of the brake lining with lubricant. Otherwise, braking performance will drop se-
riously.
• When replacing the brake shoe, 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 ADJUST-
MENT”.)
35-52
35
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
215 ± 22 N 175 N
1 Return spring load (installed length: 190) Replace
{22 ± 2.2 kgf} {18.0 kgf}
4.0
(Side shoul-
8 Brake lining thickness 10.4 Replace
der means
wear limit.)
Inner diameter 320 322 ( 321)
*a Brake drum
Cylindricity 0.05 0.20
Repair or replace
: Repair limit
Removal procedure
Removal: Return spring
• Using a flat-blade 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 screwdriv-
er with the spring hook and pry away the spring.
35-53
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.
Installation procedure
Installation: Backing plate
• Grease the backing plate at the illustrated locations.
35-54
35
Installation: Brake lining
• Using cleaning fluid, clean the surface of the brake shoe to
which the brake lining is to be mounted. Then 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 spec-
ifications.
• Around the rivets: 0.05 mm or less
• Along the shoe/lining sides:
0.3 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
• Brake linings used on the same axle should be in the same
size and have the same identification mark. Otherwise, un-
even braking will occur.
35-55
REAR DRUM BRAKE
Wheel Cylinder
Disassembly sequence
1 Spring 7 Adjust screw 13 Boot
2 Spring & fitting 8 Adjuster 14 Air bleeder
3 Lever 9 Washer 15 Body
4 Piston 10 Washer
5 Piston cup 11 Piston : Non-reusable parts
6 Boot 12 Piston cup
Assembly sequence
Follow the disassembly sequence in reverse.
35-56
GROUP 36 PARKING BRAKE
SPECIFICATIONS............................................................................... 36-2
36-1
SPECIFICATIONS
Item Specifications
Type Internal expanding type acting on propeller shaft
Brake
Operation type Mechanical cable type
Type Duo servo type
Parking brake Brake drum I.D. mm φ190
Lining width × thickness mm 45 × 4.0
36-2
STRUCTURE AND OPERATION 36
1. Parking Brake Control
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
ratchet bar 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 ratchet bar is returned to the released
position, the repercussive force of the shoe return spring releas-
es the brake.
36-4
TROUBLESHOOTING 36
Symptoms
(drags)
small
large
Possible causes
Inner cable elongated or damaged O O O O
Parking brake cable Inner cable rusted O O O
Inner spring fatigued or broken O O
Ratchet pawl to ratchet bar engagement abnormal O
Parking brake ratchet bar Pulling stroke too small O O
Pulling stroke too large O O
Shoe-to-drum clearance too small O O
Shoe-to-drum clearance too large O O
Parking brake drum inside surface deformed/distorted O O
Parking brake drum inside surface smeared with oil or
Parking brake main body O O
grease
Linings worn unevenly O
Lining surfaces smeared with oil or grease O
Shoe return springs weakened or broken O
36-5
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection of Parking Brake Drum Mount for Looseness
• Inspect the parking brake drum mounting nut for looseness us-
ing a spanner or similar tool.
• If any looseness is found, tighten it to the specified torque.
• Apply chocks to the front wheels and raise the rear wheels with
a jack.
• Operate the parking brake ratchet bar to release the parking
brake (the parking lever becomes free of pull forces).
• Using a screwdriver or similar tool inserted through the shoe ad-
justing hole in the parking brake drum, turn the adjusting screw
in the shoe expanding direction until the shoes closely contact
the brake drum.
• From the above point, turn the screw in the shoe contracting di-
rection by 8 notches; the shoe-to-drum clearance is now adjust-
ed to the standard value.
36-6
36
3. Inspection and Adjustment of Parking Brake Ratchet Bar Pulling Stroke
[Inspection]
• Measure the pulling stroke when the parking brake ratchet bar is
pulled from the released position by an operating force of 294 N
{30 kgf}.
• If the measurement deviates from the standard value, adjust
with the adjusting nut of the parking brake cable.
[Adjustment]
• Tighten the adjusting nut until the mark can be seen.
• Tighten the lock nut to the position of the adjusting nut.
• Tighten the lock nut to the specified torque.
• Check the clearance is to the illustrated dimension when the out-
er cable of the parking brake cable is pulled by an operating
force of 59 to 98 N {6 to 10 kgf}.
• Operate the ratchet bar two or three times after adjusting to veri-
fy the pulling stroke to make sure that the parking brake is oper-
ating properly and that the parking brake drum does not drag
when the parking brake is released.
• If there is any abnormality, inspect the parking brake ratchet bar,
parking brake cable, and parking brake.
36-7
PARKING BRAKE CONTROL
Removal sequence
1 Parking brake ratchet bar (See later section.)
2 Parking brake cable
Installation sequence
Follow the removal sequence in reverse.
• Perform the inspection and adjustment of the parking brake ratchet bar after installation. (See “ON-VEHICLE IN-
SPECTION AND ADJUSTMENT”.)
36-8
PARKING BRAKE RATCHET BAR 36
Disassembly sequence
1 Push nut
2 Pin
3 Ratchet pawl
4 Ratchet spring
5 Push nut
6 Pin
7 Return spring
8 Ratchet bar
9 Parking brake switch
10 Grommet
11 Clip
12 Support
Assembly sequence
Follow the disassembly sequence in re-
verse.
36-9
PARKING BRAKE
Disassembly sequence
1 Shoe return spring
2 Washer
3 Strut spring
4 Shoe hold down cup
5 Shoe hold down spring
6 Shoe hold down cup
7 Shoe hold down pin
8 Adjuster
9 Adjuster spring
10 Strut
11 Retainer
12 Shoe and lining
13 Parking lever
14 Backing plate
Assembly sequence
Follow the disassembly sequence in re-
verse.
CAUTION
• To prevent poor working of the brake, do not smear the surface of shoe and lining with grease or oil.
• Perform the adjustment of the brake shoe clearance after installation. (See “ON-VEHICLE INSPECTION AND
ADJUSTMENT”.)
0 to 0.0049 N·m
Static rotation imbalance –
{0 to 0.5 gf·m}
36-10
36
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Shoe and lining contact points on both ends of adjuster
screw
Brake grease AKB100 As required
Anchor pins and shoe and lining contact surface on back-
ing plate
Inspection procedure
Inspection: Shoe and lining
• If the measured value is lower than the limit, replace the shoe
and lining.
36-11
GROUP 37 STEERING
SPECIFICATIONS............................................................................... 37-2
37-1
SPECIFICATIONS
Steering wheel, steering shaft and power steering gear
Specifications
Item
BE63DE BE63DG, BE63DJ
Type 2-spoke type
Steering wheel
Outer diameter mm 400
Steering shaft Type Universal joint type (high-tilt type)
Manufacturer JTEKT Corporation
Type Ball nut type
Power steering gear
Form Integral form
assembly
Gear ratio 22.6
Cylinder diameter mm 78 85
37-2
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.
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 en-
gine.
• 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 during steering wheel ma-
nipulation.
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 as-
sembly
(1.1) When not functioning (oil pump
in operation at low speed)
• Oil pressure in the chamber A is weak-
er than the combined force of oil pres-
sure in the chamber B and tension of
the flow control spring, and the flow
control valve remains stationary.
37-7
TROUBLESHOOTING
Symptoms
37-8
37
Symptoms
O
cient
Oil line crushed or clogged O
Air caught in oil pump O
Oil pump interior seized O O O
Mounting bolt and nut loose O
Pump body faulty O
Valve malfunctioning O
Difference excessive in wheelbase be-
O
tween left and right
Propeller shaft runout excessive O Gr25
Rear axle housing bent O Gr27
Final drive gear and final drive pinion
Other abnormalities
O Gr27
damaged or improperly engaged
Tire pressure insufficient O
Tire pressure excessive O
Difference excessive in degree of wear
O
between left and right tires
Gr31
Left and right tires different in outer diam-
O
eter
Front tire radial and lateral runout, static
O
and dynamic balance incorrect
Braking force unbalanced O Gr35
37-9
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Steering Wheel Play
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Steering wheel play (measured at At engine start 5 to 50 – Replace
–
outer periphery of wheel) Engine stopped 10 to 20 – Adjust
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 loose-
ness.
• Check the connections of hose and pipe for looseness.
• If any looseness is found, tighten the loose parts to the specified
torque.
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 spec-
ified 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.
37-12
37
6. Performance Verification Test of Power Steering System
Service standards
Location Maintenance item Standard value Limit Remedy
Power steering system fluid pressure (steering wheel 0 to 490 kPa
– – Repair or replace
not turned) {0 to 5 kgf/cm2}
9.3 +0.20
–0.30 MPa
– Relief set pressure {95 +2 2 – Replace
–3 kgf/cm }
37-13
STEERING COLUMN
37-14
37
Removal sequence
1 Column cover outer lower 11 Twist-off bolt
2 Column cover outer upper 12 Starter switch
3 Column cover inner lower 13 Spring
4 Column cover inner upper 14 Steering column (See later section.)
5 Horn pad 15 Dust cover
6 Horn spring 16 Dust cover
7 Contact plate <Optional steering wheel> 17 Dust cover
8 Cover
9
10
Steering wheel
Combination switch
*a:: Power steering gear assembly
Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
• After installation, check the steering column for looseness. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
37-15
STEERING COLUMN
Removal procedure
Removal: Horn pad
• Insert a flat-blade screwdriver into the gap between the steering
wheel and the horn pad at the shoulder section of the horn pad.
Pry up the horn pad until it clicks and comes off.
• Insert your finger into the gap and remove the horn pad.
37-16
37
Installation procedure
Installation: Steering column
• If the spline comes off the steering column, assemble it with the
yokes facing in the same direction.
• The threads of the two bolts shown in the illustration must be el-
liptical to ground the horn circuit.
37-17
STEERING COLUMN
Steering Column
37-18
37
Disassembly sequence
1 Support bracket 11 Lock plate
2 Spring seat 12 Wave washer
3 Stopper 13 Lever support
4 Bearing spacer 14 Clevis pin
5 Steering shaft 15 Column support upper
6 Lock lever 16 Telescopic shaft
7 Return spring 17 Column support lower
8 Return spring
9 Snap ring : Non-reusable parts
10 Cam
Assembly sequence
Follow the disassembly sequence in reverse.
37-19
STEERING COLUMN
Installation procedure
Installation: Clevis pin
• Install the clevis pin with the dimension shown in the drawing.
Installation: Cam
• Position the crest of the cam as shown in the drawing by the le-
ver support and install the cam.
37-20
37
Work after installation
Inspection: Operating force of lock lever
• Check that the operating force of the lock lever is 49 N {5 kgf} or
lower.
• Set the lock lever in “free” position and check that the steering tilt
operation can be performed smoothly.
37-21
POWER STEERING GEAR ASSEMBLY AND DRAG LINK
Removal sequence
1 Grease nipple 7 Drag link
*b:
a: Knuckle arm
2
3
End plug
Ball seat
8
9
Feed pipe
Return pipe
*: Pitman arm
Non-reusable parts
4 Ball seat 10 Power steering gear assembly
5 Spring (See later section.)
6 Grease seal
Installation sequence
Follow the removal sequence in reverse.
37-22
37
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Entire surface of ball seat
Arm mounting points of grease seal Wheel bearing grease
As required
Inside of drag link [NLGI No. 2 (Li soap)]
Through grease nipple
Installation procedure
Installation: Drag link
• Fully tighten the end plug and then loosen it a half turn.
• Insert the split pin with its head pointing outside of the vehicle.
• Bend the split pin. Adjust its head to the dimension shown in the
illustration.
• Attach the identification label on the drag link on the forward side
of the vehicle.
37-23
POWER STEERING GEAR ASSEMBLY AND DRAG LINK
Power Steering Gear Assembly
Disassembly sequence
1 Pitman arm 9 Adjusting plate 16 O-ring
2 Dust cover A 10 Sector shaft 17 Oil seal
3 Side cover 11 Dust cover B 18 Needle bearing
4 O-ring 12 Seal ring 19 Y-packing
5 Backup ring 13 O-ring 20 Backup ring
6 Y-packing 14 O-ring 21 Gear box
7 Needle bearing 15 Valve housing and
8 Adjusting bolt ball screw set shaft : Non-reusable parts
• Do not attempt to disassemble the valve housing and ball screw set shaft because it is of a unit construction.
Assembly sequence
Follow the disassembly sequence in reverse.
37-24
37
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
0.98 N·m
Starting torque –
{0.1 kgf·m} or less
Adjust
0.2 to 0.49 N·m
– Power steering gear assembly Engagement torque –
{0.02 to 0.05 kgf·m}
0.15 to 0.69 N·m
Normal turning torque – Replace
{0.015 to 0.07 kgf·m}
8, 10 End play of adjusting bolt and sector shaft 0 to 0.1 – Adjust
Stepped wear of sliding area of gear box with sector
10 – 0.003 Replace
shaft
15, 21 Clearance between ball screw set shaft and gear box 0.022 to 0.069 – Replace
BE63DE 78.012 to 78.034 78.05
21 Inner diameter of gear box Replace
BE63DG, BE63DJ 85.012 to 85.034 85.05
37-25
POWER STEERING GEAR ASSEMBLY AND DRAG LINK
Work before removal
Inspection: Starting torque
• Measure the starting torque before disassembly for reference at
the time of reassembly.
A: Starting torque
(= engagement torque + normal turning torque)
B: Engagement torque
C: Normal turning torque
Removal procedure
Removal: Pitman arm
37-26
37
• Loosen the nut and remove the sector shaft by tapping the shaft
end with a plastic hammer.
• If the sector shaft is stuck, it may be deviated from neutral posi-
tion. In this case, set the shaft in the neutral position. Do not at-
tempt to force it out by hammering.
Installation procedure
Installation: Sector shaft
• Set the sector shaft in the neutral position and insert it in the
gear box.
• When inserting the sector shaft, cover up its threaded end and
serration portions for protection.
• Turn the ball screw set shaft to check that it makes roughly five
turns lock to lock.
• If the number of turns is insufficient, check the engagement of
the ball screw set shaft with the sector shaft.
[Adjustment]
• Loosen the nut.
• Rotate the ball screw set shaft approximately 1/4 turns left and
right, while making adjustment for proper starting torque with the
adjusting bolt.
37-27
POWER STEERING OIL PUMP
Disassembly sequence
1 Eye joint 8 Vane 15 Flow control valve
2 Hose 9 Rotor 16 Flow control spring
3 Suction connector 10 Cam ring 17 O-ring
4 O-ring 11 O-ring 18 O-ring
5 Pin 12 Side plate 19 Body
6 Cover 13 O-ring
7 Cartridge assembly 14 Connector : Non-reusable parts
• See Gr11 for removal and installation of the power steering oil pump.
• Do not attempt to disassemble the flow control valve and body because they are of unit construction.
Assembly sequence
Follow the disassembly sequence in reverse.
37-28
37
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Stepped wear on rotor and vane contact surfaces of
6 – 0.05 Replace*
cover
8, 9 Clearance between vane and rotor 0.01 0.06 Replace
Stepped wear on rotor and vane contact surfaces of
12 – 0.05 Replace*
side plate
Air leakage of flow control valve
15 0 cm3 {0 mL} – Replace*
(applying pressure 390 to 490 kPa {4 to 5 kgf/cm2})
15, 19 Clearance between flow control valve and body 0.01 to 0.02 0.03 Replace*
16 Free length of flow control spring 36.5 33.5 Replace
Inspection procedure
Inspection: Cover
• Check if there is not stepped wear or scratch that causes finger-
nail to catch on the sliding surface of the rotor and vane. If any
abnormality is found, replace the cover.
37-29
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 ro-
tor.
• If any abnormality is found, replace the cartridge assembly.
37-30
37
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 out-
side.
37-31
POWER STEERING OIL TANK
Disassembly sequence
1 Hose
2 Filler cap
3 Strainer
4 Filter
5 Packing
6 Tank
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.
37-32
GROUP 41 FRAME
SPECIFICATIONS............................................................................... 41-2
41-1
SPECIFICATIONS
Item Specifications
Frame type Ladder type
Cross section configuration of side member shaped (open) channel section
41-2
STRUCTURE AND OPERATION 41
1. Frame
• The frame has cross members fastened to the web of the side members (lateral linkage) so that stress on the
joints is minimal. This allows joint rivets to maintain tightness and ensures long-lasting high torsional rigidity.
41-3
FRAME
: Non-reusable parts
CAUTION
• Do not reuse the mounting bolts or nuts of cross members and spring hangers, etc.
Inspection procedure
Inspection: Frame
• Thoroughly remove mud, grease, rust etc. from the outer and in-
ner surfaces of the frame.
(1) Inspection for deformation
• If deformation or any other defect is found, repair the frame.
41-4
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.
41-5
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 af-
ter welding.
41-6
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 loos-
ened rivet.
CAUTION
• Loose rivets could break off or allow frame cracks to devel-
op from the rivet holes, leading to an accident.
• 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.
41-7
GROUP 55 HEATER, AIR-CONDITIONER,
VENTILATION
COMPRESSOR.................................... 55-18
EVAPORATOR AND
COOLER DUCT ................................... 55-22
55-1
SPECIFICATIONS
Specifications
Item
BE63DE, BE63DG BE63DJ
Model – BM372
Cooling capacity W {kcal/h} – 12800 {11000}
System
Type – HFC134a
Refrigerant
Quantity kg – 2.7
Manufacturer DENSO
Heat radiation W {kcal/h} 4400 ± 440 {3780 ± 378}
Front heater Temperature control system Air mixing type
Type Sirocco fan type
Blower
Rated voltage V 24
Manufacturer DENSO
Fan motor type Sirocco fan type
Rear heater Rated voltage V 24
Heat radiation W {kcal/h} 3500 ± 350 {3010 ± 301}
3/h
Air capacity m 220 ± 22
MITSUBISHI HEAVY
Manufacturer –
INDUSTRIES, LTD.
Model – MSC90BA
3
Compressor Ejection amount cm {mL}/rev – 90 {90}
Type – S-PAG56
Lubrication oil Quantity LH : 235 +20 +20
0 {235 0 }
–
cm3 {mL} RH : 235 0 {235 +20
+20
0 }
MITSUBISHI HEAVY
Manufacturer –
INDUSTRIES, LTD.
Condenser
Rated voltage V – 24
Fan motor W – 200 + 170
MITSUBISHI HEAVY
Manufacturer –
INDUSTRIES, LTD.
Evaporator Rated voltage V – 24
3/h
Air capacity m – 1620
Motor input W – 96
55-2
STRUCTURE AND OPERATION 55
1. Air Conditioner Schematic Diagram
55-3
STRUCTURE AND OPERATION
3. Air Duct
• Depending on open/closed status of each damper in the heater unit, outside and inside air introduced from the
blower flow as shown above.
55-4
55
4. Air Conditioning Switching
4.1 Mode switching
• Mode switching (opening and closing of the damper) is performed by transmitting the movement of the mode
switching lever via the mode switching control wire.
• Air-mix switching is performed by changing the opening of the damper to adjust the amount of warm air from the
heater core and cool air that does not pass through the heater core.
55-5
STRUCTURE AND OPERATION
4.3 Inside/outside air switching
55-6
55
5. Heater Schematic Diagram
<Front heater>
• The heater system is a hot water system that consists of the rear heater and hot water piping and uses coolant
(hot water) circulating from the engine.
55-7
TROUBLESHOOTING
Front Heater
Symptoms
No warm air.
Possible causes
Fuse blown O
Connector improperly connected, harness open-circuited, grounding improper O Gr54
Front heater switch operation defective O O
Foreign object catching fan O O
Fan motor operation defective O O O
Heater core clogged O
Belt incorrectly adjusted O
Water pump operation defective O
Thermostat does not close O Gr14
Cooling system defective O
Insufficient coolant amount O
Air-mix damper operation defective O
Gap between internal components and floorboard mount area O
Gaps around the body O
Duct connection defective O
Air-mix damper operation defective O
Duct clogged by foreign objects O
Register operation defective O
Defroster hose warped, bent, connection defective O
Defroster duct incorrectly attached O
Foreign objects have fallen into defroster duct O
Mode switching control wire incorrectly adjusted O
55-8
55
Rear Heater
Symptoms
No warm air.
Possible causes
Fuse blown O
Connector improperly connected, harness open-circuited, grounding improper O Gr54
Rear heater switch operation defective O O
Foreign object catching fan O O
Fan motor operation defective O O O
Water valve closed O
Heater core clogged O
Belt incorrectly adjusted O
Water pump operation defective O
Thermostat does not close O Gr14
Cooling system defective O
Insufficient coolant amount O
Gap between internal components and floorboard mount area O
Gaps around the body O
Register operation defective O
55-9
TROUBLESHOOTING
Air Conditioner System
Symptoms
55-10
55
M E M O
55-11
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Discharging Refrigerant
55-12
55
2. Charging Refrigerant
• See MITSUBISHI BUS AIR CONDITIONER BM372 WORKSHOP MANUAL.
4. Adding Refrigerant
• See MITSUBISHI BUS AIR CONDITIONER BM372 WORKSHOP MANUAL.
55-13
AIR CONDITIONER PIPING
Removal sequence
1 Discharge hose 4 Low pressure pipe
*a: Compressor
2 High pressure pipe 5 Liquid pipe
*b: Condenser
3 Suction hose 6 Sight glass
*c: Evaporator
Installation sequence
Follow the removal sequence in reverse.
55-14
55
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (installation of discharge hose and suction hose) 19.6 to 29.4 {2.0 to 3.0} –
Bolt (installation of pipes and hoses) 4.9 to 6.0 {0.5 to 0.7} –
Installation of discharge hose and high pressure pipe 19.6 to 24.5 {2.0 to 2.5} –
Installation of high pressure pipe and condenser 34.3 to 39.2 {3.5 to 4.0} –
Installation of suction hose and low pressure pipe 29.4 to 34.3 {3.0 to 3.5} –
Installation of low pressure pipe and evaporator 63.7 to 93.2 {6.5 to 9.5} –
Installation of low pressure pipe 49 to 56.7 {5 to 5.85} –
Installation of liquid pipe and condenser –
Installation of liquid pipe and sight glass 11.8 to 14.7 {1.2 to 1.5} –
Installation of liquid pipe and evaporator –
Installation procedure
Installation: Connecting hoses and pipes
• (See “CONNECTING AIR CONDITIONER PIPING”.)
55-15
CONNECTING AIR CONDITIONER PIPING
1 Nut
2 Pipe or hose
3 O-ring
4 Union
5 Pipe or hose
• Care should be taken regarding the following items when connecting the air conditioner pipes and hoses.
• For the tightening torque of the nut and the refrigeration oil, see “AIR CONDITIONER PIPING”.
CAUTION
• Do not twist the O-ring that seals the connection area. It may be damaged.
• The O-ring cannot be reused since it is a special part of refrigerant HFC134a.
• Do not tighten the union since it will cause the pipe to deform, resulting in possible coolant leaks. Tighten
the nut.
55-16
55
M E M O
55-17
COMPRESSOR
Removal sequence
1 Discharge hose 4 Belt 9 Collar
(high pressure side) 5 Compressor (left-hand) 10 Tension pulley shaft
2 Suction hose 6 Compressor (right-hand) 11 Tension pulley bracket A
(low pressure side) 7 Tension pulley cover 12 Tension pulley bracket B
3 Pipe stay 8 Tension pulley
• Recover the refrigerant before disconnecting the hose. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
Installation sequence
Follow the removal sequence in reverse.
• See the CONNECTING AIR CONDITIONER PIPING section for the installation of hose and pipe.
• After installation, tension the belt to specification. (See Gr14.)
55-18
55
Inspection procedure
Inspection: Compressor
• Perform the following inspections. If any abnormality is found,
replace or overhaul the compressor at your nearest service sta-
tion.
(1) Operation and oil leakage
• Check the compressor proper for malfunction and oil leakage.
55-19
CONDENSER AND RECEIVER
Removal sequence
1 High pressure pipe 6 Panel
2 Liquid pipe 7 Condenser
3 Insulator
4 Lower panel : Non-reusable parts
5 Protector
Installation sequence
Follow the removal sequence in reverse.
55-20
55
Inspection procedure
Inspection: Condenser
• Clean the fins of the condenser if they are clogged with dirt,
dust, etc. Use a spatula or the like to repair any distortion of the
fins.
55-21
EVAPORATOR AND COOLER DUCT
Removal sequence
1 Front inner duct 6 Outside duct 11 Drain port
2 Cooler duct cover (See Gr63.) 7 Panel 12 Bracket
3 Air outlet grill (See Gr63.) 8 Inside duct 13 Low pressure pipe
4 Cooler duct (See Gr63.) 9 Cooler duct inner sheet 14 Liquid pipe
5 Air outlet duct 10 Drain hose 15 Evaporator
Installation sequence
Follow the removal sequence in reverse.
55-22
55
Removal procedure
Removal: Evaporator
• Disconnect the connectors that connect the evaporator with the
body harness.
• Disconnect the connection with the low pressure pipe and liquid
pipe.
55-23
EVAPORATOR AND COOLER DUCT
Installation procedure
Installation: Drain hose
• Be sure to seal the drain hose floor penetration area with seal-
ant.
55-24
55
M E M O
55-25
HEATER CONTROL
Removal sequence
1 Air-mix control wire 4 Front heater switch
2 Mode switching control wire 5 Heater control
3 Inside/outside air switching control wire 6 Rear heater switch
CAUTION
• Do not disconnect the wires from the heater control except when they are replaced to avoid heater con-
trol clip tabs being deformed.
Installation sequence
Follow the removal sequence in reverse.
Installation procedure
Installation: Air-mix control wire
• Place the temperature control lever on the heater control in the
maximum heating (MAX HOT) position on the extreme right.
• Move the air-mix damper lever in the heater unit to the MAX
HOT position.
• Connect the air-mix control wire to the air-mix damper lever
while still in this condition, and secure it firmly with a clip.
55-26
55
Installation: Mode switching control wire
• Place the mode switching lever on the heater control in the de-
froster (DEF) position.
• Move the mode switching damper lever in the heater unit to the
defroster position.
• Connect the mode switching control wire to the mode switching
damper lever while still in this condition, and secure it firmly with
a clip.
55-27
HEATER AND AIR DUCT
Removal sequence
1 Heater duct LH 7 Defroster duct RH
2 Heater duct RH 8 Center side defroster duct RH
3 Passenger face duct 9 Center side defroster duct LH
4 Driver face duct 10 Center duct
5 Center face duct
6 Defroster duct LH
*a: Front heater
Installation sequence
Follow the removal sequence in reverse.
55-28
FRONT HEATER, DUCT AND BLOWER 55
Removal sequence
1 Front heater 5 Blower
2 Duct
3 Blower register
*a: Water hose (See “REAR HEATER AND HOT WA-
4 Drain hose TER PIPING”.)
Installation sequence
Follow the removal sequence in reverse.
55-29
REAR HEATER AND HOT WATER PIPING
Front Part
55-30
55
Rear Part
Removal sequence
1 Rear heater 4 Water valve *a: Front heater
2 Water hose 5 Bracket
3 Water pipe
Installation sequence
Follow the removal sequence in reverse.
55-31
REAR HEATER AND HOT WATER PIPING
Work before removal
Alignment mark: Water hose
• Be sure to make alignment marks before removal.
Removal procedure
Removal: Rear heater
• Remove the nuts and disconnect the body harness connector
from under the floor.
• Push the heater harness grommet and connector into the vehi-
cle from under the floor to remove the rear heater.
Installation procedure
Installation: Rear heater
• Apply sealant to the mounting surfaces for the rear heater and
mounting hole for the heater harness grommet.
55-32
55
• Apply sealant to the water hose joints.
55-33
GROUP 63 BODY
63-1
SPECIFICATIONS
Door engine <Automatic door>
Specifications
Item
Folding door Swing door
Manufacturer TOSHIN TEC CO., LTD.
Type Vacuum type Electric type
Magnetic valve V–W 24 – 10.7 –
Stroke mm 175 –
Cylinder Output force N {kgf} / kPa {mmHg} 735 {75} / 60 {450} –
3
Displacement cm {L} Approx. 2100 {2.1} –
Airtightness kPa {mmHg} / sec 2 {15} or less/15 –
Voltage range during use V – 22 to 30
Temperature range during use °C – –30 to 60
Angle of rotation ° – 139 or more
Maximum rotational torque N·m {kgf·m} – 98 or more {10 or more}
Rated load torque N·m {kgf·m} – 2.94 {0.3}
Door opening and closing time sec – 3.0 to 4.5
Rated operating current under load
– 10 or less
(when the rated voltage at room temperature is 26 V) A
63-2
63
M E M O
63-3
STRUCTURE AND OPERATION
1. Body
63-4
63
3. Side Door Locking System
3.1 Folding door
63-5
STRUCTURE AND OPERATION
4. Back Door Locking System
63-6
63
6. Trunk Lid Locking System
63-7
STRUCTURE AND OPERATION
7. Automatic Door System <Folding Door>
7.1 Outline
• The automatic door system consists of a door engine, an automatic door switch, vacuum piping, a limiting valve
and other components. The piston rod in the cylinder is connected to the door side.
• Pushing the automatic door switch supplies vacuum to the door engine to activate the cylinder piston rod, which
opens and closes the door.
• With the automatic door switch OPEN, the door opening magnetic valve is activated, the door closing magnetic
valve is deactivated. As a result, the piston rod is moved to the door opening side.
• With the automatic door switch CLOSE, the door opening magnetic valve is deactivated, the door closing magnet-
ic valve is activated. As a result, the position rod is moved to the door closing side.
• With the starter switch in the ACC or LOCK position, the doors can be opened and closed manually.
• Even when the starter switch is in the ON position, placing the emergency switch in the MANUAL position allows
the doors to be opened and closed manually.
63-8
63
7.2 Door open/close and each switch and device operation
Starter switch Automatic door switch Neutral switch Brake indicator lamp Door status
ACC, LOCK Free
ON OPEN OFF Goes off Does not open
ON OPEN ON Goes off Opens
ON OPEN OFF Comes on Opens
ON OPEN ON Comes on Opens
ON NEUTRAL Stops
ON CLOSE Closes
• With the starter switch in the ACC or LOCK position, the doors can be opened and closed manually.
• Even when the starter switch is in the ON position, placing the emergency switch in the MANUAL position allows
the doors to be opened and closed manually.
63-9
STRUCTURE AND OPERATION
8. Automatic Door System <Swing Door>
8.1 Outline
• The automatic door system consists of a door engine unit, an automatic door switch and other components. The
link on the door engine is connected with the swing door arm.
• Pushing the automatic door switch turns the door arm, which opens and closes the door.
63-10
63
8.2 Door open/close and each switch and device operation
Automatic door Brake indicator
Starter switch Neutral switch Door lock actuator Door status
switch lamp
ON OPEN OFF Goes off Locks Stay closed
ON OPEN OFF Comes on Operates Opens
ON OPEN ON Goes off Operates Opens
ON OPEN ON Comes on Operates Opens
ON CLOSE Locks Stay closed
• Even when locked with the key from outside the vehicle or by pushing the lock button inside, the door can be au-
tomatically unlocked and opened by placing the red handle in the AUTOMATIC position and setting the automatic
door switch to the OPEN position. With the red handle in the MANUAL position, the door lock cannot be released.
63-11
STRUCTURE AND OPERATION
8.3 Flow chart
NO Is an Is an
YES
Fully opens and stops Stops immediately exessive exessive
and intermittent load applied? load applied?
buzzer sounds
NO NO
Has 5 seconds
passed after the Fully closes and stops Stops immediately
NO emergency stop? and intermittent
buzzer sounds
YES
YES
Intermittent
buzzer sounds
63-12
63
8.4 Timing chart
63-13
STRUCTURE AND OPERATION
9. Front Wiper and Washer
63-14
63
10.Rear Wiper and Washer
63-15
STRUCTURE AND OPERATION
11. Seat Belt with Emergency Locking Retractor
63-16
63
63-17
TROUBLESHOOTING
Entire Body
Symptoms
vibration)
Possible causes
Body mounting section loose, too much play O O
Body-related
Body installation faulty O O
Cross axes angle of propeller shaft excessive due to
increased tilt caused by deteriorated engine mount- O
ing Gr11
Engine-related
Engine installation faulty O
Intake and exhaust system installation faulty O Gr15
Transmission-related Transmission installation faulty O Gr22
Propeller shaft swing excessive O
Universal joint worn excessively O
Slip yoke joint spline loose O
Propeller shaft-related Center bearing play excessive O Gr25
Cross axes angle of mounting dimension excessive
O
due to deteriorated center bearing cushion rubber
Cross axes angle of propeller shaft excessive due to
O
increased drive shaft tilt caused by overload
Front axle-related Axle seat resonance O Gr26
Reduction gear engaged incorrectly O
Rear axle-related Gr27
Differential gear engaged incorrectly O
Wheel and tire swing excessive O
Wheel and tire unbalanced O
Wheel and tire-related Gr31
Size and kind of tire unequal O
Wheel mounting surface warped O
Suspension-related Leaf spring friction between leaves excessive O Gr33, 34
Brake drum unbalanced O
Brake-related Brake drum eccentric O Gr35
Disc brake rotor eccentric O
63-18
63
Door Lock
Symptoms
is pressed
handle
handle
Possible causes
Door installation faulty O O
Striker installation faulty O
Door latch rod deformed O O O O O
Door latch rod removed O O O O O
Front door
Door latch rod interference O O O O O
Key cylinder deformed O O
Joint screw installation faulty O
Inside door handle spring fatigued O
Door installation faulty O O
Side door <Folding> Stopper installation faulty O
Door lock faulty O O
Door installation faulty O O
Striker installation faulty O
Door latch rod deformed O O O O O
Side door <Swing> Door latch rod removed O O O O O
Door latch rod interference O O O O O
Key cylinder deformed O
Remote control faulty O O O O
Door installation faulty O O
Striker installation faulty O O O O O
Back door Door latch rod deformed O O O O O
Door latch rod removed O O O O O
Key cylinder deformed O
Door installation faulty O O
Striker installation faulty O
Emergency door Door latch rod deformed O O
Door latch rod removed O O
Door latch rod interference O O
63-19
TROUBLESHOOTING
Automatic Door System <Folding Door>
Symptoms
63-20
63
Automatic Door System <Swing door>
Symptoms
63-21
TROUBLESHOOTING
Wiper and Washer
Symptoms
work
Possible causes
Wiper motor faulty O O O O
Washer motor faulty O O O
Wiper and washer switch faulty O O O O O
Wiper control unit faulty O O
Gr54
Wiper relay faulty O O
Fuse/high-current fuse blown O O
Connector improperly connected, harness open-circuited, ground-
O O O O O
ing improper
Wiper motor crank arm set position incorrect O
Wiper link and wiper arm connection faulty O
Wiper blade faulty O O
Wiper arm defective O
Washer hose twisted O O
Washer hose connection faulty O O
Washer nozzle clogged O O
Washer fluid insufficient O
63-22
63
M E M O
63-23
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Front Door Fitting Adjustment
• Adjust front door fitting using the door hinge and striker.
63-24
63
1.3 Front door fitting dimensions
63-25
ON-VEHICLE INSPECTION AND ADJUSTMENT
2. Side Door <Folding Door> Fitting Adjustment
• Adjust the fitting of the side door <Folding door> at hinges and
weatherstrips.
63-26
63
3. Side Door <Swing Door> Fitting Adjustment
• Adjust side door <Swing door> fitting using the arm bracket,
guide arm and striker.
• Remove the step side arm bracket and adjust with the shims.
63-27
ON-VEHICLE INSPECTION AND ADJUSTMENT
3.3 Lateral direction adjustment
• After loosening and adjusting the nut of the guide arm, tighten it
to the specified torque.
63-28
63
4. Back Door Fitting Adjustment
63-29
ON-VEHICLE INSPECTION AND ADJUSTMENT
4.3 Back door fitting dimensions
63-30
63
5. Emergency Door Fitting Adjustment
63-31
ON-VEHICLE INSPECTION AND ADJUSTMENT
5.3 Emergency door fitting dimensions
63-32
63
6. Trunk Lid Fitting Adjustment
• Adjust trunk lid fitting using the hinge and striker.
63-33
ON-VEHICLE INSPECTION AND ADJUSTMENT
6.3 Trunk lid fitting dimensions
63-34
63
7. Fuel Lid Fitting Adjustment
• Adjust fuel lid fitting using the door
hinge and hook.
• Using the door hinge and hook mount-
ing screws, adjust the entire circumfer-
ence clearance between the body and
lid to the dimension shown in the illus-
tration.
63-35
FRONT DOOR
Door Hinge and Striker
Removal sequence
1 Door harness 6 Weatherstrip
2 Door hinge 7 Weatherstrip
3 Door panel (See later section.) 8 Grommet
4 Striker 9 Door switch (See Gr54.)
5 Shim
Installation sequence
Follow the removal sequence in reverse.
• After installation, perform front door fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
63-36
63
M E M O
63-37
FRONT DOOR
Front Door Panel
63-38
63
Disassembly sequence
1 Handle 10 Outer handle 19 Door glass
2 Door pocket 11 Joint cover 20 Lock plate
3 Inner side handle 12 Trim 21 Tap plate
4 Door trim 13 Clip 22 Door check
5 Water-proof cover 14 Sash 23 Front door panel
6 Inner lock knob 15 Run channel
7 Bushing 16 Plate : Non-reusable part
8 Plate 17 Plate
9 Lock link 18 Lock lever
Assembly sequence
Follow the disassembly sequence in reverse.
Removal procedure
Removal: Door trim
• Remove all the clips but the clip A (10 pieces) from the front door
panel.
• Slide the door trim toward the rear of the vehicle to remove it
with the clip A left on the front door panel.
CAUTION
• The clip A is secured to the front door panel. Pulling off the
door trim by force can break the door trim.
63-39
FRONT DOOR
Removal: Sash
• Remove the joint cover and trim. Move the door glass forward or
backward to remove the upper and lower clips.
Installation procedure
Installation: Trim
• Apply butyl rubber tape to the entire circumference of the sash to
install the trim.
• Attach butyl rubber tape with its joint under the door.
63-40
63
Installation: Bushing
• Apply an appropriate instant adhesive to the bushing or the door
panel at the illustrated position. Make sure that the adhesive is
applied neatly within the area. (Double-stick tape can be used
instead of the instant adhesive.)
• Fit the bushing into the door panel.
63-41
SIDE DOOR <FOLDING>
Disassembly sequence
1 Bracket 9 Stopper 18 Seal rubber
2 Ball bushing 10 Cover 19 Hand rail
3 Plate 11 Hinge 20 Weatherstrip
4 Bearing 12 Hinge (handle side) 21 Side door glass
5 Bearing 13 Weatherstrip (pillar side) 22 Shaft
6 Check plate 14 Weatherstrip (door side) 23 Side door panel
<Except automatic door> 15 Door lock 24 Weatherstrip
7 Stopper bracket 16 Cushion rubber 25 Weatherstrip
8 Shim 17 Plate 26 Stopper
Assembly sequence
Follow the disassembly sequence in reverse.
• After installation, perform side door <Folding door> fitting adjustment. (See “ON-VEHICLE INSPECTION AND
ADJUSTMENT”.)
63-42
63
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (installation of bracket)
Bolt (installation of stopper) 4 to 6 {0.4 to 0.6} –
Bolt (installation of stopper bracket)
Removal procedure
Removal: Side door glass
• While lifting the lip area of the weatherstrip with a screwdriver,
push off the side door glass from the door from inside.
Installation procedure
Installation: Weatherstrip
• Apply an appropriate adhesive to the positions shown in the il-
lustration and install the weatherstrips in place.
63-43
SIDE DOOR <FOLDING>
Installation: Side door glass
• Apply an appropriate sealant to the entire outside circumference
of the flange of the side door panel.
• Firmly push the glass from outside while pulling one end of the
string from inside to fit the cab side mounting groove of the
weatherstrip to the flange part of the side door.
63-44
63
Adjustment after installation
Adjustment: Stopper
• Adjust the number of shims so that the contact area between the
stopper and door lock falls within the range of dimension shown
in the illustration.
63-45
SIDE DOOR <SWING>
Guide Arm and Swing Door Arm
Disassembly sequence
1 Bracket 7 Shim 12 Striker
2 Plate 8 Boot 13 Shim
3 Guide arm 9 Cushion rubber 14 Door check
4 Arm bracket (door side) 10 Swing door arm 15 Check plate
5 Arm bracket (pillar side) 11 Swing door panel
6 Arm bracket (step side) (See later section.)
Assembly sequence
Follow the disassembly sequence in reverse.
• After installation, perform side door <Swing door> fitting adjustment. (See “ON-VEHICLE INSPECTION AND AD-
JUSTMENT”.)
63-46
63
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Nut (installation of guide arm) 19 to 28 {1.9 to 2.9} –
Bolt (installation of plate)
17 to 26 {1.7 to 2.7} –
Bolt (installation of arm bracket)
Bolt (installation of arm bracket) 35 to 55 {3.6 to 5.6} –
Nut (installation of cushion rubber) 34 to 50 {3.5 to 5.1} –
Bolt (installation of striker) 8.8 to 14 {0.9 to 1.4} –
Bolt (installation of door check)
Bolt (installation of door check arm bracket)
Bolt (installation of door check arm) 4 to 6 {0.4 to 0.6} –
Nut (installation of door check arm bracket and door check
arm)
63-47
SIDE DOOR <SWING>
Swing Door Panel
Disassembly sequence
1 Side door glass 12 Latch
2 Molding 13 Cover
3 Glass clip 14 Inside lock knob
4 Trim edge 15 Sub link
5 Clip 16 Link
6 Trim 17 Key cylinder
7 Water-proof film 18 Swing door panel
8 Vent cover 19 Weatherstrip
9 Outside handle 20 Weatherstrip
10 Inside handle
11 Latch : Non-reusable parts
Assembly sequence
Follow the assembly sequence in reverse.
63-48
63
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Glass clip surface Yokohama Rubber RC-50E As required
Side door glass surface Yokohama Rubber GM-78 As required
Adhesive surface between glass clip and side door glass Yokohama Rubber WS-30 As required
Side door glass surface Sika Cleaner No.1 As required
Adhesive surface of side door glass Sika Flex 250PC-JM1 As required
Water-proof film mounting surface on swing door panel Butyl rubber tape As required
Removal procedure
Removal: Side door glass
• Insert a piano wire or a cutting machine in between the side door
glass and swing door panel and separate them.
Leave a layer of adhesive at least 1 mm in thickness to prevent
the paint coating (ceramic film in the case of glass) from coming
off.
• If the paint coating is come off, apply primer VP209. If the ce-
ramic film of the glass is come off, mend the glass by applying
black primer.
Installation procedure
Installation: Vent cover and water-proof film
• Apply butyl rubber tape to the entire circumference of the water-
proof film and vent cover mounting surface as shown in the illus-
tration and install them.
63-49
SIDE DOOR <SWING>
Installation: Trim edge
• Appropriately cut (2550 mm long) the trim edge and install it with
its joint at the center of the door.
• After the primer is dried, bond the glass clips to the side door
glass with adhesive (Yokohama Rubber WS-30). The fitting po-
sitions of the glass clips are as shown in the illustration. Make
sure that the difference of dimension C and D is less than 1 mm.
63-50
63
• Apply adhesive (Sika Flex 250PC) to the entire circumference of
the swing door panel as shown in the illustration.
CAUTION
• The adhesive application cross section should form a trian-
gle that has a bottom 8 mm wide and a height of 12 mm.
• Be sure to apply the adhesive evenly. The amount of the ad-
hesive tends to decrease or increase at the beginning and
end points of application and the corners.
• Since the adhesive is quick to dry, work on one window at a
time and finish installing the glass within 8 minutes after the
start of adhesive application.
• Since the adhesive is urethane, it has poor compatibility
with silicone sealer. For this reason, adhesion failure may
occur if their locations are not taken into consideration. If
the distance between them is less than 1 m, apply one of
them 24 hours after the other was applied. When the dis-
tance is more than 1 m, work on the vehicle in a sufficiently
ventilated place though this case poses no danger normal-
ly.
• Lift the window using suction cups or the like to keep the appli-
cation surface clean and insert the glass clips on the side door
glass into the three holes in the swing door panel to install the
glass.
CAUTION
• If you should touch the application surface with bare hands
or lubricant should adhere to it, apply the adhesive again.
63-51
BACK DOOR
Hinge and Catch
Removal sequence
1 Spring pin 7 Spacer
2 Door check 8 Rubber
3 Hinge 9 Weatherstrip
4 Back door panel (See later section.) 10 Weatherstrip
5 Catch
6 Skid : Non-reusable part
Installation sequence
Follow the removal sequence in reverse.
• After installation, perform back door fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
63-52
63
Back Door Panel
Removal sequence
1 Weatherstrip 9 Rubber
2 Back door glass 10 Spacer
3 Outer weatherstrip 11 Striker
4 Inner weatherstrip 12 Shim
5 Assist grip 13 Back door panel
6 Back door trim
7 Water-proof film : Non-reusable parts
8 Skid
Installation sequence
Follow the removal sequence in reverse.
63-53
BACK DOOR
Removal procedure
Removal: Back door glass
• While lifting the lip area of the weatherstrip with a screwdriver,
push off the back door glass from the door from inside.
Installation procedure
Installation: Inner weatherstrip
Installation: Weatherstrip
• Apply sealant to the adhesive surface between the weatherstrip
and the back door glass.
• Install the back door glass with its joint under the door.
63-54
63
• Firmly push the back door glass from outside while pulling one
end of the string from inside to fit the cab side mounting groove
of the weatherstrip to the flange lip area of the body.
• If the edge of weatherstrip does not stick on the flange lip area of
the body at the corners (4 places), apply adhesive to stick it fast.
63-55
BACK DOOR
Door Lock System
Disassembly sequence
1 Lock knob 6 Lock 11 Latch
2 Bushing 7 Outer handle 12 Back door panel
3 Inner handle 8 Retainer
4 Remote control 9 Key cylinder : Non-reusable parts
5 Insulator 10 Door lock controller
Assembly sequence
Follow the disassembly sequence in reverse.
63-56
63
Installation procedure
Installation: Door lock controller
• Turn the regulation pin of the door lock controller to adjust the
distance between the rod end and the center of the regulation
pin to the dimension as shown in the illustration.
Installation: Insulator
• Apply adhesive to the slits of the insulators.
• Install the insulators in the lock at regular intervals.
63-57
EMERGENCY DOOR
Door Check, Hinge and Catch
Disassembly sequence
1 Door check 5 Shim
2 Hinge 6 Stopper
3 Emergency door panel (See later section.) 7 Weatherstrip
4 Striker 8 Weatherstrip
Assembly sequence
Follow the disassembly sequence in reverse.
• After installation, perform emergency door fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
63-58
63
Emergency Door Panel
Disassembly sequence
1 Door pull handle 6 Emergency door glass
2 Cover 7 Inner weatherstrip
3 Edge molding 8 Outer weatherstrip
4 Emergency door trim 9 Lever cover
5 Weatherstrip 10 Emergency door panel
Assembly sequence
Follow the disassembly sequence in reverse.
63-59
EMERGENCY DOOR
Removal procedure
Removal: Emergency door glass
• While lifting the lip area of the weatherstrip with a screwdriver,
push off the emergency door glass from the door from inside.
Installation procedure
Installation: Lever cover
• Fit the inner weatherstrip into the lever cover. The weatherstrip
should be a little longer at the joint.
CAUTION
• Do not pull the inner weatherstrip too tightly when fitting it.
Otherwise, it will shrink later, forming gaps.
Installation: Weatherstrip
• Apply sealant to the adhesive surface between the weatherstrip
and the emergency door glass.
• Install the emergency door glass with its joint under the door.
63-60
63
Installation: Emergency door glass
• Overlap a strong string in the body mounting groove of the
weatherstrip.
• Firmly push the emergency door glass from outside while pulling
one end of the string from inside to fit the cab side mounting
groove of the weatherstrip to the flange lip area of the body.
• If the edge of weatherstrip does not stick on the flange lip area of
the body at the corners (4 places), apply adhesive to stick it fast.
63-61
EMERGENCY DOOR
Door Locking System
Disassembly sequence
1 Controller panel
2 Door lock controller
3 Insulator
4 Upper door lock
5 Latch
6 Stopper
7 Striker
8 Shim
9 Emergency door panel
Assembly sequence
Follow the disassembly sequence in re-
verse.
Installation procedure
Installation: Upper door lock
• Turn the regulation pin of the upper door lock to adjust the dis-
tance between the rod end and the center of the regulation pin to
the dimension as shown in the illustration.
Installation: Insulator
• Apply adhesive to the slits of the insulators.
• Install the insulators in the upper door lock at regular intervals.
63-62
63
Installation: Door lock controller
• Turn the regulation pin of the door lock controller to adjust the
distance between the rod end and the center of the regulation
pin to the dimension as shown in the illustration.
63-63
TRUNK LID
Disassembly sequence
1 Ball joint 7 Retainer 13 Shim
2 Damper stay 8 Lock cylinder 14 Weatherstrip
3 Hinge 9 Latch 15 Weatherstrip
4 Christmas tree clip 10 Handle
5 Trim 11 Trunk lid panel : Non-reusable part
6 Water-proof film 12 Striker
Assembly sequence
Follow the disassembly sequence in reverse.
• After installation, perform trunk lid fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
63-64
63
Installation procedure
Installation: Water-proof film
• Apply butyl rubber tape to the entire circumference of the water-
proof film mounting surface as shown in the illustration and then
install the water-proof film.
63-65
AUTOMATIC DOOR SYSTEM <FOLDING DOOR>
Removal sequence
1 Clevis pin 6 Tail bracket 12 Cover
2 Cylinder cover 7 Door bracket 13 Vacuum reservoir tank
3 Vacuum hose 8 Vacuum pipe
4 Emergency switch (See 9 Vacuum hose
*a: Side door (See “SIDE DOOR
Gr54.) 10 Vacuum hose <FOLDING>”.)
5 Cylinder (See later section.) 11 Limiting valve
* b: Vacuum pipe
Installation sequence
Follow the removal sequence in reverse.
63-66
63
Installation procedure
Installation: Vacuum pipe and vacuum hose
• Install the vacuum hose and vacuum pipe with the insertion
depth shown in the illustration and secure them with the hose
clip.
Installation: Cylinder
• Check that cylinder mounting surface is flat. If there are irregu-
larities, mend the surface.
CAUTION
• If the cylinder is installed in the irregular mounting surface,
the door will not open and close smoothly.
• After making sure that the door can be properly opened and
closed in the above temporary installation positions, secure the
tail bracket and set the adjustment screw.
• Open the door and pull out the clevis of the cylinder to the fully
closed position.
• Install the cylinder by aligning the door bracket with the center of
the play in clevis in the vertical direction.
63-67
AUTOMATIC DOOR SYSTEM <FOLDING DOOR>
• Loosen the nuts of the clevis part of the cylinder and door brack-
et to adjust the dimensions to those shown in the illustration
when the door is opened and closed.
• After installation, supply air to the cylinder, insert the clevis pin
into the door bracket and secure it with the cotter pin.
• Move the door manually again to make sure that it moves
smoothly and there is sufficient stroke.
CAUTION
• Make sure that the area around the door is safe when begin-
ning to supply air since the cylinder may suddenly operate.
63-68
63
Cylinder
Disassembly sequence
1 Front hose 8 Cylinder tail 15 X-ring
2 Wiring harness 9 Clevis 16 Cylinder head
3 Solenoid valve unit 10 Boot 17 Felt
4 Stud bolt 11 Packing 18 Cylinder shell
5 Adjustment screw 12 O-ring
6 O-ring 13 Piston rod : Non-reusable parts
7 Packing 14 Packing
Assembly sequence
Follow the disassembly sequence in reverse.
CAUTION
• Clean the cylinder tail, piston rod, cylinder head and cylinder shell with cleaning oil before assembly.
63-69
AUTOMATIC DOOR SYSTEM <SWING DOOR>
Removal sequence
1
2
Door lock actuator (See later section.)
Door engine cover
*a: Swing door arm
(See “SIDE DOOR <SWING>”.)
3
4
E-ring
Link collar
* b: Trim
(See “Swing Door Panel”.)
5 Door engine (See later section.)
Installation sequence
Follow the removal sequence in reverse.
63-70
63
Removal procedure
Removal: Door lock actuator
• Remove the trim.
(See “Swing Door Panel”.)
• Remove the rod clip to disconnect the connection with the re-
mote control.
• Remove the mounting bolt to remove the door lock actuator.
Installation procedure
Installation: Door engine
• Check that the door engine mounting surface is flat. If there are
irregularities, mend the surface.
CAUTION
• If the door engine is installed in the irregular mounting sur-
face, the door will not open and close smoothly.
63-71
AUTOMATIC DOOR SYSTEM <SWING DOOR>
Door Lock Actuator
Disassembly sequence
1 E-ring
2 Link
3 Wave washer
4 Motor bracket
5 Lock motor
Assembly sequence
Follow the disassembly sequence in re-
verse.
63-72
63
Door Engine
Disassembly sequence
1 E-ring 8 Dog collar 15 Grommet
2 Joint pin 9 Rubber cover 16 Box bracket
3 Link 10 Wire harness set 17 Automatic door control box
4 Plate 11 Separator 18 Motor
5 Arm 12 Retainer 19 Gearbox
6 Plate spring 13 Red handle
7 Collar 14 Lever
Assembly sequence
Follow the disassembly sequence in reverse.
63-73
WINDSHIELD AND REAR WINDOW GLASS
Removal sequence
1 Weatherstrip
2 Windshield
3 Weatherstrip
4 Rear glass
Installation sequence
Follow the removal sequence in reverse.
63-74
63
Removal procedure
Removal: Windshield
• While lifting the lip area of the weatherstrip with a screwdriver,
push off the side door glass from the body from inside.
Installation procedure
Installation: Windshield and rear glass
<Windshield>
• Apply the sealant A (Orotex BM4 × 8) to the areas of the body
shown in the illustration.
• Apply the sealant B (Nitto Sealant No.687) to the entire periph-
ery of the windshield mounting surface of the body.
63-75
WINDSHIELD AND REAR WINDOW GLASS
<Rear glass>
• Apply the sealant B (Nitto Sealant No.687) to the entire periph-
ery of the rear glass mounting surface of the body.
• Install the weatherstrip with its joint at the center of the door.
• Firmly push the windshield or the rear glass from outside while
pulling one end of the string from inside to fit the cab side mount-
ing groove of the weatherstrip to the flange part of the body.
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63
• Fill the glass fitting portion of weatherstrip with the sealant.
63-77
SAFETY WINDOW GLASS
Removal sequence
1 Safety window glass
2 Fastener
3 Dam
: Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
Removal procedure
Removal: Safety window glass
• Insert a piano wire or a cutting machine in between the safety
window glass and body and separate them. Leave a layer of ad-
hesive at least 1 mm in thickness to prevent the paint coating
(ceramic film in the case of glass) from coming off.
• If the paint coating is come off, apply primer VP209. If the ce-
ramic film of the glass is come off, mend the glass by applying
black primer.
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63
Installation procedure
Installation: Safety window glass
• Fit the dam to the entire body side periphery of the safety win-
dow glass.
• Fit the fasteners to the appropriate positions in the glass and
body shown in the illustration.
• Lift the safety window glass using suction cups or the like to
keep the application surface clean and install it in the body as
shown in the illustration. Push the fitting area lightly to engage
the fasteners fitted on the glass and body properly.
CAUTION
• If you should touch the application surface with bare hands
or lubricant should adhere to it, apply the adhesive again.
63-79
SIDE WINDOW GLASS <SLIDING WINDOW>
Disassembly sequence
1 Joint cover 6 Packing
2 Side window trim 7 Glass
3 Clip 8 Run channel
4 Lock 9 Center seal
5 Connector 10 Side window sash
Assembly sequence
Follow the disassembly sequence in reverse.
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63
Removal procedure
Removal: Side window sash
• Remove the joint cover, side window trim and clip from inside
the vehicle.
• Push off the side window sash to the outside with the glasses
moved to the center of the sash.
Removal: Glass
• Remove the glasses while lifting the upper frame of the sash.
63-81
SIDE WINDOW GLASS <SLIDING WINDOW>
Installation procedure
Installation: Side window sash
• Remove butyl rubber tape completely from the body and side
window sash.
• Wipe off dirt, dust, grease and all other foreign matter from the
adhesive surface of the body with the side window sash using a
clean piece of gauze or cloth moistened with isopropyl alcohol.
• Attach butyl rubber tape to the entire backside circumference of
side window sash.
CAUTION
• Make sure the tape joint is at the bottom.
• Press-fit the side window sash to the body. Fit the clips at the po-
sitions shown in the illustration.
• Install the window trim in place and fit the joint cover at the joint.
CAUTION
• Locate the window trim joint at the position shown in the il-
lustration to prevent overlap with the clip.
• Install the joint cover with its longer flange inside.
63-82
63
M E M O
63-83
SIDE WINDOW GLASS <FIXED WINDOW>
Disassembly sequence
1 Joint cover 5 Glass
2 Side window trim 6 Weatherstrip
3 Clip 7 Side window sash
4 Weatherstrip
Assembly sequence
Follow the disassembly sequence in reverse.
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63
Removal procedure
Removal: Side window sash
• Remove the joint cover, side window trim and clip from inside
the vehicle.
Installation procedure
Installation: Glass
• Clean the edge of the glass with unleaded gasoline.
• Install the weatherstrip in the glass.
• Apply soapy water to the weatherstrip.
• Install the side window sash with the glass indication mark inside
the vehicle and under the side window sash.
63-85
SIDE WINDOW GLASS <FIXED WINDOW>
• Batten the side window sash and tap it lightly to install the glass
with the dimension shown in the illustration.
• Press-fit the side window sash to the body. Fit the clips at the po-
sitions shown in the illustration.
• Install the window trim in place and fit the joint cover at the joint.
CAUTION
• Locate the window trim joint at the position shown in the il-
lustration to prevent overlap with the clip.
• Install the joint cover with its longer flange inside.
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63
Installation: Weatherstrip
• Install the weatherstrip with side window sash.
63-87
FRONT BUMPER
Disassembly sequence
1 Molding 7 Front bumper
2 Cap 8 Bumper bracket
3 Front grille 9 Splash shield <Without fog lamp>
4 Grommet
5 Head lamp bezel
*a: Front combination lamp (See Gr54.)
6 Head lamp bracket
*b: Head lamp (See Gr54.)
Assembly sequence
Follow the disassembly sequence in reverse.
Removal procedure
Removal: Molding
• Remove the clip and Velcro 1 with a screwdriver or the like. Take
care not to damage the clip.
• Remove Velcro 2. While pulling out the tab toward the vehicle
center, remove the molding.
CAUTION
• When removing the clip, take care not to scratch the body.
• If the molding is pulled by force, the tab may be broken.
63-88
REAR BUMPER 63
Removal sequence
1 Bracket *b:
a: Cross member
2 Rear bumper
3 Grommet
* Rear side panel
Installation sequence
Follow the removal sequence in reverse.
63-89
GARNISH
Removal sequence
1 Rear garnish
2 Trim clip
3 Weatherstrip
Installation sequence
Follow the removal sequence in reverse.
Installation procedure
Installation: Weatherstrip
• Stick the weatherstrip (cut it to the appropriate length) on the
body at the positions shown in the illustration.
63-90
63
M E M O
63-91
INSTRUMENT PANEL
Lower Panel
Disassembly sequence
1 Cigarette lighter 6 Driver side lower panel
2 Ashtray 7 Fuse box lid
3 Center lower panel 8 Lower side panel
4 Lower panel bracket
5 Idling speed adjustment knob
*a: Instrument panel (See later section.)
Assembly sequence
Follow the disassembly sequence in reverse.
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63
Area around Meter Cluster
Disassembly sequence
1 Switch or plug 9 Box
2 Plug 10 Bracket
3 Switch or plug 11 Air conditioner control panel
4 Center upper panel 12 Bracket
5 Meter cluster (See Gr54.) 13 Heater controls (See Gr55.)
6 Radio bracket
7
8
Box
Radio or audio system (See Gr54.)
*a: Instrument panel (See later section.)
Assembly sequence
Follow the disassembly sequence in reverse.
63-93
INSTRUMENT PANEL
Removal procedure
Removal: Switch or plug
Removal: Plug
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63
Removal: Switch or plug
63-95
INSTRUMENT PANEL
Instrument Panel
63-96
63
Disassemble sequence
1 Instrument panel bracket 5 Air outlet grille
2 Oil tank lid 6 Center frame support
3 Glove compartment 7 Instrument panel support bracket
4 Instrument panel 8 Instrument panel frame
Assembly sequence
Follow the disassembly sequence in reverse.
63-97
HEAD LINING <FRONT>
Removal sequence
1 Inside mirror
2 Sun visor
3 Air outlet grille (single and double)
4 Clock
5 Molding clip
6 End cap
7 Head lining molding
8 Front head lining
9 Head lining support rail
: Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
Removal procedure
Removal: Air outlet grille (single)
• Using a flat-blade screwdriver, remove the air outlet grille.
63-98
63
M E M O
63-99
HEAD LINING <CENTER>
Removal sequence
1 Rack
2 Room lamp
3 Speaker
4 Air outlet grille
<With air conditioner>
5 Molding clip
6 End cap
7 Head lining molding
8 Cooler duct cover
9 Head lining
10 Clip
11 Cooler duct <With air conditioner>
Trim <Without air conditioner>
12 Cooler duct sheet
<With air conditioner>
: Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
Removal procedure
Removal: Air outlet grille
• Using a flat-blade screwdriver, remove the air outlet grille.
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63
Removal: Head lining molding
• Lowering the head lining molding will bring the molding clip into
view. Cut it off using scissors or a utility knife.
CAUTION
• When cutting off the molding clip, be careful not to damage
the head lining.
Removal: Trim
• Remove the screws and then remove the trim from the body.
63-101
HEAD LINING <REAR>
Removal sequence
1 Air outlet grille
2 Molding clip
3 End cap
4 Head lining molding
5 Christmas tree clip
6 Louver
7 Frame
8 Rear head lining
9 Head lining support rail
: Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
Removal procedure
Removal: Head lining molding
• Lowering the head lining molding will bring the molding clip into
view. Cut it off using scissors or a utility knife.
CAUTION
• When cutting off the molding clip, be careful not to damage
the head lining.
63-102
63
M E M O
63-103
OUTSIDE REAR VIEW MIRROR <DRIVER SIDE>
Disassembly sequence
1 Mirror
2 Stay
Assembly sequence
Follow the disassembly sequence in re-
verse.
Installation procedure
Installation: Stay
• Align the alignment marks as shown in the illustration and install
the stay.
63-104
OUTSIDE REAR VIEW MIRROR <PASSENGER SIDE> 63
Disassembly sequence
1 Mirror
2 Under mirror
3 Stay
Assembly sequence
Follow the disassembly sequence in re-
verse.
Installation procedure
Installation: Stay
• Align the alignment marks as shown in the illustration and install
the stay.
63-105
FRONT WIPER AND WASHER
Removal sequence
1 Wiper blade 7 Wiper link
2 Blade rubber 8 Washer nozzle
3 Wiper arm 9 Grommet
4 Seal rubber 10 Cable strap
5 Wiper motor (See Gr54.) 11 Tube
6 Motor bracket 12 Washer tank motor (See Gr54.)
CAUTION
• Remove the instrument panel before disassembling the wiper motor, motor bracket, wiper link, grommet,
cable straps and tube. (See “INSTRUMENT PANEL”.)
Installation sequence
Follow the removal sequence in reverse.
Service standards
Location Maintenance item Standard value Limit Remedy
Driver side 7.3 ± 0.5 N {740 ± 50 gf} – Replace
3 Wiper arm pressing force
Passenger side 6.2 ± 0.5 N {630 ± 50 gf} – Replace
63-106
63
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Nut (installation of wiper arm) 23.8 ± 4.8 {2.4 ± 0.5} –
Bolt (installation of wiper link)
Bolt (installation of motor bracket) 4.7 ± 0.9 {0.5 ± 0.1} –
Bolt (installation of wiper motor)
Nut (installation of motor bracket) 11.2 ± 2.2 {1.1 ± 0.2} –
Removal procedure
Removal: Washer nozzle
• Grip the washer nozzle with pliers.
• While bending the tabs, pull the washer nozzle to remove it.
Take care not to damage the exterior body panel.
• Remove the tube.
CAUTION
• Take care not to damage the washer nozzle.
Inspection procedure
Inspection: Wiper arm pressing force
• If the measurement deviates from the standard value, replace
the wiper arm.
63-107
FRONT WIPER AND WASHER
Installation procedure
Installation: Washer nozzle
• Connect the tube to install the washer nozzle.
63-108
63
M E M O
63-109
REAR WIPER AND WASHER
Removal sequence
1 Cover 7 Washer nozzle
2 Wiper blade 8 Grommet
3 Blade rubber 9 Cable strap
4 Wiper arm 10 Tube
5 Pivot cap 11 Washer tank motor (See Gr54.)
6 Wiper motor (See Gr54.)
CAUTION
• The grommet, cable straps, tube and washer tank motor cannot be accessed without removing the trunk
trim. To disassemble the rear wiper and washer, remove the trunk trim first.
Installation sequence
Follow the removal sequence in reverse.
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63
Service standards
Location Maintenance item Standard value Limit Remedy
4 Wiper arm pressing force 4.2 ± 0.4 N {430 ± 40 gf} – Replace
Removal procedure
Removal: Washer nozzle
• Grip the washer nozzle with pliers.
• While bending the tabs, pull the washer nozzle to remove it.
Take care not to damage the exterior body panel.
• Remove the tube.
CAUTION
• Take care not to damage the washer nozzle.
Inspection procedure
Inspection: Wiper arm pressing force
• If the measurement deviates from the standard value, replace
the wiper arm.
63-111
REAR WIPER AND WASHER
Installation procedure
Installation: Washer nozzle
• Connect the tube to install the washer nozzle.
63-112
SEAT BELT 63
Removal sequence
1 Shoulder anchor cover
2 Emergency locking retractor
3 Buckle
Installation sequence
Follow the removal sequence in reverse.
CAUTION
• Do not disassemble the emergency locking retractor.
63-113
(EURO 3)
chassis
FEBRUARY 2013
550 (H)
Pub.No.00ELB0011, FEBRUARY 2013