FORWARD

This Maintenance and Repair Manual has been prepared to

provide the n2cessary information and data for the correct
maintenance and repair of THE ELECTRA VAN 6 0 0 .

J Z T I N D U S T R I E S , INC.
AUSTIP; , TEXAS
 CHAPTER 1: BODY

1- 1 . COMPOi-JENT P A X T S O F BODY CONSTP,UCTIOIl . . . . . . . . 1

1- 2 . C H A S S I S FRAME DATUFI P O I N T . . . . .. . . . . . . . 2

1- 3 . . . . . .
BODY PARTS . . . . . . . .. . . . . . . . 3

1- 4. DOORS . . . . . . . . . . . . . . .. . . . . . . . 4

1.5 . WINDSHIELDGLASS . . . . . . . . . .. . . . . . . . 18

1.6 . INSTRUMENTPANEL . . . . . . . . . .. . . . . . . . 20

1- 7 . SEAT . . . . . . . . . . . . . . .. . . . . . . . 27

1.8 . I N N E R T R I M . . . . . 5 . . . . . . . . . . . . . . 29

1- 9 . INNER ACCESSORIES . . . . . . . . . . . . . . . . . 31
1-10 . OUTER ACCESSORIES . . . . . . . . . . . . . . . . . 32
1- 1. COMPONENT PARTS OF BODY CONSTRUCTION

Rescrvoir tank flap Bracket

Pillar Rear sheli
Front pillar Ccnler pillar (Inner)
Front panel Side rail
Weather slrip Lower slide rail
Drip rail Rcar quarter pancl (Inner)
Shutter Rear quarter panel ( o u k r )
Front rail Upper slide rail
Roof panel Center pillar (Outer)
Rcar rail Cussct
Cab floor Chassis frame
Fender Front under covcr
Back panel Center under cover
Hand brakc cablc protector Rcas under covcr
Reiniorccnicnl Engine room covcr
Ccnler floor panel Under covcr brackcl

- . --

Fig. . I Component parts of body construction

Fig. 1 Charsisfrurne datum poiniJ
1- 3. BODY PARTS

1. Front Bumper
REMOVAL AND INSTALLATION

1) Remove the screws on bumper pad under right and left

combination lights. Remove rubber b~cmpercovering.

2) Remove the two bolts under the right and left combina-
tion lights to disconnect bumbez.
3) Installation is the reverse order of .-remqval.
2. Rear Bumper - k

REMOVAL AND INSTALLATION

1) Remove the four screws under the right-and left combina-

2) Remove the four bolts on bumber uider the right and left
combination light to disconnect bumper.
3) Installation is the reverse order of removal.
-*

1-4
 1-4. DOORS
i
A. COMPONENT PARS OF DOORS
1

1 Cab door pancl 11 Cab door latch

2 Sash 12 Slrikcr wcdgc
3 Spring 13 Door striker
4 Cab door hinge Id Spacer
5 Weather strip IS Run ctlanncl
6 Cab door repulator 16 Door glass
7 Regulator handle 17 Cab door remote control
8 Oulcr handle 18 Escutcheon
9 Sealitrg cover 19 Door handlc
10 Pull hsridle T21-018

Fig. Conlponent parts of cab door

Wcrlher strip Suspender
Slide glass rail Plale
Slide glass frame Inner handle
Slide g l ~ s s Esculchcon
Slide door panel Slide door remote colilrol
Slide door upper arm Door latch
Outer handle Wedge
Slide door lower arm Spaccr
Slide door stoppcr S trikcr
Striker Slide door arm

Fig. . 9 Component parts of slide door

m%
D€TAIL 'C' DETAIL '0'

I Weather strip 8 Key lock

2 Wcathcr strip 9 Latch
3 Joint 10 Striker
4 hloulding 11 Slop nu1
5 Back door glass I2 Back doar hinge
6 Back door panel 13 Back door stay
7 Clip 14 Stopper

Fig. 5 1, Ccmtponent ports 01back door

&,
B. CABDOOR 2. Door hinge
1) INSPECTION
1. Door lock striker
a. When the door rattles in thc axial direction
1) . ADJUSTMENT and right angle direction, tighten the hinge
Move the d m r lock striker mounting posi- mounting bolts.
lion up and down and left and right, and adjust b. When the hinge pin section rattles, replace
in the front and rear with shims so that the the hinge assembly. .
door is closed easily and does not rattle. 2) ADJUSTMENT
a. Perform adjustment using the door hinge set
bolt wrench.
Adjustment is also possible with a common
tool if the front grille and front bumper are
removed.
b. Adjust the door in the vertical and trans-
versal directions by loosening the pdlar side
hinge boIts.

Fig. . b Adjrrsting dour luck striker

NOTE:
After adjustment of the door, confirm there
is no play around the door when the outer
handle is depressed with the door closed.
Play, if found, shall be removed according
to the following procedure.
1) Loosen four screws; Fig. .' 8 Adjusting door hinge
2 ) Turn the wedge around the pin with
the wedge centering on the wedge c. Small amount of adjustment in the door
receiver. transversal direction and vertical dircction
3) ,Loosen screws. can be performed by loosening the door side
4 ) Close the door to check play of the hinge.
door.

1 1
Fig. 7 Fig. . q : Adjusting door hirye

a *I-..
3. Door window regulator d . Turn the glass while rotating the regulator
tlandlc, remove the glass from the regulator
1) REMOVAL and hold the glass so that it doesn't iaII.
a. Remove the regulator handle, inner remote
k
.
: handle
.. ;Ad..door inner pull handle, and NOTE:
'remove.Ith;- .door trim.
-?

When-~emovingt h e glass, hold its f r o n t o r

rear side up and remove upward.

Fig. 1 0 'Removing door trim

b. Remove the sealing cover.

Fig. 13 RemovinggLzsj

e . Remove the window regulator mounting

bolts and remove the regclator frorn the
working hole.

Fig. 11 Removing senling cover

c. Place the glass in the middle position (verti-
cal) and remove t w o regulator rail mounting
bolts.

Fig. . 4 Removing r e p l a i o r

2) INSTALLATION
Installation js the reverse of renioval. Pay
careful attention to the direction o f the puU
handlc, the regulator handle and remote handle
Fig. ) 1. Pemoving bolts installation angle.
4. Cab door glass

1) REPLACEMENT
a. Remove the glass assembly from t h e regula-
tor in t h e same manner as rcmoving the
regulator. ,
b. Installation is the reverse of removal.

NOTE:.
To hold the glass horizonatally and move up
and down without iildinalion, finely adjust
the rail of the regulztor sub arm up and
dcwn.
Fig. I b ' Removing rear quarter trim
5. Door lock
I ) REMOVAL AND REINSTALLATION b. Remove t h e stopper (sliding door) from tlie
a. Remove rhc d c o r trim, and t h e service hole lower rail.
cover, and raise t h e glass t o the top.
b. Remove t h e safety knob, and disconnect the
outer handle and inner remote wire con-
nec t ion,
c . Unscrew the door lock rnounting screws, and
remove the lock through the working hole.
d. Installation is the reverse of removal.

Fig. ./ 7.- R ~ m o v i n gStopper (sliding door)

c. Remove the stopper (center arm) from the
center rail.
Marking the mounting position during re-
moval will facilitate installation.

Fig. 1s Removing door lock

C. SLIDING DOOH

I. Sliding door

1) REMOVAL
a. Remove the rear quai-ter trim (refer t o trim
panel item). Fig. .I 8 Removing stopper (center a m )
)

=-%
 --

d. Move the door to the rear end, pull the

lower arm out from the lower rail and the
upper roller from the upper rail. Floor
When moving the door, be careful that the
door is not slanted. Socurly insert

clearance.

TZf 0 2 2

Fig. Installing stopper (sliding door)

Fk. 1 9 Removing slid in^ door r

0
0
I
0
e. SIide the door to the front end 1 rernove
the center arm from the center i a l l .

/
Stopper (sliding door 1

Fk. 251 Stopper (sliding &or)

e. Fasten the door stopper (center arm) tern-

porarily (so that it can be moved by hand).

2) INSTALLATION
a. Fit the upper arm to the upper rail.
b. Fit the lower arm from the rear cnd of the
lower rail.
c. Slide the door to the front end and fit the /
center arm to the center rait, Stopper (center arm)
. d . InstaU the stopper (sliding door). At this
time, insert the flange of the stopper secure-
ly between the flanges of the rail, Fig. 13 Stopper (center a r m )
f. With the door closed (striker and ratchet
perfectly meshed), tighten the stopper
(center arm) securely.
g. Install the rear quarter trim.

NOTE:
Tightening torque:
Stopper (sliding door)
8 mm bolt:
1.2 to 1.4 kg-m 18.7 to 10.1 ft-lb)
5 m m bolt:
Fig.& Adjusting sliding d o o r
0.25 to 0.30 kg-m (1.8 to 1.0 ft-16)
Stopper (center arm)
8 mm bolts: When inequality has appeared between door
1.0 to 1.2 kg-rn (7.2 to 8.7 ft-lb) and pillar, adjust it by moving the upper arm or
striker to the left or right.

3)
-
Removing and installing the galss
The glass can be removed and installed
together with the rubber.

24
Fig.I.r Moving upper arm

Fig. 3 Rmtovinggh$

4) Adiustment of thc s1idin.g door

. when the sliding door is inclined, adjust it
by moving the lower arm up and down. Fk. & Moving striker i
NOTE: 5) Inspection o f the arms
When performing above procedure, pay at- a. 1s there any rattling at the slaked section o f
tention to the contact between striker and each arm ? -- Staking.
suspender. b. Is there any leaning wear on the roller ? --
Replace roller.
c. Is the spring o f the center arm abnormal ?
-- Replace when permanently strained or

-
, broken.
d. Does rhe roller turn smoothly-?.-- Apply
grease on the roller axis.

NOTE:
Tightening torque:

Upper arm, lower arm

8 mm bolts:
1.30 to 1.50 kg-m
(9.4 to 10.9 tt-lb)
Center arm
6 rnm screws:
0.45 to 0.50 kg-m (3.3 to 3.6 ft-lh)

28
Fig, Suspender

6) Door latch

Rubber

Difference of the
eech canter line should

Striker

I
Sliding door
721-023

29
Fig. r r Contact
~ between s t r i k e r
and suspender Fig. Component ports of door b t c k
 a . Adjustment 4) Rcmove t h e mounting bolt and two
1 ) Fix t h e connector s o that there is n o mounting screws, then remove t h e latch.
looseness when the wire is stretched fully.
1 2) Adjust and install t h e outer handle so
1 that t h e push lever and adjusting screw
contact wheu thc safety rod is pushed
I
d o w n . Aftcr adjustment, push the push-
b u t t o n , and confirm moving of the pinion
by hand.

!
Adjusting
screw

1
Push lwer T3t 4 2 4
Fig. & Removing lorck

31
Fig. Adjustins screw
5) Raise t h e safety rod upward and remove
b. Removal t h e o u t e r handle. At tlus time, be careful
1) Remove t h e stopper bushing and inner not t o drop t h e mounting nut inside t h e
I
handle. door.
2) Rernovc the trim pancl (refer t o trim 6) Remove the safety rod knob while twist-
panel item). ing it.
3) Remove the connector screw. At this 7) Remove the remote by removing two
lime, b e careful not to d r o p t h e screw o r mounting bolts.
washer inside t h e door.

32 35
Fig. Removing connector sciew Fig. Rcrnoving rcmote
7) Sliding door inspection

Syrnptom Cause Inspection and corrective action

Door 'closcs Striker (latch) position Is vertical direction good? Good if door is
poorly. incorrect. Is the door too far insidc? locked whcn
pltshcd by hand
~ & in
e arrow direction.

Stopper (cen ler arm)

position incorrect.
.-

Stopper (ccn trr arm)

I Temporarily fasten the stopper, close the door
complete, and thcn relighten the stopper.

RcpIace bushing. (Install a bushjng which can be

bushing deformed or easily rotated by hand.)
cracked. Coat the inside and outside periphery of the
bushing with grease.

/ ;.,.-. ,
. ,
i
':stopper . .
(center arm)
.. .. -
j-:I,.;
I
. '
- ;:., .c...:;!.,*',..-'f.: ' .. . .
 Symptom Cause Inspection and corrective action

Door closes Latch pinion cover and Insert the spacer under the striker as required for
poorly. striker mesh when the adjustment.
door opened and closed.

*
I

Striker

T ~ w s r

cww
T2 1-025

38
Fig. s&t

Rattles when
vchicle is
moving.
Striker protrudes too far. Install inside.

- r. ..

- _ ...
, --
.a-

+ .. ' .-. - ..

hr. .. ..,..- .--.

Fig. &
Suspender and striker Adjust so that the difference between the sus-
(suspender) position pender and striker (suspender) position is within
incarrect. 1 rnm (0.04 in)
When the strikcr (suspender) is eccentrically
worn. replam.

Fig. &
 Symptom Cause Inspection and corrective action

Rattles when Roller is not moving. Apply grease between the rollcr and shaft.
the d o o r is slide,
Door doesn't Roller ecccn tric wear Replace the roller, coat the shaft with grease,
slide s m o o t h . znd inside and outside and confirm that rotation of the roller is
diameter wear. smooth. - -

Foreign matter such as Remove the foreign matter and keep clean inside
the sand, mud, etc. are of the rail.
fitted on the roller
surface.

Door doesn't Center arm spring pcrma Coat the spring with enough amount of grease.
open nently straincd or spring When the spring i s permanently strained, replace.
sufficiently. coils are rubbed each
(Door does n o t other.
fly open when
outer handle
push b u t ton
depressed.)

2. Sliding door rail 2) Remove the rear quarter trim.

3) Loosen and rerndve six 6 mrn flange nuts
under t h e rail.
4) Reinstallation is the reverse of removal.

Fig. Ab Sliding door rail

REMOYAL AND REINSTALLATION

I) Remove t h e sIiding door from body. Fig. Removing sliding door roil
D. BACK DOOR
1. Door lock striker
ADJUSTMENT
Move t h e installation position t o the front
and rear and right and left, and use shims in the
vertical direction so that there is n o rattling
when the d o o r i s closed lightly.-- .

Fig. & Adjusting door hinge

c. Perform door transversal and longitudinal

adjustment by loosening thc rear pillar side
hinge bolts.

Fig. &' Adjusting door lack striker

Fip. Adjurtinp door hinge

3. Stay
1) REMOVAL
2. Door hinge a. Remove t h e nuts mounting the stay upper
1) INSPECTION from the d o o r (hinge) with the door opened.
a. Whcn the door hinge rattles in t h e front and
rear. left a n d r i g h t , , or top and b o t t o m
directions, tighten the hinge bolts.
b. Whcn the hinge pin is loose, replace the
hinge assembly.
c. Adjust d o o r drooping, joggling and split line
as fouows.
2) ADJUSTMENT
a. Perform adjustment using a spanner or b o x
wrench.
b. Perform door vertical and longitudinal ad-
justn~cnt by loosening the door side hinge
bolts, Fig. * Rernovittg stay
b. Rctt~orcIwo stay lower mounting bolls from
the body.

nti
\

50
Fig. Installing door lock

Fig.
4% R ~ ~ n o v i yslay
g

2) INSTALLATION
Installation is t h e reverse of rernoval,

4. Door lock
I) REBIOVAL
a. Remove the door trirn.
b, Remove the d o o r lock mounting bolts and .I-5. WlNDSHlELD GLASS
remove the lock from the working hole.
REMOVAL AND INSTALLATION
1) Remove the wiper arms.
2) Bend the weather strip inwards and push
the dass, outw3:ds by foot from Ule inside of
thc passenger compartment. Then @ass is
removed.

Fig. Retnoving door loch

2) lNSTALLATlON
lnstallalian is the reverse o f removal. Fig. Pushing w i n d s h i e l d g b r
3) When installing windshield glass to t h e 5) Pushing the glass from the outside, p~adual-
body, f i t t h e weather strip onto the windsllield lv pulling t h e work cord at a ri&t angle to the
glass and insert the work cord into t h e weather glass.
strip.

NOTE:
a. Overlap the ends of the work cord at the top
of the glass.
b. After the work cord is fitted to the weather
+ strip, coat all around with clean gasoline,
NOTE:
a. Fitting is carried out from the upper center
of the glass to the l e f t and right.
b. Install the glass sufficiently to the body;
gerhly pushing it with hands from the
outside.
c. Fit the weather strip on the outside of the
body correctly.
d. Apply a sealing compound (Cernedine
8366E3 into the groove of the weather strip.

1 Work cord

5 A
Fig. M Fitting work cord

54
Fig. alw Appbing senling compound

4) Put the glass into the correct position

from the outside, pull the work cord into the
inside of h e body. Body panel
I
Sealing compound

A24-090 .
5s
Fig. a Sealing pbdtion

S3 6) Return the wiper arm to surface o f the

Fig. Installing windthieldglass glass.
; 1 4 . INSTRUMENT PANEL

1. Component Parts
RIGHT-HAND DRIVE VEHICLE

Front panel stay Ash tray holder

Instrument panel retainer Ash b a y
lnstrurncnt panel Glove box lid
lnstrurncnt panel cushion Lock
Instrument panel Pocket
Lighting switch Defroster nozzle
Fuse box lid Defroster duct
Wiper switch Ventilator duct
Washer pump Vcnt Ualor duct
Label Control lcvcr
b.
arp
Fig. Sf-&
,Component parts of instrument panel
LEFT.IIAND DRIVE VEHICLE

Front panel slay Ash tray holder

Insfrurnent panel retainer Ash tray
Instrumenl panel Glove box lid
Instrument panel cushion Lock
lnslrumcnl panel Pockc t
Lighting switch Defroster nozzle
Fuse box lid Defroster duct
Wiper switch Venfifator duct
Washer pump Venlilator duct
Labcl Control lever T2 1 4 2 8

I
Fig. bS'lb Componerlt parts of inrtrtrmmt porn1
21
a -33
2. Combination meter 3. Ash tray

REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION

1) Remove four combination meter installing 1) Pun out the ash tray.
screws. 2) Remove two 5 mm tapping screws mount.
ing the holder and remove the holder.

Fig.
ss
P - P Removing combination meter
6.
Fig. 1-1Et3 Removing l ~ o f d e r

2) Disconnect the speedometer cable. 3) Installation is Ule reverse order of re~noval.

3) Take out the combination meter and then
disconnect speedometer cable and wiring 4. G l o v e box lid.
harness junction block from back side of the
combination meter. REMOVAL AND INSTALLATION
1) Remove three 5 mm screws under the lid.

r. .LA.'". . .-...-I, Y ' . ..

6'
Fig. a-S Removing lid
-0

Fig. a-%d
e Y
~ i r c o n n c c t i nvbing
~ harness

2) Pull out the dove box lid from the instru-

ment panel.
4) Installation is the reverse ordcr of removal. 3) Installation is the reverse order of removal.
5. Glove box lid lock. 2) Pull out the fuse box lid from the instru-
ment panel,
After removing the instrument panel, per. 3) Installation is the reverse order of removal.
form removing the glove box lid lock.

7. Instrument panel

REMOVAt-AND INSTALLATION
1) &or to removing the iristrurnent panel,
remove the steering wheel.
2) Remove the combination meter.
3) Pull out the ash tray and remove the ash
tray holder.
4) Remove the glove box lid by removing Lhc
installing screws.

1 Flange nut 5 Screw

2 Rc~aincr 6 Lock
3 lnsrrurncnt pancl 7 Tapping screw
4 Lid

b4
Fig. 4UOl Removing glove box lid

6. Fuse box lid 5 ) Remove the fuse box lid by removing the
installing screws.
REMOVAL A N D INSTALLATION
I ) Remove 5 nirn screw under the lid.

F~~.B-& Removing screw Fig. Removing fuse box lid

6) Remove 5 mm screw at the underside of NOTE:
the instrument panel center. When loosening the screws on thc top of
the instrument panel, it is recommendable to
use short Pillips screwdriver or "L" shaped
one.
9) Remove the control knobs from air flow
control levcr and heater control lever.

Fig. Removing screw

bb'
7) Remove 5 mm flange scrcw inslalling
rightside of pocket and two 5 mrn lapping
screws installing luggage shelf. .(Right-hand
drive vehicle only).

I 1
Fig. %- Removing control knob

10) Take o u t the instrurncnt panel and dis-

connect the wiper switc!l wiring harness and

T71-332

Fig. %-qRemoving screru

8) Remove four 5 mm screws uppcr the in-
strument pancl.and remove the retainer.
Fig. =-& Removing instrument panel

Fig. -4- a Removfng retainer Fig.31-

/
4Removing wiper switch wiring hantcss
2$
8. Front luggage s h e l f
(Right-hand drive vehicle o n l y )
1) Remove Ihe instrument panel. (Refer t o
Kcnioval of instrument panel.)
2) Removo four 5 mrn tapping screws and
takc out thc luggage sl~clf.
3) Disconnect the control cable clamp to
remove the control cable from the duct as-
sc~nbly .
4) Remove the heater fan switch harness.
5 ) Remove three tapping screws fixing the
lever assembly t o the body panel.

Fig. W f f Rcniovirt~~ U ~ Q R ~s <h~cCy 7Y

'74 Fig. LLT-W Renloving topping screw of lcurr
(LFSL'PTIbly

6) Rernove the lever asscmbly by pulling i t

out.

9. Air flow and heater control lever

REMOVAL AND INSTAL~ATION

1) Remove the instrument panel (Sec "Re-
moval of instrument panel.")
2) Disconnect control cable clamps t o
remove the each control cable from the heater
unit.

Fig. J5 Removing lever assen:bly

NOTE:
When pulling out the lever assembly, take
care the soldered portion where cables are
I d
connected to the heater fan switch is not
Fig. a - nDisconnecti~rgcontrol cable damaged by the body panel.
 7) Installation the lever assernbly in the 4) Remove two screws fucing the v e i i l a t o r
reversc order of removal. duct to the lower part of the instrument panel.
I 1

NOTE:
a. When connecting control cables, confirm
all shutters and cock completes are entirely
closed.
b. After connection, confirm the operation of
each shutter and cock complete.

,
Removing wentihior duct installing
screw

5 ) Remove the license plate.

6) Remove four tapping screws f i n g the air
flow ventilator duct t o the front panel.

3b
~ i gB-m
. Shutter closing position

10. Air flow ventilator duct

REMOVAL AND INSTALLATION

1) Remove the instrument panel. (See "Re-
moval of instrument panel.")
2) Remove the Air flow and heater control
lever. (See "Removal of air flow and heater
control lever.") .-- . . - -" Fig. S- W Removing ventilator duct installing
.--

i
7

screw

7) Remove the duct assembly after moving i t

to left side.
8) Install in thc reverse order of ren~oval.
I
I NOTE:
a. When mounting the duct assembly, re-
place the urethane (671042040).containing
sealing agent by new one t o prevent water
leakage through the junction of the front
panel and the duct.
b. Apply sealing agent (Cemedine 366E)
I t o front panel mounting screws before
I installation.
I c. Fix the control cable by attaching the
1 firmly.
11-7. SEAT

1. Component parts of seat

2. Removal and installation

FRONT SEAT
I ) Remove the cushion by lifting the front
end of it while pushing it to the rear.

2 , .
Fig. &b. .Removing bcck rest

3) Installation is the reverse order of rcmovd.

NOTE:
The seat cushion has two positioning pins on
right and left sides of it.
Mount the cushion so that the pins are
80 inserted in predetermined holes.
Fk. 23- Rerrroving cushion

2) Remove the frame under the back rest

from the hook attached to the lower part o f
the back panel. Remove the back rest by lift-
ing.

I I

81
Fig. S-= Removing back rest

For truck and flat bed truck, first remove

the back rest from the lower hook, then remove
the back rest from the upper hook with d ~ e
back rest moved upward.
 81-8. INNER TRIM

1. Component parts

-.>J
. -. DETAIL "C'
DETAIL 'A" m .-.

1 Roof trim seal

2 Cab door trim panel
3 Slidc door trinl pancl
4 Rear quartcr trim panel
5 Back door trim oanc[
DETAIL "€3. 6 Clip
7 Clip
8 Shrorld trim
9 Insulator
10

2. Cab door trim

REMOVAL AND INSTALLATION NOTE:

1) Remove the regulator handle, pull handle
and door inner remote handle.
2) Disconnect the resin clip from the door
inner panet with a (-) screw driver to remove
the door trim.
a. When removing the resin clip, take care
not l o bend the trim panel.
b. The resin clip can be removed easily by
using the special tool shown in Fig.
 NOTE:
Tha resin clip can be removed easily b using
Welded portion
Y
the special tool shown in F i g S U 5 . )=(
,____--- --
18 (0.70) About 50 About 400 (15.701

P ~ p e( 12 10.47) dia.1
Unit: mrn linl
T 2 1.039

1 Clip
2 Trim pancl

I 3 Special tool
T2 1.042 I
Fig. a-HSRemoving t r i m

3) Installation is the reverse order of removal. 1

1

1 T r i m panel
2 Clip NOTE:
3 Special tool
T2 1 -040 If the removed resin clip is damaged, replace
it with new one.
Fig. Ronoving trim

3) Inst allation is the reverse order of removal.

4. Back door trim
3. Slide door t r i m
REMOVAL'AND INSTALLATION
REMOVAL AND INSTALLATION 1) Remove the resin clip from the back door
1) Remove the inner remote handle. inner panel with a (-1 screw driver or special
2) Remove the .resin clip from the slide door tool to pull out the back door trim.
inner panel with a (-) screw driver t o pull out 2) Installation is the revcrse order of removal.
the door trim from the rail.

2 Screwdriver

Fig. PY-rn Removing resin clip F 9 . S ' Removing back door trim
8& 30
rn -*
. 1-9. INNER ACCESORIES

2. Sun visor When reinstalling i t , be careful not to dam-

age the screw because the screw is made of
The sun visor is removed by loosening the plastic.
tapping screws. The mirror is adjustable in up and down
direction by turning i t .
3. Rear view mirror (inner)
The rear view mirror is fallen down resulring 4. Assist rail
from breakage of the screw made of plastic in
case of collision. And it can be removed by The assist rail can be removed by loosening
loosening the screw. two screws.
3)
w -42
El-1O.OUTER ACCESORIES

1. Component parts

3 Front side grille

-t
S Ccntcr slide door rail

10
Fig. $F-= Component parts of outer accesories

2. Front side grille 3. Rear view mirror

b o s c n three screws, and the front side The rear view mirror is removcd by looscn-
grille is removed. ing two cap nuts.

Fig. a?-&
4. Splashboard

The splashboard is removed by loosening

bolts and nuts.

93
Fig. H a
 CHAPTER 2 : BODY ELECTRICAL S Y S T E M

2- 1. WINDSHIELD WIPER . . . . . . . ., . . . . . . . . . . 2

2- 2. COhIBINATLON METER . . . . . . . . . . . . . . . . . . 5

2- 3. HORN . . . . . . . . . . . . . . . . . . . . . . . . 7

2 - 4 . TURNSIGNALANDHAZARDUNITS . . . . . . . . . . . . 10

2 - 5 . SWITCHES . . . . . . . . . . . . . . . . . . . . . . 12

2- 6. LIGHTS . . . . . . . . . . . . . . . . . . 14

2- 7. FUSE BOX AND W I R I N G HARNESS . . . . . . . . . . . . . 17

 2-1. WINDSHIELD WIPER

1. Construction and operation

1 W v r blade
2 wiperum

6 Wanher
7 Cushion A
8 Cushion B
9 W~pcrtink
10 Packing
11 Wtpcr motor bracket
12 Wiper motor

Fig. H-I Wiper component parts

The wiper uses a small motor as the drive Wipsr motor

source and the wiping operation is performed
by driving the wiper shaft (shaft mounting the
blade and arm) in a reciprocating manner with a
link device by means of a clamp and rod at the
rotating shaft (wiper motor output shaft)
whose speed has been reduced to the specified
speed by means of a reduction gear (worm
reduction gear).
1) When the wiper switch is turned ON,
current flows through the circuit BS2(A)-E
and the motor is operated. Refer to Fig. %!-2.
2) The 'motor is kept operated even after
turning off the wiper switch while the igni-
tion-starter switch is in "ON" position until
the lever is pushed up and the cam inside the T22-002
motor reaches the specified position, since the
circuit B ( Q ~ ) S ~ S ~ < A )is- E
closed. Fig. a - 2 Wiper wiring diagram
3) When the circuit is intempted at the e. Remove both right and left wiper arms by
specified position, the circuit (A)S2-S, .P-(A) loosening the wiper arm tightening bolt.
indicated by the arrows ifl the diagram is
formed and the motor is t l t c t r i d y braked and
stops a1 the specified position.
4) When the wiper switch is set t o OFF when
the key switch is in the OFF position, no
currents flow in the circuit and tht motor stops.
However, if -the key switch is set to ON, the
actions of (2) and (3) above are repeated and
the motor is stopped in the specified position. *.

Fig. x-4

f, Pull out the rubber caps on the shaft and

remove wiper link installing nuts.
2. Removing and reinstalling the
wiper motor g. Remove the steering wheel.
h. Remove the combination meter. 5
1) REMOVAL i. Remove lighting switch.
a. Remove battery grounding wire. j. Remove the defroster.
b. Remove the light ring on right-hand side k. Disconnect wiring harness of the wiper
(right-hand drive vehicle) or left hand side motor.
(left-hand drive vchiclc). I. Disconnect the wiper linkage from the motor
c. Loosen headlight adjusting screws and re- shaft.
move the right headhght (right-hand drive m.Take out the wiper motor assembly through
vehicle) or left headlight (left-hand drive the instrument paneI.
vehicle), whil* turning it to the right.
d. Laosen and remove the wiper motor
stailing nuts. w e e flange nuts)

Fig. Lt-5 Removing wiper motor

2) INSTALLATION
Fig. $2-3 R emotting nuts installation is h e reverse of removal,
 Connection fault or Check the connections. Correct connections.
wiring error in S 1
(yellow) or B (blue)
circuit.
Incorrect - - .-
wiper Switch
Bad connection
stopping between terminals 1
and 2 of switch
continuity between
U-2. COMBINATION METER

1. Component parts

-.

1 Meter visor
2 Combinalion meter glass
3 Combination meter window plate
4 Combination mctcr
S Thermometer
6 Fuel meter 8
7 Printed plate 8
8 Bulb
9 Socket
10 Buzzer
11 Sgccdorneter TZZ-005

Fig. #-6 Combination meter

2. Removal and installation 2) Disconnect the speedometer cable.

3) Take out the combination meter and then
1) Remove four combination meter installing disconnect speedometer cable and wiring har-
screws.
nesses junction block, from back side of the
combination meter.

Fig. 2 - 7 Removing combination meter Fig. 22-8 Dirconnecting wiring harness

P-*5
4) installation is the reverse order ofremoval.

3. Disassembly and assembly

1) Remove four tapping m e w s on lower
back side of combination meter and disasem-
ble the meter visor and lens complete.

Fig. a - 1 1

4) Remove three nuts and remove fuel meter

unit.

Fig. s - 9

2) Remove two screws installing the speed-

omcter gear.

Fig. L k i Z Removing fwel meter unit

5) Remove thrce nuts and remove thermom-

eter.

Fig. m-10 Removing speedometer installin2

screws

3) Remove a screw on right side of mmbina-

Fig. &!-I 3 Removing thermometer I
tion meter panel and remove the speedometer
and combination meter panel as assembly. 6) Assembly is the reverse ordisasscrnbly.
 6. Combination meter connecfions

1 Thermometer terminals
2 Fuel meter termindl
3 Meter ilturninstion hght
4 High beam indicator light
5 Direct terminal
6 Meter illumination light
7 Buucr
8 Combination meter c u e
9 Specdomatar a b l e bou
10 Left turn signal light
1 I Right turn signal light
1 2 Charge indicator tight
13 Hand brake and brakc fluid level wuning light
=-R
722016

Fig. -9

I
1
42-3. HORN

1. Specifications

Volt age 13V

Current
, + 0.5 A
3.0 - 1 .o
Basic frequency 330-370 Hz
Sound pressure 100 - 110 dB
-
4. Checking combination meter NOTE:
With the drive shatt turning at 1,020 rpm,
1) Speedometer the nominal indication i s 60 MPH.
a, Indicated error as measured with a speed-
ometer tester is acceptable if il conforms to
values in the following table. With the drive b. When the pointer fluctuation is large, the
shaft turning at 637 rpm, the nominal cable may be defective or installation may
indication is 60 kmfh.. be incorrect.
- -

Kilometer indication Mile indication

Nominal Nominal
indication 20 40 60 80 100 120 indication 20 40 60
{kmlh) MPH
Tolerance -1 t0.4 t2 t3.8 t5 - Tolerance -0.1 +f.S t3.0
(km/h) -3.5 -2.6 -2 -0.6 -0 MPH -1.9 -1.1 -0.1

2) Fuel meter
a. Check for a grounding or open circuit
between fuel meter and unit. Check if each
conncction a n f c o n t a c t are insufficient.
b. When unit terminal connection is discon-
nected, the meter indicates "0" (empty). If
the meter pointer slowly shifts toward the
"1" (full) position when the disconnected
lead i s grounded through the pilot ljght
(12V-3W),the meter is functioning properly.
If the plot light does not light in this situa-
tion, the heat coil of the meter is open.
-- -- /
2. Operation
Sound energy is produced by a diaphragm Ignltion-ltsmr switch
set into motion by electric means. Pushing the
horn switch closes a circuit which allows
current t o flow through the horn coil and the Horn button
coil attracts the plunger. The diaphragm COU- --
-
pled directly with !he plunger is attracted -Bansry
rapidly pnd density of air ir! front of diaphragm
becomes low. At tlus time, one part of the -
plunger strikes the contact spring, opening the
coil circuit. The magnetic field collapses and 10V rrngs
the plunger returns t o its original slate by virtue T2241B
of spring force o f the diaphragm. This action
cornbresses air in front of the diaphragm. At
Fig. m-21Horn inspection
the same time t h e contacts reclose and the
sequence repeats itself. Repetition continues as
long as the horn button remains depressed.
Sound is generated by repeating change o f air
density.

4. Removal and installation

I ) Disconnect the wiring, and remove the

horn installing nut.

Fig. @-20 Horn operation

?:., * 7.
3. Inspection , '.

When the horn does not sound, check the

voltage with the tester as shown in Figure.
Fig. m-22Removing horn
\ m e n voltage: -
below 2V:
Horn is abnormal.
over 2V:
Worn horn button or faulty ground, 2) Installation is the reverse order of removal.
 2-4. TURN SIGNAL A N D 3. Operating principles
HAZARD UNITS
Automatic flashing and snapping o f those
1. Specifications units are accomplished b y expansion-contrac-
tion of a heater band and action of a snap
spring.
a Front and rear turn signal
light: 23W x 4
A Heater band
a Side turn signal light:
Load 6W x 2
a Turn signal pilot light:
3.4W x 2

72 - 98 tirnes/min.
frequency

122-021
2. Wiring diagrams
Fig. 20 Operation A
1) Turn signal unit

Ptlot

swltch

-
-
f Battery 4
4
.+
T22-019 Fig. 2 1 Operation B

Fig. 18 Turn signal circuit

4. Cautions for handling the turn
signal light
2) Hazard unit 1) When replacing the bulb, strictly use speci-
fied one as follows:
Front turn
signal light
Front turn signal light
12V - 23W
,
(12.8V - .8A)
-
Rear turn signal
- - - - .light
- - - - - - - --
Rear turn signal light 12V - 23W

Side turn signal light 12V - 6W

.__ _ - - - - ---- -
_. I

1 2 v - 3.4W
Hazard unit Turn signal pilot light
(14V - 0.24A)

T22-020 This type of unit operates b y the current

through the lights therefore, if wrong rated
Fig. 19 Hazard unit circuit light is used in the circuit, the turn signal units
does not operale normally since different cur- at the left end of the bulkhead below the
rent flows through the circuit. instrument panel.
2) I f a single bulb is burnt out,'the flashing
frcqucncy does not change appreciably (keep
light on). . . -.
3) Do not apply large shock on turn signal or
hazard unit while handling it.
. .
4) . The turn signal and hazard units arc
getting hot like a vacuum~valveby continuous
operation, but this is not an abnromal sign.
i'

5. ' Location of turn signal and

hazard units
Fig. 1Ct-27 Locution of turn signal and
The turn signal a n d hazard units are installed hazard units

6. Turn signal circuit troubleshooting

TROUBLE AND POSSIBLE CAUSE I CORRECTIVE ACTION

Left and rightaashing frequency differ o r o n e side only functioning properly
1) Burned out bulb Replace bulb
2) Defective switch Repair o r replace switch
3) Improper bulb installed Replace with specified bulb
4) P o o r ground at bulb C o r r e c t the socket contact
5) Poor wirlng comection C o r r e c t connections .
Both sides d o n o t light
1) Blown fuse Replace the fuse
2) Open w i r e between battery and switch o r
poor connection Repair o r replace wiring
3) Defective switch Repalr o r replace switch
4) Both left and right pilot lights burned o u t Replace bulbs
5) Defective turn signal unit Replace turn signal unit .
Both sides remain lit . -s
1) Defective turn signal unit Replace turn signal unit
!, . q..
High flashing frequency 'i:

1) Low wattage bulb used Replace with specified bulb

2) P o o r ground a t bulb .. . C o r r e c t the socket contact
3) Defective t u r n signal unit Replace the turn signal unit
Low flashing frequency
1) Low source voltage Charge the battery
2) High wattage buIb used Replace with specified bulb
- 3) Defective turn signal unit Replace turn s i g n d unlt
 p2-5. SWITCHES
1. Lighting and parking switch
This switch is actuated both by pulling and
turning. Pulling the knob to the first position
lights the clearance lights. Moreover, when the
headlight beam switch lever is operated, the
headlights (low beam). can bc lighted. While
pulling the knob to the second podtion, these
lights light together (in this case tither high
beam or low beam lights up). With the knob
pushed in (OFF position), the parking lights
are lighted by turning the knob t o the right.
Fig. #-29 Lightingswitch

REMOVAL AND REINSTALLATION

a . Detach the combination meter.
b. After detach the lighting switch knob, un-
screw the dress nut.
c. Put the hand into the inside of instrument
panel through the combination meter hole
and take out the lighting switch. A
d. Reinstallation is the reverse of removal.

2. :darter switch
For Wt-hand drive, the stdrter
switch is Qtached by dress nut to the.dnstru-
ment panel. For !eft-hand drive, the rgnition-
starter switch is attached with stetring lock
system IocateC. under the instrument panel.
Connections are made by meanyof a junction
block.'

3 T22023
.
.
.'j -
f . .
Fig. s - 2 8 Lighting circuit diagram

Note that the knob cannot be pulled out

while it is turned when using as the parking
switch and that it can not be turned while it is
pulled out when using as the lighting switch.
Always operate the switch from the OFF
pdsit ion. Fig.4 - 3 0 Ignition-starter switch
 . 4. Combination switch
ACC REMOVING AND REINSTALLING
1) Remove the steering wheel. (Refer to
infomation on steering .wheel in Chapter O.8
15-3, on page Y 4).
2) Remove the hazard switch , h o b by un-
screwing it.
3) Separate the switch'assembly by removing
the 4 mm screw securing it t o the bracket.
,4) Reinstallation is the rcvemof rlmoval.
R ST
NOTE: . .
a. Install the steering wheel so t h a t the horn
bar lies horixontally.
b. Install the canceling cam so that it is located
at right angles t o the t u r n signal lever.

T2242
Fig. fP-31 &nnedionr

Combination switch
3. Back-up light switch 1
REMOVAL AND REINSTALLATION
1) Open the trap door.
2) Take out the insulator.
3) Detach the back-up light switch attached
-on the left side of transmission.
4) Reinstallation is the reverse of removal.

5. Wiper s w i t c h

The *per switch is attached to the instru-

ment i h c l by means of an dren nut. Loosen
thc screw at the bottom of the knob and
remove the knob. Remove the dress nut and
separate the switch from the panel. ,

NOTE:
In reinstalling the knob, turn it so t h a t the
Pig. 3f-32 Back-up light sul'tch m e w is located a t the bottom. ,
 Fig. 9 - 3 3 Stop light switch (Left-knnd drive)
Fig. a - 3 4 Wiper switch

6. Stop light switch

-
- ..- -
. .- -
The stop light switch is mounted on the
pedal bracket and is operated by the brake
pedal. Fig. SZ-36 Stop light switch (Right-hand drive)

92-6. LIGHTS

1. Specification

12V - 50W/40W (Right-hand drive vehicle)

Headlight
12V - 45W/40W (Left-hand drive vehicle)

Front corr~binationlight
Turn signal light 12V - 23W
Clearance light I Z V - 5W

Side turn signal light 12V- 6W

Rear combination Iight
Turn signal light 12V - 23W
Stop and Tail light 12V - 21W/5W
Back-up Iight 12V - 12W

License plate light 12V - 10W -

Room light 12V- 8W
 2 Headlight

'.

Fig. a - 3 8 Removing headlfight

1 Hcadllight assembly
2 Screw
3 Ring
4 Washer
5 Spring
6 Set plate B
7 Screw
6 Sealed bcarn unit
9 Set plate A TZZ-025

Fig. 83-37 Hedllighi ussembly Fig. -0 Front combination light

3. Front combination light

For Right-hand drive model, the headllight is

of an all-glass sealed b q m type. For Iaft-hand
drive model, the heaWght is of a bulb type.
Two filaments, 50 & 4GW for sealed beam, 45
& 40W for bulb, e n c a k d in the bulb and lights
are changed over by means of head-light beam
switch. Adjustment is performed with screws.
1) Removal and reinstallation
a. Remove the headlight vessel.
b. Loosen the head!amp installing screws (ad-
justing screws) until the spring tension be-
comes free.
c. Hold the ring and remove the headlight by
turning it to the right.
d. Disconnect the wiring.
e. Reinstallation is the reverse of removal. Fig.ZI340 Front combination light
 Thc ftont conbination Light includes the
turn signal light (23W), clearance and parking
light (SW).
1) Removal and reinstallation
a. b s w n n e c t the wiring harness,
b. Remove the lens by removing the lens
mounting screws.
c. Take out the light case from t h e body.
d. Reinstallation is the reverse of removal.
2) Changing bulb
Remove the lens mounting screws and lem.
Remove the bulb bg depressing it and turning
to the left.

Fig. -42 Side turn signal light

5. License plate light

Fig. #Z-41 Rentorring bulb

4. Side turn signal light

The side turn signal lights are installed on
both (right and left) sides of the headlight
vessel.
When changing the bulb, remove the lens !:..c
mounting screws and lens, and rcrnovc the bulb Fig. 62-43 Liceti& pbtr light
by depressing it and turning to the left.

The lianse plate light lights at both the &st

and second pull positions of the lighting sw3d.h.
When changing the bulb, remove the c a e r
r and lens by unscrewing two cover m o u d n g
Sidc turn signal light bulb 6W screws, and remove the bulb by depressi- i it
and turning to the left.
REMOVAL AND INSTALLATION
A. VAN
I) Pull down the Iens by turning the mark
position ( Q or "OEW' mark) to the lever
part.
2) Remove the light assembly by loosening
the screws.
3) Disconnect the 64ring harness.

B. TRUCK-
1) Remove the lens by pushing the lens edge
with fingers.
2) Remove the light assembly by loosening
the screws.
3) Disconnect the wiring harness.
Fig. fP-48 Repkacing fuse
CHANGING BULB
Remove the lens and pull out the bulb.
- ..-

R2-7. FUSE AND WIRING HARNESS

(SEE NEXT PAGE)

14

!
I
Fig. a - 4 9 Fure
2. Cautions for removing and
reinstalling the wiring harness
1) Before carrying out operation, be sure t o
i disconnect the battery (-1 tennirul.
1 2) When pulling out the wiring harness which
1 runs through inside of the front pillar, rear
) quarter and,qa& door, tie the wiring harness
i with the wire% string and pull it out
i 3) I f the &;ing harness is contacted with the
I: clamp or other parts, protect the harness
; contacting point with the vinyl tape.
: 4) When installing the parts, d o not put the
' harness between the parts and its fitting posi-
tion.
5 ) When connecting the connector, be sure to
confirm the color w r d of the connector with
the wiring diagram.
i 6 ) When connecting the battery cable, turn
I off each switch and confirm whether the wiring
harness is shorted or not by contacting the
: battery cable t o the battery terminal.
c2-'dP),7
6. Rear combination light I) Removal and reinstallation
8. Remove seven (Van) or k lens
- installing screws and remove the lens.
b. Discomcct the wiring harness.
c. Reinstallation is the reverse of removal.
2) Changing bulb
R'emovc the lens by removing the lens
installing screws and remove the bulb by
depressing it and turning t o the left.
3) Back-up light
\
.- When removing, remove two lens installing
screws and remove the lens, and disconnect the
i b
wiring harness. Reinstallation is the revtrsc of
removal.
When changing the bulb, remove the lens by
removing the lens installing screws and remove
the bulb by depressing i t and turning t o the
left.

1 Rear mrnbinatfon light r d y ' 7- Shde B

2 Bulb (21I5W) 8 Lens complete
3 Bulb (12V-23W) 9 Pan-had r a e w
4 Bulb(l2V-12W) . 10 S a e w .
5 ShadcA 11 S u c w
6 Packing
T22432
i

F&.19-46 Remuwt'ng back-up Iight ( T n r c k )

7. Room light

Truck Van

1 Rear oornbinalion light ass'y

3 . Bulb (I ZV-2115W)

7 Lens complete
8 Pan hm~dscrew 2 Room light .
3 Bulb
T22034
-
Fig. L1-45 Rear combimfion light (Truck) Fig. W-47 Room light
 2- 7. FUSE AND WIRING HARNESS
In addition to the fuse box located on the instrument
: panel which contain the f.ises shown in box below.

FUSE WIRE COLOR ITEM

5A Red-Blue Tail lights
License plate light

15A Green Turn signal lights

Stop light
Back-up light
Horn
Wiper motor
Drive motor fan key switch

Red-Yellow Headlight upper beams

A : Hazard light
Xoom light

2 0A Red-Green Headlight lower beams

r

m
2 5A Black Fan motor
Vent fan accessory cirpuit
(Radio)
(Cigarette lighter)

Additional fuses are located as follows:

FUSE WIRE COLOR ITEM LOCATION
16 AMP 3ied Heater Under dashboard and
behind fuse box.

3 5 0 AMP Cable Drive- , Next to auxiliary

motor battery.

15 APIP 3lack Controller Above

1----30 AMP 1----Black Aux. Battery Above charger

 2- 7. FUSE AND W I R I N G HARNESS
I n a d d i t i o n t o t h e fuse box l o c a t e d on t h e i n s t r u m e n t p a n e l
which c o n t a i n t h e f u s e s shown i n box below.

Fuse Wire Color Item

5A Red-Blue Tail lights

License p l a t e l i g h t

15A Green Turn s i g n a l l i g h t s

Stop l i g h t
Back-up light
Horn
Wiper motor
D r i v e motor f a n key s w i t c h

20A Red-Y e l l o w H e a d l i g h t upper beams

Hazard l i g h t
Room l i g h t

20A Red-Green H e a d l i g h t l o w e r beams

2 5A Black Fan motor

Vent fan a c c e s s o r y circuit
(Radio)
.(Cigarette lighter)

A d d i t i o n a l fuses a r e l o c a t e d a s f o l l o w s :

The 1 6 amp h e a t e r fuse i s l o c a t e d i n a s p r i n g l o a d e d fuse h o l d e r ,

w i t h red w i r i n g , under t h e d a s h b o a r d b e h i n d t h e fuse box. The
350 amp fuse f o r the d r i v e m o t o r i s located by t h e b a t t e r y power
pack, on o n e s i d e of t h e accessory b a t t e r y . The 1 0 amp fuse,
part of t h e d r i v e m o t o r ' s c o n t r o l l e r , i s next t o t h e large fuse.
A 30 amp fuse f o r the a c c e s s o r y battery i s l o c a t e d i n t h e l o w e r r i g h t
c o r n o r o f t h e v a n , above t h e b a t t e r y c h a r g e r compartment. This
fuse is e a s i l y a c c e s s i b l e , but is not readily seen. I t can be
l o c a t e d by r e a c h ' i n g under t h e deck i n t h e r i g h t c o r n o r .
 CHAPTER 3: CLUTCH

3- 1. DESCRIPTION ..................... 2

3- 2. CLUTCH DISASSEMBLY AND REASSEMBLY . . . . . . . . . . 3

3- 3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 7
.3,.1. DESCR IPTlON The clutch control mechanism is a mccha.
nical type of simple construction as shown
1. Construction in figure. The clutch cover is a n overcover type
strap drive system. The spring is a diaphragm
- type which has an excellent characteristics such
1 Clutch disc
as less change o r installed spriqg setting load
2 Clutch cover
3 Clutch rckav bearing against the wear of the clutch disc and can be
4 Clutch r c k n w fork operated with light pedal pressure. Woven
5 Clutch cable asbestos i s used for the facing material of the
6 Clutch pedal d u t c h disc,. The clutch disc is provided with
torsion springs (coil springs) to absorb rota-
tional shock a t clutch engagement.

T 10-001

Fig. W Clutch system

2. Specifications

l tern Value

Outer diameter of cover 206 mm (8.1 102 in)

Outer diameter of pressure plate I 63 mrn (6.4 1 73 in)

4

Inner diameter of pressure plate 107 mm (4.2126 in)

Cover
Setting load of diaphragm spring 1202 10 kg (264.55 2 22 Ib)
Fitted diaphragm height (from cover
installing surface of flywheel)
24.1 + 0.8 mm (0.9488 + 0.0315 in)
Facing material Woven asbestos

Numbcr of facing 2

Dimensions (Out. dia. x Inn. dia,

. ;'
1 6 0 x 11Ox3mm
x Thickness) (6.2992 x 4.3307 x 0.1 18 l in)
Disc
compressed thickness 7.1 + 0.2 mm (0.2795 + 0.0079in)
Free thickness 7.9 + 0.2 m m (0.31 10 2 0.0079 i n )

Number of torsion spring 6

Number of spline hub teeth 23

3- 2. CLUTCH DISASSEMBLY AND
REASSEMBLY

T 1c o o 2

1 Clutch di'sc 6 Release bearing holder spring

2 Clutch mxr 7 Clutch release fork
3 Balt(6xlSx18) 8 Straight pin (5 x 22)
4 Clutch rekasc bearing :- 9 "0"ring (10.8 x 1.9)
5 Rekut bearing holder I 0 clutch ~ k a lever
s
p '

,
..
r r

Fig. E Exploded view of clutch

I. Clutch lever d. Replace the O-ring on the &itch release
lever if worn or damaged.
3) Installation
a. Apply grease (equivalent t o Unilube No. 2)
to groove of the clutch release lever COMPL
at t h e point indicated by arrows in Fig. B-3,
and install I t t o the transmissibn case with
the pin hole aligned t o that of the clutch
release fork. '
Then drive in the straight pin (5 x 22) with
its split end facing the contact surfau of
transmission we.

Fig. 211) Chtch fever componmts

I) Removal
a. Remove the transmission. (Refer t o Chapter
11.) L
b. ~ e m o b ethe release bearing holder springs
8.
c. Remove the clutch release bearing @ and
release bearing holder @ together. Fig. llED Driving in straight pin
d. Using a special tool "Remover I1 (straight
pin)'', drive out straight pin (5 x 22) @ b. Apply grcase (equivalent to Unilube No. 2) .
until the clutch release lever compl. @ can t o groove of the clutch release bearing
be pulled out. holder a t the point indicated by an arrow in
Fig. b - 3 , and put it on the transmission case
guide along with the clutch release bearing.
39879 1600 Join the pawl of release fork and relcaw: '
Special tool
(Remover 11) bearing holder with the release bearing
holder sprinp.
6 I

d. Remove the clutch release foik @ and lever

cornpl. Q .
2) inspection
a. If the bearing is damaged, seized, or un-
smooth in rotation, replace the ,clutch re-
lease bearing.
b. R e p l a u any release bearing holder or clutch
release bearing whose contact surfaces are
unusually worn.
c. Repair if the internal surface of release
bearing holder and clutch release lever shaft
are seized. Replace them if seizure is exces-
sive. (Also check condition of the transmis-
sion case guide.) Fig. Installing holder spring
2. C l u t c h cover and disc
1) Removal
a.
*-1Remove the tral;smission, (Refer to C h p t c r
b. Insert a special tool "Clutch disc guide" in
the clutch disc compl. (Fig. L86)
NOTE:
Apply a light coat of oil or grease on 14 mrn
dia, shaft, the end of clutch disc guide.
FivI Guide (Clutch disc)
c. ZJniformIy loosen bolts (6 nim) attaching the
clutch cover. cornpl. by slaw degiees, and
remove the clutch cover and clutch disc
com pl.
NOTE:
Be careful not t o let the'disc facing get
soaked with grease or oil.
FQ. Removing clutch
2) Inspection and adjustment
Clutch'covet compl.
a. Replace the clutch cover if the pawls of the
diaphragm spring are excessively worn.
b. Replace the clutch cover i T it makes any
abnormal sound when shaken up and down,
or if its riveted parts are in any way unusual.
c. Replace i t if the contact surface of pressure
plate is worn, warped, or damaged.
Clutch disc'co~n~l.
a. Measure the sinkage of rivets with sl~dc
calipers. And rcplace the clutch disc if the
facing is worn beyond the limit.
-.
Sinkage limit 0.3 mm (0.01 I R in)
b. Replace the c h t c h disc If the torsion springs
are broken or fatigued, or if the spline hub
rivets are,loose, ,
. .
Fk. Incpec:ing clutch
Fig. Meomring facing sinkuse
c. Check disc plate for runout whenever the
old disc or a new one is installed.
d. If runout e::ceeds 0.5 mm (0.020 in) at the
outer circumference of facing [K = 75 mrn
(2.95 in) from the hub center], replace or
repair disc. See Figure t0-9.
e. Put a special tool "Clutch disc guide" in thc
clutch disc compl. and install t o the fly-
wheel.
 Tighten it with six bolts (6x1 8x1 8 rnm).
499745400
Special toot
Guide (Clutch disc)
Tightening torque 1.0 L 0.075 kg-rn

3)
Fig. -
Installation
Measuring runout

Instal! the clutch cover w m p l . to the

flywheel by aligning two knock pin holes
(clutch cover) with knock pins (flywheel). Fig. Knock pin holes
3- 3. TROUBLESHOOTING
, - -, . -
I
Condition and probable cause Rem-edy
.- -- - - . -- - -. .-
I . . N o clutch pedal play. Adjust.
* '
. I t
2. h'o play at release fork tips. M Adjust. ! ..

3. Oil-soaked clutch lacing. , Replace. _ .. . I s

4. Worn clutch facing. Replace.

5. Distorted pressure plate or nywhccl. Repair o r replace. , . .
. -. -
1. Excessive play of clutch pcdal. Adjust.
2. Excessive play o f clutch release fork. Adjust. .
3. Reduced stroke of dutch release fork Adjust.
tips.
4. Rusted splines of clutch disc and Remove rust and grease, or replace.
main shaft.
5. Excessive runout of clutch disc. Repair or replace.
6. Defective ~ a r t ( s )in control, or im- Repair o r replace.
proper installation.
 Condition and probable cause
I Remedy
4 .

3) Judder . .

The entire body vibrates uncomfortably when vchicle starts in half-clutch condition.
. .
1. Hardened facing. ~ e ~ r i r 9 t h emery cloth 'or re-
place.
2. Oil-soaked facing. Replam.
3. Broken o r fatigued torsion springs. Replace disc ycompl.
4. Improper contact of facing, or cxces- Replace disc cornpl.
sivt runout of disc.
5. Distorted pressure plate or flywheel. Rcpair,or replace.
I
6. Loose disc rivets: RepIaa.
7. Loose engine mounting or fatigued Tighten, o r replace rnounling'rubber.
mounting rubber.
. .
4) Noise or abnormal sound
Examine whether the noise is generated when clutch is disengaged (1.2) or engaged'(3,4,5).

1. Broken or worn release bearing, o r Replace.

insufficient lubrication.
2. Eccenlric clutch cover and .bearing. Repair o r replace.
3. Loosened clutch disc hub. Replace disc compl.
4. Cracked torsion spring retainer. Repla'ce disc compl. ' . ' .

5. Fatigued or broken torsion springs. Replace disc compl.

5) Rabbit-jump ' . .
. . . :.
clutch engages suddenly in half-clutched s t a t c w h c n starting. Vehicle will. not accelerate
smoothly, but moves forward jerkily.

1. Oil- or grease-soaked facing. , . Replace.

' 2. Worn facing or loose rivets. Rcplace.
- W O ; ~dr
rurtrd splines of clutch disc
. - Replacc, or remove rust and grease. '
.: .. hub and main shaft.
I + ,

4. Fatigued or broken torsion springs. Replace.

5: Distorted or partially worn flywheel Repair or replace. .
. . and pressure plate.
 CHAPTER 4 : TRANSI4ISSION AND TPANSAXLE

.................
GENERAL D E S C R I P T I O N 2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 2

COMPONENT PARTS OF TRANSMISSION . . . . . . . . . . . 3

DISASSEMBLY ..................... 6

INSPECTION . . . . . . . . . . . . . . . . . . . . . 11

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 13

INSTALLATION. . . . . . . . . . . . . . . . . . . . . 21

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 22
 -,&I,GENJ&~L DESCRIPTION

...-- . ,-.,. . .

F*. P)-1 Transmission Fig. a - 2 Ccar train

The transmission provides 4 forward and 1

reverse speeds; forward gears are of the inertia
lock type with full synchromesh. Gear shift
lever is a IImr shift type. I k a d d i t i o n to the
former oil bath type lubrication system, an oil
passage is provided in the main shaft to dircctly
lubricate the bearings. This dual lubrication
system improves lubrication performance. The
differential is houscd with the transmission in a
2-section cast separable top and bottom, which
is lubricated with common oil.

' 4- 2. SPECIFICATIONS
[
& 1
Model T23B I
I .

1st 4.363 (4811.1)

2n d 2.625 (4211 6) . 5

1
Gear ratio 3rd 1.809 (38121) i
4th 1.107 (31/28)., - *..
Reverse 4.272 (4711 1)
Final rcduclion gear ratio 5.733 (86/ 15)
Diilertntial Number of side gear teeth 18
gear Number of pinion gear tceth 13 !
Oil quantity 0.9 L (0.95 U.S. qt., 0.80 Imp.qt.)
----.
4-3. COMPONENT PARTS OF TRANSMISSION
.
.
... .
.
. .
1. Component parts of transmission case

2 Bolt m d washer u s y f 8 O h g (14.3 x 2.4)

3 Transmission cover ' 19 Trmsrnirrion a r c
4 Caxket 20 O i l m d ( 1 S x 2 5 x 5 )
5 Air bruBlrr pipe 21 Stud (10 x 38 x 15)
6 Plug (8 x 10.5) 22 Wa:hcr
7 Shifter fork rail spring 23 Boll (8 x 45 x 20)
8 BaU (6.350) 24 B o I t ( 8 x 95 x2O) .
9 A h b r u t h c r nipple 26 Bolt and washer ,

10 Accent p1ungcr spring 27 Boll (8 % 65 x 20)

1.1 Selector plunger 2 8 S t u d ( 8 ~3 6 x 12)
12 Shiftcr rrm shaft 29 Cmkct (20.5 x 26 x 1.5)
13 Shifter m 30 011 drain plug complctc
14 Spring pin 31 Transrni,rion case cap 3
15 Selector urn *32 Washer (39 x 49.5 x t)
16 Gear selector arm 3h;it 33 Transmislion case cap
17 Oii level gauge 34 Plug (1 3 x 5)
'35 Washer (39 x 53.2 x 1 )
36 Straight pin (4 x 22)

37 Shirter fork 2

*39
40
Reverse shifter levcr
Shifrcr urn 2
-
-41 Shiftcr fork
42 Shifter fork rail

43 Shifter fork rail 2

44 Shiflcr fork roil 3
45 Ball (5.5563)
46 S W t t r r.il plunge!
4 7 Bolt and w v h c r rzsy
48 Shifter I& plate
49- Shifter x a i l plate

I
53
Back-up light switch
54
clutch u b l c c k m p
)Sluminu,lr gasket
55
I
Plug (14 x 9)
56
57
Plug (clutch hourinn
timinu hole).
58 Accent plun3e1 spring 2
59 Shifter fork spring
' Selectire puts
2. Transmission gear component parts ,- 1.

. -. .- - . .

. .

'1 Snap ring outer (20) 16 Thud driven gear

2 Eall b a r i n g (#6204 NR) 17 Synchxanizcr dctve
3 Washer (20.2 x 2 9 x 0.2) 18 4 th driven gear
4 Ball bearing (n6204) 19 Neallc bcving (34 x SO x 20)
5 Drivc pinion spacer 20 Ram (needle k i n g )
6 First driven gear 21 Drivc pinion
7 Synchronizer ring 22 Ball bearing (IY6303C3)
8 Rcversc driven gear 23 Washer (17.2 x 26 x 0.2)
9 Synchronizer hub spring 24 Transmission main shaft
10 Synchronizer hub insert 25 Ball k i n g (#6004)
1 1 Synchronizer hub 26 Washer (31 x 40.8 x 0.5)
12 Gcax thrust spacer key 27 0 a 4 (19.8 x 35 x 7 )
13 G e u thrust spacer 28 R e v e r r idler gear shaft
14 Second driven gear 29 Straight pin (6 x IS)
15 Gear I h m t mpaccr 1 I 30 Reverrc idler gear
Selective p u t
111-002

Fig. S - 4 Exploded view Af transmission

la - 4
3. Differential gear component parts

' \

. .
'5 .

$8 , e,
, 1 Oilseal(27x45x9] '$8 %'asher (53 x 65.5 x t)
2 Oil -1 retainer 9 Diffcrcntial caw
3 BaU bearing ( j 6 0 0 7 ) 10 Differential pinion shaft . ,

.4 Washa (27.1 x 4 2 x t) 1 1 Straight pin (4 x 35)

5 Diffcrcnttl sidegur
6 Differential pinion
7 Oil d ( 2 7 x 62 x 9 )
1
. 12 F i d g u r
1 3 F h l g m lock washer
14 Bolt (10 x 21 x 13)
Selective parts
T 1 1-003

Fig. 1 - 5 Exploded view of di/ferential

a - 5
 4- 4. DISASSEMBLY
1) Clutch lever
Refer t o the paragraph "Clutch lever" for
1. Removal removal.
2 ) Transmlss~oncase
Pull out the 011 gauge near the differential
chamber of the upper case Place the transmis-
1. Jack vehicle rear wheel off sion case upside down, unscrew twenty fixing
floor,. bolts and disassemble the case into two sec-
2. piace jack under motor [for tions T h e twenty fixing bolts to be loosened
support only) . are 8 m m 18 pcs. and 6 mm 2 pcs.
3. Disconnect hose clamps and re-
move hoses from motor cooling fan. 8 m m Bolt.
4. Unplug red wire on fan and two L = 4 5 m m ( l 77111) : 1 3
red wires on transmission. L = 65 mm ( 2 56 in) . 3
5. Remove fan. L = 95 mm (3.74 in) 2 '

6 . Disconnect axle shafts

6 m m Bolt.
A. tap out spring pins, using a
L = 3 2 m m ( 1 76in).?-
3/16 inch punch. NOTE: DO NOT
DRIVE PINS INTO TRANSMISSION
HOUSING .
8. Remove gear shift rod on front
of transmission.
9. Remove front and rear support
bolts and 4 motor bolts.
10. Separate and removc through
bottom.

F ~ 7. Disassemhlrnf trnnsmlssion case

2. Disassembly NOTE:
When removing the lower case, be careful
Wipe the transmlss~on clean of grcasc and n o t t o lose the straight pin 8
on the reverse
dirt. loosen d r a ~ nplug ( 7 0 x 10) and drdln oil
Remove metal powder etc. attracted o n magnet
, idler shafta.
of the drain plug.
Retighten the plug after 011 1s d r a ~ n e d

3 5 + 0.4 kg-nl
T~ghtenlngtorque
( 2 5 3 + 2.9 ft-lb)
 3) Main shaft, drive pinion and differential
assemblies

Main shaft

Fig. Pt-10 Components of muin shaft

assembly

" b. Remove the ball bearing @ (#6004) and

v
Fig. %1-8Disassembling transmission two ball bearings @ (#6303C3) with a
-3 washer (17.2 x 26 x 0.2) @ using a puller
4 or press.
E Remove the washer and caps, and take out 5) Drive pinion assembly
)
: the main shaft assembly, drive pinion assembly,
a. Remove the snap ring with a special tool I
and differential assembly from the transmission
..
P

MSC.
5
"Expander" and remove ball bearing (#6204
NR), washer (20.2 x 29 x 0.2), ball bearing
(#6204) and washer (20 x 38 x 3).

. -Main
- shaft ass'y
Special tool
Expander
899474 100

'Fig. H - 9 Disassembling t r a ~ m k s i o n

4) Main shaft assembly.

a. Remove oil seal @ J (19.8 x 3 5 x 7) and Fig. 9 - 1 1 Removing rnup ring
washer @ (31 x.40.8 x 0.5). (Fig. S-10)
b. Remove the 1st driven gear. synchronizer
NOTE: ring, and hub assembly (1st & 2nd speeds),
Before removing oil seal, cover the spline of
Then remove the key (gear thruit spacer).
the shaft with tape t o prevent damage t o the
lip.

Fig. I - 1 2 Removing key (gear thrust spacer)
c. Remove the gear thrust spacer 0 ,synchro-
nizer ring 0 , 2nd driven gear @ , gear
'
thrust spacer II @, 3rd driven gear @ ,
synchronizer ring @, gear thrust spacer I1
0 ,hub assembly (3rd & 4th speeds) @ ,
synchronizer ring @, 4th driven gear @ ,
and gear thrust spacer I1 @ in that order.
Fig. l - 1 3 Duassembled drive pinion assembly
d. Remove the needle bcaringi:@.,(34 x 50 x
20).
'y
6) Hub assembly (1 st & 2nd spetds)
-
Fig. W-f 4 Hub assembly (I st B 2nd speeds)
Remove the synchronizer hub springs @
and pull out the synchronizer hub inserts@
Separate the reverse driven gear @ from the
synchronizer hub 0 .
7) Hub assembly (3rd & 4th speeds)
~ & . @ - 1 5Hub assembly (3rd & 4th speeds)
r .
f-
~ e m o v cthe synchronizer hub springs @
and pull out the synchronizer hub inserts @.
Separate synchronizer hub sleeve @ from the
synchronizer hub @.
8) Diifcrential assembly

.,. . .. -'.
->.;..-
,,. a,
* 7 - - " I ..>
. . -
.-
Fig. *-I8 Removing side gear
Fig. @ - I 6 Removing oilseal
d. Drive the straight pin (4 x 35) @ out from
the differential case @ sidc and then dif-
a. Wind vinyl tape on the spline of side gcar ferential pinion shaft @. Remove the dif-
shaft t o prevent damage l o oil seal lips. ferential pinion @, differential side gear @,
Remove the oil seal (27 x 62 x 9) from the and washer (27.1 x 42 x t).
differential case side first. Then remove the
oil seal (27 x 45 x 9) and retainer from the
final gear side.

b. Straighten the bends of lock washers on the

final gear, and remove the bolls (10 x 21 x
13) to separate the final gear from the
differential case.

Fig. m-19 Driving out straight

. .
, .
NOTE: 1%''

Keep the sidc g e a r s and adjusting washer

separate with reference to t h e final gear side
and differential case side.

e. Rcnrove'the ball bearing (lj16007) from the

Fig. #-I 7 Drivivg o u t straight pin final gear and differential case with a puller
or press.

c. Remove the differential side gcar and washer

(27.1 x 42 x 1) from the final gear side.'
 9) Gear shift mechanism of transmission
cover compl,

Fig. 1 - 2 1 Removing plug and sekcrm

phngn

Fig. 111-20 Gear shijt mechnism 11)

a. Loosen two 6 mrn bolts ( L = 12 mm).
Remove the shifter rail spring plate 0 ,
three shifter fork rail springs @ , and thrcc
Loosen four 6-mrn bolts (L = 25) and
remove the transmission cover compl. Take lock balls (6.350 rnm dia.)@ .
out spring pin (6 x 28) a
using a special tool
Then remove shiflcr rail plate @ by loosen-
ing two 6 mm bolts ( L = I 2 mm).
"Straight pin remover II", separate the gear
selector arm shaft compl. @ from the selector
arm 0 , and remove the shifter arm @ and
shifter arm shaft @.

special
tool :
I Straight pin remover 11:
398791'700

10) Reverse accent mechanism of transrnis-

sion cover (Fig. 8 -21)
a. Loosen the plug (8 x 10.5) @ and take out
thc shifter fork rail spring @ and ball
a.
(6.350) - . ..
-

b. Remove the :&lector plunger @, accent

Fig. &-22 Removing rhiftrr rail
-
!: .q., .
plunger sprin&@ and accent plunger spring
11 @. spring plate
Y
b. Using spechl tool "Shifter fork pin extrac-
. lor", remove the straight pins (4 x 22) @
,
for the 1st & 2nd speed shifter fork a, 3rd
& 4th speed shifter fork I1 0 ,and reverse
shifrer arm 11 @. (F~~.'P-23)
Then, remove the shifttr fork rail for 1st '
and 2nd speeds, shifter fork rail I1 @ for
3rd and 4th speeds, and shifter fork rail 111
a for reverse in that order. Rail 111 should
be removed after taking off the back-up Light

Fig. B-23 Removing shijter fork
switch (with aluminum gasket). Remove the
shifter forks a and 0 ,shifter arm I1 0 ,
and reverse shifter lever @) from the trans-
mission case.
c. Four interlock balls (5.55 rnm dia.) are
provided in the interlock holes in the trans-
mission case, two balls tach between the
threc shifter fork rails. Remove these baUs
carefully so as not to lose them. Take care
not t o lose the plunger installed on rail 11.
1 Rail 111 (Shifter fork)
2 Raii I! (Shifter fork) -
3 Plunger (Shilter rail)
4 Interlock baU (5.55)
.
r'
-
i.
5 Spring (Shifter fork rail) ?
,. 6rLock ball (6.350)
'('7 'Rail (Shilter fork)
- -
Fig. a - 2 4 Component parts of shiftcr
mi! and lock balk
12) Revtne idler gear
Fig..#-25 Removing reverse idler gear
Take out the straight pin (6 x 15) 0and
remove the reverse idler gear compl. @ by
moving the reverse idler gear shaft @ to the
clutch side. The reverse idler gear shaft @
should be removed outside after the plug (1 3 x
5) @ is driven out.
NOTE:
Do not remove the reverse idler ear shaft
unless necessary.
4- 5. INSPECTION
Thoroughly clean ail disassembled parts and
theninspect. *
NOTE:
Oil seal must never be washed in gasoline as
it causes their lips t o swell.
7. Gears
Tll.007
-
I) Replace gears whose teeth surfaces are
broken, damaged or unusually worn.
2) Replace gears if the cone surfaces with
which the synchronizer rings are in contact are
seized or damaged.
3) Replace any bearings whose inner walls or
end faces are excessively worn or damaged.
4) Replace any spacer whose end faces are
excessively worn or damaged.
5) Thrust clearance of each gear
 3. Gear shift mechanism '.
Gear Standard value
I ) Check the clearance between the shifter
1st
0.050- 0.350 nim fork and the groove of the synchronizer hub
(0.0020- 0.C 138 in) sleeve. .

2nd &-3rd
0.110 - 0.430 m m
,(0.0043- 0.0169 in) 0.2- 0.4 rnm
Standard clearance'
(0.0079- 0.0157 in)
0.1 10 - 0.480m m
4th
(0.0043- 0.0189 in)
2) ~ e ~ l a c the
e ' lock ball (6.350 .mrn dia.),
shifter rork rail spring, shifter rail plunger, and
interlock ball (5.55 mm dia.) if they are
excessively worn or deformed,

2. Synchronizer ring

1 Back lamp switch 7 Arm (Selector)

2 Rail Ill (Shifter fork) 8 Shaft (Shifler arm)
3 Rail I1 (Shifter fork) 9 Folk (Shifler)
4 Rail (Shifter fork) 10 Fork I1 (Shifter)
5 Straight pin (4 x 22) 11 Arm 11 (Shillex)
6 Arm (Shifrtr) 12 Lever (Reverse shiftcr)
Tll-009
Fig. a - 2 6 Ring-lo-cone clearance
Fig. W-2 7 Inspecting gear sliifr mechanism
1) Replace any synchronizer rings whose
I
internal zurfaces or teeth surfaces are damaged 3) Replace the shifter fork rail if the edge of
or excessively worn. lock ball groove is worn. .
2) : Measure; the' clearance "C" between the
ends facing ep$h other with the ring pressed 4. Bearing
onto the cone'of the gear.
Replace the bearing if seized, worn,noisy. or
unsnioofh rotation.
Standard value 1.3 - 1.7 mrn
of "C" 5. Oil seals and caps
(0.051 2 - 0.0669in)
i) Oil scats
Lirnil value of
0.5 mm (0.0197 mm) Rcplace any oil seal whose lips arc de- -
"C" formed, hardened, or worn. Also replace if its
periphery i s damagcd.
2) Caps
3) Replace the ring if its contact surface with Replace any cap whose periphery is dam-
the synchronizer hub inserr is excessively worn. aged.
6. Other parts keep the clearince of outer race of the two
ball bearings.
Replace any part if it is dcformcd, exccs-
sively worn, or defecfivc.
2 ) Apply grease [equivalent to Uniiube No.
21 between the lips of the oil sea1 (19.8 x 35 x
7. Differential
.. 71, wind tape around the main shaft spline and
I ) Replace the 'final gear and drive pinion if carefully install the pit seal on the shaft.
the iooth surfaces are damaged or excessively
warn.
2) Replace the drive pinion if the contact
surface with the needle bearing inner race or
the gear sliding spline is excessively worn.
3) Replace the differential pinion, side gear,
washcr (27.1 x 42 x t), and pinion shaR if they
are seized, worn, or damaged.
4) Rcplace lhc differential case if crackcd or
defective in any other respect.

4- .6. ASSEMBLY Fig. 9 - 2 9 I m t a l l b ~ goil seol

The transmission and differential should be
assembled in the reverse order of disassembly. .I
Points requiring attention in assembly arc de- 2. Drive pinion assembly
scribed below. Be sure toapply gear'oil to each
part before assembling. NOTE:
The needle bearing has installing direction,
1. Main shaft a s s e m b l y when install the bearing, set *Z1" side to
the gear side. . .
1) The ball bearings (f6004, #6303C3)
should be press-fitfed by a press with the
stamped side facing out,
L,>L2 - To gear side

8all bearing (f6303C3) I

' Inner
I
Needle bearing
Tll-011 I
- -

Fig. 01-30 Installing direction of

. needfe bearing
Fig. 1 - 2 8 Ball beurings G washer on
muin shaft 1) Hub a&drnbly (3rd & 4th spceds)
Instal! the synchronizer sleeve s o that the
NOTE: *mark part in Figure 8 - 3 1 may be placed on
The washer (17.2 x 26 x 0.2) is installed the H, side of 38 rnm dia. boss of thc synchro-
between the ball bearings W6303C3) to nizer hub.

Fig. 1 - 3 1 Assembling hub ussembIy
(3rd G 4th speeds)
Set the synchronizer spring so that the cut
:
ends of spring on both sides be in opposite
direction, and make sure that the insert is
properly installed.
2) The hub assembly should be installed on
the drive pinion in such a manner that the H2
side of the 38 mrn dia. boss faces the 4th driven
gear and the untoothed part of angular spline of
the synchronizer hub is placed away from the
oil hole in the drive pinion. ( H >~H I )
NOTE:
This untoothed part is where the gear thrust
spacer key is s e t
3) The gear thrust spacer betwecn the 2nd
driven gear and hub assembly (1st & 2nd
speeds) should be inserted with the end face
with a notched groove (6.6 mrn wide, 1 .S mm
deep) facing the 1st driven gear and aligned to
the untoothed part of the above spline. Put the
spacer key in the notched groove t o lock.
F*. 11 -32 Instolling g m r thrust spacer
4) Hub assembly ( l st & 2nd speeds)
Fig. I - 3 3 InstuIling hub a$sembly
(1st ond 2nd speeds)
Install the reverse driven gear so. that the
fork groove side may be placed on the H I side
o r 38 mrn dia. boss of the. synchronizer hub.
(HI<Hz) 9
5 ) Put the hub assembly on the drive pinion
with the HI side of the 38 rnm dia. boss facing
the 2nd driven gear.
6) Install the drive pinion spacer with the oil
groove side end race facing the 1st driven gear
and with the L , side of ball bearing (#6204NR) ,
>
facing the 1 st d r h e n gear. ( L , L ~ )
. Washer ft - 3)
#62M NFi
Washer (20.2 x 29 x 0.21
T I 1.015
Fig. 9 - 3 4 Rear bearings on drive pinion
NOTE:
The washer (2b.2 x 29 x 0.2) is inPtalled t o
keep clearance between bearing outer races.
 7) Select a snsp ring that will provide a
clearance of 0 to 0.05 rnm (0 to 0.0020 in)
between the inner race end fact of ban bearing
(#6204 NR) and the snap ring. Press fit the
snap ring in the groove using a special tool
"Prcss assembly" and make sure that the
snap ring isrccurely seated in the groove.
3. Differential assembly
1) Press fit the baU bearings (#6007) onto the
final gear and differential case i n a d v a n a .
2 ) Select a suitable adjusting washer t o adjust
the differential backlash t o 0.05 t o 0.15 mm
(0.6020 t o 0.006Win) and install on the back o i
the side gear.

.
;
5-.
.
.-
.,-
-
, '
. - - A -.-.
. : - . . :
1 Adjusting washer
2 Pinion (Differential)
3 Adjusting washer
4 Gear (Dificrcntkl side) Tl1-016

A
NOTE: Fig. t&36 Adjusting washer
Always replace the snap ring once it has
been removed,

NOTE:
Guide (snap ring) Selective adjusting washers must be as-
Special tool: 899754121 sembled with t h e chamfered face of the
Press assembly washer toward the gear.
899754 100 Press (snap ring)
899754 102
J

Adjusting washer
Snap rings

Part No. Thjckness

Part No. Thickness
80312708 1 1.000 rnm (0.0394 in)
2.5 I t 0.01 5 mm
805020022
+
(0.0988 0.0006 in) 803 127082 . 1.050 rnm (0.041 3 in) r; '<.

2 5 7 + 0.015 rnm 803 127083 . 1.lo0 rnrn (0.0433 in)

(0.1012 + 0.0006 in)
805020024

- 2.63+0.01Smm
80S020026
+
(0.1035 0.0006in)

805020028 '
+
2.69 0.015 mni
(0.1059 2 0.0006 in)
3) Tighten bolts (10 x 21 x 13) to the
specified lorque and bend the lock washers
(final gear).
Fig. XI-37 Bending lock wnrher
Tightening lorque 6.3 + 0.5 kg-m
(10 mm Bolt) (45.6 + 3.6 Tt-lb)
4) Apply gearoilbetween the l i p s o f t h e o i l
seals (27 x 45 x 9 , % 27 x 62 x 9). Wind tape
around the side gear spline and install the oil
seals carefully. Be sure to keep a gap of about 3
m m between the oil seal (27 x 62 x 9) and the
end face of ball bearing (#6007). Keep the oil
seal (27 x 45 x 9) in close conlact with the oil
scal retainer.
Fig. S 3 8 Installing oil scal
5) Reverse idler gear . :
Fig, St-39 Installing reverse i d l e r g a r
Install the reverse idler gear shaft @ on the
case with the pin hole facing outside. Then. put
the reverse idler gear @ o n the shaft as the
groove i n . which .the lever is placed faces
outside, and lock with fhe straight pin (6
x 15). (Apply a small amount of grease lo the
pin head t o prevent i t from falling off when
assernblingthe-cast I.) Drive the plug (1 3 x 5)
into the case.
4. Gear shif-t mechanism
I) Transmission cover
1 Spring (Acotnt plunger)
2 Spring 2 ( A c a n t plunger)
3 Selector plunger
. Fig.lP-40Tra~muJionc0verCOMPL
Coat the screw of plug (8 x 10.5) with liquid
packing (Fuji Bond "C" or equivalent). While
inserting the shifter'arm shafi into the cover as
a guide of selector plunger and accent plunger
springs, screw in the plug with the selector +.
plunger pushed fully inward until the plug head , Identification
becomes flush with the cover surface. Makc Part No' Remarks
mark on lcver
sure that the selector plunger pushed ope:ates
smoothly. Approach to
2 ) Shifter forks and shifter fork rails 3A2772101 ,.. A ' the I st gear
., The shifter forks and rails should be installed side
in the following manner, beginning with the
reverk side. 342772 102 B Standard

Approach to
342772 103 C the 2nd gear
side

NOTE:
After having determined the lever, use wash-
ers of correct thickness t o provide 0.5 t o 1.0
mm (0.0197 to 0.0394 in) clearance be-
tween the lever and gear compl. (reverse
.idler).

Fig. a -41 Itutalling shyter a m I I

. .
a. With the lock ball groove on the shifter fork Reverw! rhilter lever

rail 111 a facing down, put the rail through

the case. lnstall the reverse shifter lever @
in the reverse shifter lever shaft press-
fitted in the case, and put the shifter a r m I1
@ o n top of the lever as shown in Figure
-1. Then align the pin holes in rail 111 and
a m 11 and drive the straight pin (4 x 22)
therein. . .
b. Temporarily assernbie the lock ball (6.35 Fig. r-42Adjusting the fiver porition
' 'i.
rnm dia.) with the shirter fork rail spring, I'
and shift the reverse shiftcr lcver to the I
reverse side. ~ d j u s t i k gL s h e r
Place the drive pinion assembly and main
shaft assembly in the normal position (as far . .
over on the d u t c h side as possible), and Part No. - ~hickidss
apply red lead t o the tooth surface of reverse
driven gear. Put case I over them with the tip 803015082 ' 1.1 m m (0.0433 in)
of reverse shifter lever placed in the groove
of the reverse idler gear compl. tc check the 803015086 0.8 mm (0.0315 in)
mesh of the gears, and select the reverse
shi fter lever that provides tooth contact of 803015087 0.4 rnm (0.0157 in)
80%or more. i
 Then remove case I and set the reverse
shifter Iever t o the neutral position.
. c. Put two interlock balls (5.55 mrn dia.) in the
interlock holes of the case side. Apply a
small amount o f grease to the baUs t o
prevent them from falling off during anem-
bly.
d. Install raii I1 fn the case as in Step (a.) on
page 11-17), assemble fork 11 with it, and
lock by driving in the straight pin (4 x 22).
(Fig. 8 - 4 1 )
t. Operation similar t o Step (b.)
f. Install the rail. in the case in the same Fig. H4.S Selecting shifrer fork I I
manner as step(a.),assemble the fork with it
and drive in the straight pin (4 x 22). Temporarily assemble the shifter fork rail
spring and lock ball (6.35 mm dia.), and
place the forks in the neutral position. Select
the shifter fork and shifter fork I1 so that
the synchronizer sleeve and reverse gear wit1
be set as shown in Figure 8 - 4 2 when the
drive pinion assembly is placed in the normal
position.

Shifter fork

Identification
Part No. mark on Remarks
the fork
Approach to
342012101 A the 2nd gear
side
Fig. PI43 Installing sh$er fork
342012102; B Standard
Approach to
3420 I2 103 C the 1st gear
g.-.Selecting shifter fork and shifter fork 11 side
Shifter fork I1
. .
ldentificidon
Part No. mark i;n Remarks
the fork I1

Approch t o
3420221 1 I A the 3rd gear
side

342022 112 B Standard

Approach t o
3420221 13 C the 4th gear
side
Fig. a 4 4 Selecting shifter fork

81 - 1 8
h. Tighten the shifter rail spring pLtt and
shifter rail plate with two &mm bolts (L =
12 mm) tach. The shifter rail spring plate
should be installed with the flange for the
harness clamp placed outside.

Tightening torque 1 + 0.075 kg-m

(6 mm Bolt) (7.23 2 0 5 4 ft-lb)

i. Tighten 'the back-up light switch t o the

specified torque. Be sure to use the alumin-
um gasket. Fig. H-47 Mmsuring ckumacc

Tightening torque 1.8 + 0.2 kg-m

FQ. 1 - 4 8 Meusuring clearance

Fig. a - 4 6 Installing lmck-rcp light switch

. Wssher (39 x 49.5 x t) for main shaft

3) Washers and caps
a. Place the main shaft assembly, drive pinion
assembly, and differential assembly in the
5..I Part No. I Thickness (rnm)
I
standard position (wkijirc?.the main shaft and
drive pinion asscrnblies are all the way over
on the clutch side and the differential
assembly is on the side opposite t o the
clutch). Select and install a washer that
provides a clearance of 0.01 to 0.2 mm
between the washer and each end face of the
main shaft #6303C3 ball bearing, drive pin-
ion #6204NR ball bearing, and differential
#6007 ball bearing. (Refer t o Figs. a-47
and -48.)
Washer x 53.2 x t) for drive pin'ion, Joining transmission case
Iloroughly remove oil and dirt 'from the
Part NO. Thickness (mm) mating surfaces o i case I and case I1 and
~pplyliquid packing t o case 11. Then place
+O m e I on case 11. Belore doing so, move the
803039031
-0.03 tverse idler gear cornpl. to the clutch side
~ n dassemble the' tip of re-verse shifter lever
+O with the groove on the reverse idler gear
803039032
, 2'20 -0.03 :ompl.
+O
803039033
2.35 -0.03
+O
803039034
2'50 -0.03

Washer (53 x 65.5 x I) for difrercntial

/E11
-
Part No. Thjckncss (mm)
la
80305301 1 ;o
2'3 -0.03
+O
SO3053012 2'5 -0.03 -a

803053013
+0
. .2.7 -0.03

After having selected the washer for the Bolt

differential, place the oil seal (27 x 62 x 9)
in contact with the washer using an installer.
- 8 x 45 mm 13 p a .
A 8 x 65 mm 3 pcs
b. Attach the caps (transmission case) 10 the 0 8xSSmm2pa.
washers on the main shaft assembly and the 0 6r32mm2pa.
side of drive pinion assembly. Install cap I I I T11-021
(transmission case) with its positioning
notch aligned t o the case side positioning
groove on the front side of drive pinion Fig. M-50 Sequence of tightenittg care
assembly. . ,

b. Tighten t w o 6-mm bolts and eighteen 8-mm

bolts in the numerical order given in Figure
11-50.

Tightening torque

6 mrn Bolt
+
1 0.075 kg-rn
(7.23 2 0.54 ft-lb)

2.5 + 0.2 kg-m

8 rnm Bolt
(18.08 + 1.4 ft-lb)
c. Install the oil level gauge with the transmis-
sion cover up.
5) Checking gear shift
a. Assemble the selector arm with the gear
s e l t c ~ o rarm shaft compl. and drive in the
spring pin (6 x 28).
b. Assemble the shffter arm and shifter arm
shaft, and check gear shift.
4- 7. INSTALLATION
Installation should be performed in the
reverse order of removal. First make sure that
the release bearing,is not projecting, and then
start installation.
Never install the transmission while holding
the clutch release lever compl.

..2.
Secure the transmission t o the engine with
four 10-mrn bolts.

Tightening torque 4.5 2 0.3kg-m

(10 run Bolt) (32.62 2.2 ft-lb)

3.
Remove the oil level gauge and fiU the
transmission with gear oil (MP $80). Straighten
Fk. a - 5 1 Checking gear shift condition the bent tip of the oil level gauge.

c. Tighten the transmission cover compl.

along with the gasket using four 6-mm bolls (0.95 U.S. qt..
(L = 25 mm). 0.80 Imp. qt.)
e

Tightening torque 1 + 0.075 kg-m

(6 mm Bolt) +
(7.23 0 5 4 ft.lb)

6) Clutch lever 3
Refer t o Chapter m,"CLUTCH"
 4- 8. TROUBLESHOOTING

Condition and probable cause Remedy

1. Difficult gear shifling

Difficult gear shifting is usually caused by a change rod failure andlor a transmission failure.
At the same time, however, when the lever feels heavy and gear shifting is difficult, it may be
the result of sn improperly disengaged clutch. Therefore, first check that the clutch is
operating properly and then check the change rod and transmission.

(1) Loose or separated change rod con- Adjust or replice.

nections.
(2) Worn, broken or burred chamfers of Re pla ce .
internal splines of sleeve and reverse
driven gear.
(3) Worn, broken, or burred chamfers of Replace.
gear splines.
(4) Insufficient operating stroke due t o Repair or replace.
worn sliding part or rattling.
(5) Improper contact between synchro- Repair.
nizcr ring and ring gear cone, or worn
contact surfaces.

2. Gear slips out.

( I ) Worn shifter fork, or fatigued or Replace.

broken shifter fork rail spring.
(2) Worn lock bail groove in shifter rail. Replace.
(3) Worn or damaged ball bearing. Replace.
(4) Excessive clearance between synchro- Replace. .
nizer hub and sleeve splines.-
(5) Worn chamfers and flank of each Replace.
gear spline.

3 Noisy transmission
'4

. If a noise is heard during idling but stops when the d u t c h is disengaged, the problem is
probably in the transmission.

(1) Insufficient lubrication or use of Add oil or change t o recommended oil.

-" inadequate oil.
(2) Worn or broken gear and bearing. Replace. I
..
 C

Condition snd probable cause Remedy

NOTE:
High humming i s heard at high speeds
if the wear has progressed t o the
extent that the tooth surface is worn. a
I n case of breakage rotational knock-
ihg sounds are heard even a t low
speeds.

(3) Worn splines. Replace. --

. .

4. Breakage o f differential (casc, gear, bcaring, etc.)

This causes an abnormal noise and a failure i n rotation, making it impossible for the vehicle to
run.

(1) InsufOcient oil or use of inadequate Disasscmble differential and replace

oil. broken parts.
(2) I rnproper use of vehicle such as over- Check parts for condition and replace as
loading, improper use of clutch. necessary.
(3) Excessive backlash due to worn side Adjust backlash and tooth contact.
gear, wssher (27.1 x 42 x t) and L!
pinion.
(4) Bolts fixing final gear loose. Fill recommended oil to specified level.

5. Noisy differential and final gear

In the casc of a differential failure and finat gear failure, various distinctive sounds can be
heard and the source o f trouble can often be isolated by listening closely to these. Be careful
not to mistake a symptomatic sound for one coming from the engine, muffler, tires, bearings,
body, elc. Particularly, the sound o f final gear is often confused with other gcar sounds.

The different kinds of noiscs arc as follows;

( 1 ) Noisc at starting or gcar shifting

insufficient gear oil, improperly mesfing gears, or broken gears are the cause when the
noise increases as vehicle is accelerated.
(2) Bearing noise while acccleraling or coasting
Cracked or broken bcaring.
(3) Noisc produced mainly while turning

Abnormal noise of differential side gear. differential pinion, and differential pinion shaft.

(1) insufficient oil. Add oil to normal level.

(2) Excessive backlash between dif- Replace gear or washer.
ferential side gear and pinion.
 Condition and cause Remedy
-
(3) Worn teeth of final gear and drive Replace as a set
pinion.
(4) Broken differential pinion shafr. Re place.
( 5 ) Seized o r damaged bearing. Replace.
(6) Worn washer .(27.1 x 42 x t ) and Replace.
pinion shalt.
 CHAPTER 5 : SUSPENSION

SPECIFICATIONS . . . . . . . . . . .
O U T L I N E OF SUSPENSION .......
WHEEL ALIGNMENT ...........
COMPONENT PARTS OF FRONT SUSPENSION

COMPONENT PARTS OF REAR SUSPENSION

FRONT SUSPENSION . . . . . . . . . .
REAR SUSPENSION . . . . . . . . . .
POSTURE ADJUSTMENT . . . . . . . .
ADJUSTMENT O F WHEEL ALIGNMENT . . .
TROUBLESHOOTING . . . . . . . . . .
5 - 1. SPECIFICATIONS
1. Front suspension

I tem v I VAN (K87)

Total length 504.5 rnm (19.86 in)
Effective length 434.5 mm (17.1 1 in)
Torsion bar Effective diameter 19.5 mm (0.768 in)
Number of serration teeth Inner end: 37 Outer end: 34
Spring constant 4.22 kg-m/deg. (30.5 ft-lbldeg.)
Maximum length 278.5 mm (10.96 in)
Shock Minimum length 187.5 rnm ( 7.38 in)
absorber Damping force Expansion 88 kg (194 Ib)
(at 0.3 m b c ) Compression 56 kg ( 1 23 Ib)
Height 5 5 mm (2.17 in) 57.5 m m (2.26 in)
Helper
Rubber hardness 62" 70" 1
Outer Diam.
56.4 mm (2.22 in) x 5 I .6 rnrn (2.03 in)
Outer bearing x inner Diam.
Length 30mm (1.18 in)
Bearing
Outer iriarn.
58.4 mm (2.30 in) x 53.0 mm (2.09 in)
Inner bearing x lnncr Diam.
---

-
Lcngth 3 0 m m (1.18 in)

2. Rear suspension

item
527
I VAN (K87)
mm (20.75 in)
Total length
Effective length 483.5 rnm (19.04 in)
Torsion bar Effective diameter 22.5 rnm ( 0.89 in)
Inner end: 3 7 Outer end: 34
Number of serration teeth
-
Spring constant 6.7 1 kgm/dtg. (48.53 ft-lbldeg.)
-
hlaximum length 269 mrn (1 0.59 ir;)
7

Shock Minimum length 213 mm ( 8.39 in)

absorber ExPnsion 88 kg (194 lb) ;. . C.
Damping force v -
(at 0.3 mlsec) Compression 6 4 kg (141 Ib)
Height 59.5 mm (2.34 in)
Helper
Rubber hardness 50"
Outer Diam.
52.8 mm (2.79 in) x 44 m m (1.73 in)
Rubber x Length
Outer budling
bushing Rubber
hardness
so0
NOTE:
a. The length of the shock absorber is measured as shown in figure.
Front shock absorber: .
Rear shock absorber:...-- 4~-
1
b. The length of the helper is measured as shown in figure.
Front helper.
5- 2. OUTLINE OF SUSPENSION
The front suspension employed is of a semi-
trailing arrn type. The front crossmember,
which is integral with the chassis frame and
located ahead of the front wheel center, houses
torsion bars that are the main springs for the
front suspension.
Both ends of the torsion bar are provided
with serrations; inner cnd is anchored a t the
center of the crossmcmber and the outer end is
connected to the trailing arrn.
Lsngrh
Rear helper.
?.. . e.,.
.Y
The trailing arm swings up and down w i t h '
the crossmember acting as the pivot.
Slidc occurs between the nylon bearing
press-fitted inside the trailing arm, which is
adopted t o give a smooth slide, and the metal
sleeve press-fitted on the crossmcmber.
The upper end of the shock abosrber is
attached to a bracket on the chassis frame and
the bottom end is installed on a pin welded on
the trailing arm near to the center of the wheel.
 The rear suspension is of a semi-trailing,
independent type using outer and inner trailing
arms. A crossmember, integral with the chassis
frame and located in front of the trailing arms,
houses torsion bars. T h e inner ends or the
torsion ban are connected to the center arm st
the center of the crossmember, which serves as
vehicle height adjuster, and the outer ends of
the torsion bars t o the outer trailing arms.
The inner and outer t r d i n e anns rrc con-
nected to Lhe crossmember through rubber
bushings.
The upper end of the shock absorber is
attached to a bracket on the chassis frame, and
the lower end to the pin on the inner arm,
As an auxiliary mpring. a helper is installed
on a bracket welded to thc chassis frame on
each side.

Front 275-305 mm (10.8-12.0 in)

Vehicle height*
Rcar 260-295 mrn ( 1 0.2-1 1.6 in)

+30'
Front 2010' -60' '

Camber**
+30*
Rear 3 O 15' -60.

CastereL Front 15~25'

i45'

Front IN 8-1 3 mrn (0.3 -0.5 in)

Toe -in
Rear IN 9-1 5 mm (0.35-0.59 in)
, .
. .+ Front
p i d e slip*** IN 3 mm (0.1 in) t o OUT 3 mrn (0.1 in)
..
Rear

Inside 37" *2O

Turning angle*+**
Outside 3 3 O 3 0 ' *2O

Distance between ground and center of torsion bar outer end facc, with vehicle unloaded.
Difference between right and lcft should be less than 10 mm (0.39 in).
* * With vehicle unloade.
*++ With driver in vehicle.
**++Difference between right and lcft should be less than 3 O .
COMPONENT PARTS OF FRONT SUSPENSION ,

1 Lock boll plug 8 Cushion rubber 15 Bolt

2 Torsion bar 9 Torsion bar lock boll 16 Torsion b u lock bolt
3 Helper bracket 10 Sleeve 17 Expansion plug
4 Helper 1 1 Oil s u l 18 Trailing ann
5 Rubber bushing i 1 2 Dust cover 19 King pin bushing
6 Shock absorber 13 Nylon bushing
7 Washer 14 Dust covcr TIP

F i g . dC-l Component parts of front suspension

6E -5
5- 5. COMPONENT PARTS OF REAR SUSPENSION \

Fig. 1P-2 Cornponenl parts of rear suspension

m-6
5- 6. FRONT SUSPENSION . Or
a. Turn the steering wheel l o the left (right)
1. Front suspension assembly fully to disconnect the right (left)-hand
brake hose from the wheel cylinder.
REMOVAL
1) Loosen the four w h t d nuts securing the
rim to the brake drum.
2) Raise the vehicle front and remove the
nuts-the detach the wheel.

Fig. M-5 Disconnecting brake hose from

whecl cylinder

b. Remove the union bolt at the wheel cylinder

Fig. eC3 jacking up
and remove the brake hose.
4) Removing the tie-rod end.
a. Remove the cotter pin and remove the
3) Disconnecting the brake hose from the castle nut.
brake pipe or wheel cylinder. b. Disconnect the tie-rod end irom the knuclc
a. Loosen the joint nut connecting the brake arm by using the special tool (Ball stud
hose t o h e brake pipe. remover: 92 1240000).
b. Pull out the clamp fixing the brake hose to
the bracket. N'OTE:
c. Pull o u t the brake hose from the bracket; Do not tap the knuele arm by hammer.

Fig. f 24 Disconnecting brake hose Fig. L&-6 Removing tie-rod end

5 ) When removing the left-hand side suspcn-
sion assembly, disconnect the speedometer
cable.
6) Remove the splashboard by loosening
three 8 mrn bolts.

Fig. 0 - 9 Disconnecting shock absorber

b. Loosen the two Iwk nuts on the upper end

of the shock abosrber until the load is
released from the rubber bushing at the
lower end of the shock absorber.
Fig. Y - 7 Removing splashboard
NOTE:
A The lower end of the shock absorber is used
as a reference line to determine the proper
ground clearance while the suspension is
7) Remove the trailing arm stopper bolt. being installed. Therefore, do n o t remove
the upper shock absoiber lock nut unless the
shock absorber is out of order.

c. Remove the lower end of the shock absorber

from the trailing arm damper pin.
9) Rernove the torsion bar lock bolts on the
trailing arm and at the center of the cross-
member.

Fig. --8 Removing stopperibolt

8) Disconnecting the shock absorber lower

end.
a. Remove the 10 rnm nuts and washen secur-
ing the lower end of the shock absorber to
the trailing arm. Fig. a 1 0 Removing torsion bar lock b o l t

&-8
10) Extract the suspension assembly from
the crossmember by hand.

Fig. 41-12 Applyinggruzrc on sleeve

v
-- -
'\ *<
I _
3) Install ihe front suspension assembly in
Fig. * - i f Removing suspension assembb the reverse order of removal.

INSPECTION
1) Check the bearings in t h e lrailing am for
wear and damage.
2) Chcck the sleeves on the crossmember for
wear and damge.
3) Check threaded parts for wear and damage.
4) Chcck the oiJ scal lips for wear and
damage.
5) Check the torsion bar and lrailing arm for
any evidence of deformation which may have
decreased their strength. Also check the painted
surface of these parts ior peeling, and repaint if
necessary.
NOTE:
If the trailing arm coating has come off or if
the trailing arm is rusted, carefully check the
NOTE:
a. When installing the torsion bar into the
crossmember, align the lock bolt hole in the
crossmember with the V-shaped groove a t
the torsion bar inner end and install the.lock
bolt
Also align the lock bolt hole in the trailing
arm with the V-shaped groove a t the torsion
bar outer end and,install the lock b o l t
After completing the above job, adjust the
vehicle height and side slip.
b. The torsion bar lock bolts are of special
design. Always use genuine SUSARU b o l t s
c. Tightening torque specifications are as
follows.
' r
Torsion bar lock bolt
3.0 - 4.4 kg-m
I

affected parts for cracks or damage. If (22 - 32

necessary, use a dye test t o determine
abnormalities. Trailing arm stopper 1.1 - 2.6 kg-rn
bolt '. 2; ( 8 - 19 ft-lb)
INSTALLATION r'
-.
1) Before installing the front suspension Brake h e and brake 1.5 - 2.0 kg-m
assembly, throughiy clean the b e e ' g s and pipe connecting nut ( 1 1 - I4 ft-lb)
sleeves with clean cloth and keep these parts
free of dust. .Shock abosrber lower 1.8 - 2.6 kg-rn
2) Apply new grease (about 70 gr. (2.5 02)) end installing nut (13 - 19 ft-lb)
to the crossmember sleeves.
upper 1.8 - 2.6 kg-rn
Shock absorber nut (13 - 19 ft-Ib)
Autolex A, upper end
Sunlite No. 2 lock nut lower 1 .O - 2.0 kg-m
or equivalent. nut ( 7 - I 4 ft-lb)
d . When inrtallinp the plupr shown in figure, apply a coat of sealing compound to t h e
always replace it with a new one and apply threadt.
a sufficient amount of sealer when inrtaliinp
it on the suspension.
s. Before tightening t h e torsion bar lock bolts Ccmtdine CS 1 I 1 5
Recommended
and trailing a r m retaining bolts, be sure to Ctmedine 540
sealer:
or equivalent

1- Plug
2 Lock bolt
3 Bolt

. .
.-.
.b.
I-

+
?, T 2 2-004
: : . q.L
, \'

Fig. S - I 3 Plugs and lock bolts on front suspension

ADJUSTMENT
After the front suspension assembly has
been installed, check the ground clearance and
wheel alignment. If necessary, adjust.
(Refer to "Posture adjustment" and "Adjust-
ment of wheel alignment".)
2. Torsion bar INSPECTION
. 1) Check (he torsion bar for damage and its
MMOVAL painted surface for peeling.
1) Remove the front suspension assembly. 2) Check the torsion bar serrations for wear.
(Refer to removal of front suspension assembly.)
2) Remove the torsion bar lock bolt at the INSTALLATION
center of crossmember underside. 1) Remove the upper lock nuts from the
upper end of the shock abosrber. and then
loosen the lower lock nuts. Set the shock
absorber so that three or four threads at its
-. upper end are engaged.

Fig. 8 - 1 4 Removing torsion bar lock bolt

3) Pull the torsion bar outward by hand.

lf it is hard to pull by hand, tap the end of the
torsion bar by using bended bar.

Fig. S l 7 Loosening b c k nut

2) Full the lower end of thc.shock absorber

until it extends fully.
3) Insert the torsion bar into the trailing arm.

Fig. H-15 Removing torsion bar

Fig. f t - 1 6 Removing torsion bar by tapping Fig. S - 1 8 Instulling torsion bar

4) With the torsion bar inserted into the
trailing arm, attach t h e suspension assembly to
the crossmembcr.

-
T- - v
\*.
-1
'
-.
F&. S - 1 9 I ~ t a l l i n gfiont suspension assembly

5) Attach t h e lower end of the shock

absorber to the trailing arm damper pin.
6) Manually push the torsion bar until thc
serration on both ends fits that of the cross- Fig. S 2 0 Tightening bolts and nuts
member and trailing arm.
NOTE:
a. Before tightening t h e lock halts, properly
align the V grooves on both ends of t h e
torsion bar with the holes i n the cross-
member and trailing arm.
b. Be sure to tighten all bolts and nuts to t h e
NOTE: specified torque setting.
If the serration i s hard to fit. turn the c. Install each torsion bar on the side from
torsion bar to locate the point where it which it was removed. I f the torsion bar
-easily fits. . . positions are interchanged between the right
. ;. . and leff early breakage may result The
.-. i.
torsion bars are marked as follows for
I'
=+
. ,
identification.

-!? , * .-
7) Tighten bolts and nuts in the following
621001381 (FRH)
order:
a. Torsion bar lock bolt a t lower center o f
crossmember. 621001391 (FLH)
torsion bar
b. Torsion bar at trailing arm end.
c. Trailing arm stopper bolt.
d. Two 'lock nuts 'at 'upper end of shock d. After t h e front suspension has been installed,
absorber. check the ground clearance and wheel
e. Nut a t lower end of hock absorber. alignment I f necessary, adjust
3. Bearing (Traiting arm inner and 2) Drive out thc bearing in h e following
outer) and Dust cover manner, using the special tool (Remover:
922290000).
REMOVAL a. Attach t h e hook @ to the inner side of the
I ) Remove the dust cover press-fitted to the trading arm.
inner end o f the trailing arm, by using a screw b. Open the hook @ until it catches the
driver. bearing end.
c. Insert t h e retainer @ from the serration
side of the trailing a m to prevent the from
coming off.

NOTE: . .
. d. Attach t h e cap @ to the location formerly
occupied by the dust cover.
Be careful not to damage the rubber surface e. Turn the screw @ to tighten the cap @
of dust cover. and drive out the bearing.

1 Retainer
2 Hook
3 Cap
4 Screw
5 Special tool:
(922290000)
6 Bearing

T 13-007

Fig. N-21Removing hailing arm bearing

e-13
INSPECTION
Check the followinp items for abnormalities.
lr necessary, replace.
I ) Bearing surfaces for wear or damage.
2) Resin and metallic areas for detachment.
3) Dust cover for deformation.
NOTE:
Before removing the front suspension
assembly, check the trailing arm end play
with a dial gauge, using the following
procedure. If the dial gauge pointer deflects
more than 1 mm, remove the front suspen-
sion assembly and replace the bearing.
INSTALLATION
1) With r clean cloth, wipe off dust from the
surfaces of the trailing arm, bearing and dust
cover.
2) lnstall the bearing onto the end (51.6 mm
diarn.) of the special tool (Lnstaller:
922350000), and k e n insert it into the trail-
ing arm.
3) T o d o this, drive the end of the tool with
a press or h y m e r until it comes into contact
with the end o f the-traiIing arm. Then press the
outer bearing into position.
1 Bearing (outer)
2 Special tool:
Bearing installer

1) Raise the front end of the vehicle until

the front wheels clear the ground.
2) Remove the torsion bar lock bolt, and
separate the torsion bar from the trailing a m .
3) Using a magnet stand, set a dial gauge at
a position within 5 mrn from the end of the
trailing arm.
4) Holding the tapered portion of the trailing
arm, slowly move the trailing up and down,
reading the dial gauge indication.

Fig. iS-23 ~'nstallin~

outer bearing

4) Install the bearing onto the end (53.0 mm .

Fig. ItZ-22 Measuring trailing a
diam.) of the special tool (Installer:
922350000), and then insert it into the trail-
ing arm. To d o this, drive the end of the tool
with a press or hammer until it comes into
contact k t h the end of the trailing arm. Then
m press the h e r bearing into position.
 NOTE:
D o n o t a l l o w t h e dust cover t o protrude
1 Bcaring (outer) from the trailing arm more than 1 5 mm
2 Bcaring (inner) (0.06 in).
3 Special tool:
Bearing inslallcr

Our1 cover

1.5 mm 10.06 in) TI2411

"

Fig. $2-26

4. Sleeve (Inner and Outer) and Oil

Fig. f f - 2 4 installing inner bearing
5 ) Install thc dust cover onlo the special tool
(Installer: 922360000); drive the tool with a
press or hammer until the dust cover comes
into contact with the end of the trailing arm.
seal
REMOVAL
I Insert the special tool (Puller Cap:
92260000) into the tip of the crossmember.
2) Attach the hook or the special tool
(Remover: 92203000) t o the end o f the outer
end sleeve.
3) Turn the handle of the tool to drive out
the outer sleeve.

Bearing (outer)
Bearing (inner)
Dust cover
Special tool:
Dust cover installer
(922360000)

Fig. IS25 Installing dust cover

a-15
 INSPECTION
1) Check the inner and outer sleeves for wear
or damage. If necessary, replace.

NOTE:
Measure the outside diameters of the sleeves
at points D l and D2 shown in figure.
If the difference between D l and D2
exceeds 0.1 mm, replace w i t h a new one.

Fk. S 2 7 Removing outcr slewe Fig. S-29 Measuring sleeve

2) Always replace oil seal after removal.

4) T o remove the inner sleeve, use thc same

procedure as that for the outer sleeve. Pull off
the oil seal and inner deeve at a time.

INSTALLATlON
1) Attach the oil seal to the crossmember.
2) Insert the inner sleeve into the special tool
(Installer: 922330000) and install it onto the
crossmember; drive the special tool with a
hammer until it comes into contact with the
crossmernber.

1 Oil sul
2 Inner sleeve T12-014
NOTE:
Check for proper fit of the inner sleeve
Fig. @28 Removing inner sleeve through the access h o l e in the special tool.
 5. Shock absorber
REMOVAL
1) Remove the two 10 mm nuts securing the
shock absorber to the chassis frame bracket.
2) Pull off the washer and rubber bushing
from'thc rod.

Crass m e m b e r
Hole
Special tool:
Oil scal and sleeve inctallcr
(9 22330000)
lnncr slecvc
Oil scal
TI2416

Fig. Y-30 Illstallirtg inner sleeve

Fig. &?-32 Loosening shock absorber upper end

3) Drive the outer sleeve into the cross-

member with a hammer through the special
tool (lnstallcr: 922340000).

1 Crossmember 3 Outer sleeve

2 Special tool: 4 Sleeve
Sleeve installer 5 Oil s d
(922340000) T12-017

Fig. R-31 Installing otc ter sleeve

m - 17
 3) Loosen the lOmm nut securing the
lower end of the shock absorber t o t h e trailing
arm, and detach the shock absorber.
4) Remove the washer and rubber bushing
from t h e damper pin.

I
Fig. S - 3 4 Checking oil leakage

b. I f oil is found only on the upper and l ~ w e r

portions, this does not indicate oil leakage
Fig. a - 3 3 Removing shock absorber lower end and does not require replacement of the
shock absorber.

5) Compress the shock absorber, and then

detach the upper end of the rod from dre
bracket.
6) Remove the lower end of the shock
absorber from the trailing arm.

I INSPECTION
! Check the shock absorber for the following
Fig.- m-35
items, and replace it if any of the following
abnormalities is found.
1) Excessive oil leakage or damage.
.
.
5
7
-.
b.

,-

2) Improper functioning. * INSTALLATlON

i, . c.
3) Improper travel strokes(rnin. and max.). .i: lnstdiation is in the reverse order ofremoval.
4) Deronncd or damaged rubber bushing.
NOTE:
Tighten tfie 10 mrn nuts securing the upper
NOTE: and lower ends of the shock absorber to the -
a Fully extend the shock absorber and check specified torque.
the length (PI of the rod wet with oil.
I f the length ( 9 ) is more than one-third of
the overall length (I), replace the shock Torque 1.8 - 2.6 kg-m (13 - 19 ft-lb)
absorber.
6. Helper I
REMOVAL AND INSTALLATION
1) Remove the 8 mm nuts securing the
helper to the chassis frame bracket, and detach
the helper.

Fig. H-37

Fig. 9 - 3 6 Removing helper

2) Installation is in the rcverse order of 5- 7. REAR S ~ S P E N S I O N

removal.
1. Rear suspension assembly
REMOVAL
NOTE: 1) Looscn the four wheel nuts securing the
Tighten the 8 mm nuts t o the specified rim to the brake drum.
torque. 2) Raise the vehicle rcar and remove the nuts
t o detach the wheel.

NOTE:
Attach* jack to the designated points
Torque 1.5 - 2.0 kg-rn (1 l - 14 it-lb)

lNSPECTlON
I ) Check the helper for fatigue or damage.
If necessary, replace.
2) Check the height of the helper and replace
if it is less than the specified value.
Truck: H =49 mm (1.93 in)
VAN: H = 5 l mm (2.0 in) Fig. a 3 8 Jacking up
3) Remove the bolts and nuts securing the
underside cover, and detach the covcr.
10 rnm bolt ............ 2 bolts
8 mm nut ............. 2 nuu
6 m m bolt ............. 6 bolts
6 mm tapping screw ..... 2 screws

Fig. W 1 Pulling off cuble

6 ) Tap out the spring pin and disconnect the

axle shaft from the engine.

Fig. E239 Removing under cover

4) Remove the rcturn spring, clevis pin,

cotter pin and 6 mm bolt attaching the cable
c l m p and remove the cable.

Fig. W 4 2 Disconnecting a l e shaft

7) Looscn the flare nut connecting the brake

hose to the brake pipe at the inner arm mount-
ing bracket, and separate the two.

- ,- - . . .... . .- ?.

Fig. n - 4 0 Removing cuble

,..
5) Pull the cable with the grommet off the
outer arm. Fig. &-43 Disconnecting brake hose

s - 20
8) Loosen the lock nut, then remove the 1 1 ) Remove the rear suspension assembly
outer bushing lock bolt. from the chassis frame by pulling it out.

NOTE:
T o avoid daniaging the back plab, place the
year suspension assembly on a soft surface,
such ar r a g or cardboard.

Fig. #-44 Removing b c k bolt

Remove the two bolts securing the inner
mounting bracket to the crossmember, and
detach the inner a r m bracket.
r i
- - .. . - . .&

Fig. S - 4 7 Rear suspension assembly

DISASSEMBLY
I ) Remove the flare nut securing the brake
pipe t o the brake asstrnbly.

NOTE:
Be careful not t o damage t h e head of t h e
Fig. m4.5Removing inner arm bracket nut
10) Remove the 10 rnm nut securing the
lower end of the shock absorber to the trailing
arm, separate the two.

Fig. tlD-46 Disconnecting Bock absorber Fig. S?-48 Disconnecting brake pipe
2) Remove the four 12 rnm bolts securing the ASSEMBLY AND 1NSTALLATlON
rear hub to the trailing arm. Assembly and installation arc in the reverse
order of disassembly and removal.

NOTE:
a. Tighten the outer and inner bushing lock
bolts only after ail assembling and installa-
tion work has been completed, with the
wheels on the ground and in an unloaded
condition.
b. The specified torque setting for bolts and
nuts is shown in the chart below.

Outer bushing lock 1.8 - 2.2 kg-rn

boll (13 - 16 it-lb)
Fig. B-49 Removing rear hub bolt
Inner bushing 3.5 - 4.0 kg-m
3) Pull o f f the rear axle assembly and brake attaching boll (25 - 29 ft-lb)
assembly as a unit from the trailing arm.
Inner bracket 3.5 - 4.5 kg-m
NOTE: attaching bolt (25 - 33 ft-lb)

.
Be careful not t o damage or deform t h e
brake pipe or the axle b o o t Shock absorber
attaching nut
1.8 - 2.6 kg-rn
(13 - 19 TI-lb)

Brake hose to brake 1.5 - 2.O.kg-m

INSPECTION pipesecur-ngflarcnut (11-14ft-lb)
1) Check the condition of all parts. Replace
parts if neccsary.
Rear hub attaching 7.0 - 12.0 kg-rn
2) Check for missing circlip on the trailing bolt (51 - 8 7 ft-lb)
outer ann. If it is missing. install a new one.

c. Fit t h e rear torsion bar t o the outer arm by

properly aligning the toothless points,

Fig. LT-50 lnstnlling circlip

3) Chcck the trailing inner a r m and outer

arm for cracks or damage. If necessary, use Fig. #Y-51
a dye test t o check for abnomalities, especially
on areas where coating is detached and rust d. After the rear suspension assembly has been
formation exists. installed, bleed air from the brake system.
ADJUSTMENT .
64.6 mm (2.14 In)
After the rear suspension assembly has
been installed, inflate the tires t o the specified
pressure; also make posture adjustments and
wheel alignment.

2. Rubber bushing (Outer) 2 Rubber bushing

3 Outer arm
REMOVAL T12-029

Place the trailing outer arm in a vise. Pull

off the rubber bushing with the special tool
(PuUer: 921330000),as follows:
1) Insert the cap @ into the rubber bushing.
2) Attach the spacer @ to the end of the
rubber bushing.
3) Hold the spacer @ and rubber bushing
with the body @.
4) Tightening the lead screw @, remove the
rubber bushing.
Fig. X-53 Instailing outer rubber bushing
3. Rubber bushing (Inner)
With the special tool (Installer & Remover:
922340000)and a hand press, drive the rubber
bushing out from the trailing imer arm as
follows:
1) Insert the push rod @ (special tool) into
the inner rubber bushing; then place onto the
base @ (special tool) with a hand press.
2) Drive the inner rubber bushing out from
the trailing arm by pushing the push rod 0 .

Pren

-F

Fig. e - 5 2 Removing outer rubber bushing

INSTALLATION
Press the outer rubber bushing into place
with the special tool (Installer: 92 1380000)
3 Trlilingarm
and a press. 4 Rubber bushing

N UTE: T12-030
Be sure t o center the boss i n the trailing arm
and rubber bushing when installing. Fig. &-54 Removing inner rubber bushing
3) Check the rubber bushing for cradrs or . 2 mrn
other damage. If necessary, replace. 49 mm (193 tnl (0.08 in)

INSTALLATION
With the special tool (Installer & Remover:
922340000) and a hand press, drive the inner
rubber bushing into the trail& inner arm as
follows:
1) Ptce soapy water on the inner facc of the
die 0 ,and install dic onto the trailing inner
arm bushing.
2) Apply r coatofsoapy watertotheouter
face of the inner rubber bushing, and install the Fig. EP-56
rubber bushing into the die. Then install the die
on the base @ (special toor) with a hand press.
3) Insert the push rod @ (special tool) into
the inner rubber bushing. Exert pressure on the NOTE:
inner rubber bushing liner with the press until a. When pressing the innei bushing, always
the end of t h e rubber bushing shows through rlign the center lines of the inner trailing
the access hole in the base @. arm of the rubber bushing, die 0 ,rubber
4) Make sure that the rubber bushing is
bushing and push rod aFailure to do so
pressed to the specified value.
may result in unusua! noise while driving. . I
b. After installing the bushing, a l l w the bush-
ing face t o dry for 48 houm If the trailing
arm is installed on the vehicle while the
rubber bushing is wet, the rubber bushing
may slip out of place while driving, as soapy
water acts as a lubricant I

4. T o r s i o n b a r and c e n t e r arm
REMOVAL
1) Before removing the torsion bar, detach
the rear suspcnsio? assembly from the vehicle.
Then pull off the !orsion bar, grasping the
serrated portion wit# your hand. If it is hard
to remove with han& lightly tap on the end of
the other torsion bar to push it out.
2) After the left and right torsion b a n have
been removed, remove the center arm from the
rear crossmember. - "
I @F'urhzod
2 Q Die INSPECTION
3 @Base Visually check the torsion b a n and center
4 Rubberbushing am to see if the coating is peeling or if rust is
5 Trailing m
TI2031 developing. If necessary, use a dyeing test t o
check for cracks or damage. Replace any parts
Fig. a - 5 5 Installing inner rubber bushing which are cracked.

F3-
INSTALLATION 5 ) l n s t d each tonlon bar on the side from
I ) Before installing parts, apply a coal of the which it was removed. If the torsion bar
same color paint t o any portion from which positions arc interchanged between the right
paint has peeled. and left, early breakage may result. T h e torsion
2) Apply a coat of grease to the serrated bars are marked as follows for identification. .
portions of the center arm and trailing outer
arm.
3) I n s ~ r t the center arm and torsion bars
into the crossmember.
4) Be sure t o align the toothless points at the
serration before assembling the center arm and
torsion bars.

Left-hand
torsion bar
I 621001910 RLH

Fig. fP-57 5. Shock a b s o r b a r

' REMOVAL AND INSTALLATION
For the removal, inspection and installation
of the rcar shock absorber, follow the same
procedures as Tor the front shock absorber.
In removing and installing the upper end o f
the rear shock absorber, be sure to detach t h e
'
!

trap door beforehand.

.- ,-
c. * ,.- .-..
/
Shock absorber
.,

; ,.'

..

Fig. t2-58 Installing torsion bar Fig. 8 - 5 9

XZ - 25
:5- 8. POSTURE ADJUSTMENT .
t. Front p o s t u r e adjustment

1) Park the vehicle on a flat surface and set

the steering wheel in the straight-ahead position.
2) With the vehicle unloaded, inflate all tires
t o rhe following specified pressure:
Front: 2.4 kglan'
Rear: 2.4 kgjcmz
3) Measure height ':H'' above ground (ground
clearance) at the center of the torsion bar to
determine the difference (a)from the standard
value.
Fig. S 6 1 Measuring distance L
a = 295 - W
Where 295: Standard height
8) Remove the wheel and support the brake
drum with a jack.

NOTE:
a. Be careful not t o scratch or damage the
brake drum when jacking up.
b. Failure t o use a jack when removing the
torsion bar can result in damage t o the
brake hose.

Fig. s 6 0 Mearuring vehicle height

. . .-. . . .,. .
a b.
*
I' Fig. L3-62 Jacking up brake drum
5
4) Engage t h ~ ? ~ a * n gbrake. Loosen (but do
not remove) tht<,fo;r nuts securing the front. 9 ) Remove the lock bolts securing the torsion
wheel. bar to the center of the crossmember and the
5 ) Raise the front end of the vehicle with' trailing arm.
a jack. 10) Remove the plug from the center of the
6) Remove the nuts securing the lower end of crossmember. Drive the torsion bar and the
the front shock absorber to the trailing arm, trailing arm cap, as an assembly, out of the
and detach the shock absorber to fret the crossmember by applying hammer blows t o
lrailing arm. a bent crosshead screwdriver or a bent bar
7) Mark the body fender and wheel center attached to the torsion bar end surface through
cap and measure distance "L" between the two. the hole in t h e crossmember.
 OTE:
To prevent the tentry of water through the
threaded portions, be sure to apply a coat of
cemedine to the threads.

14) Lower and remove the jack supporting

the brake drum.
15) Install the wheel.
16) h w e r the front end of the vehicle and
remove the jack. Measure the height of the
torsion bar above ground. .
17) Securely tighten the torsion bar. lock
bolts.
- Fig. PI-63 Removing torsion bar by tapping 18) lnstall the lower end of the shock "

abosrber t o the trailing arm.

19) Plug the hole in the center of the cross-
member.
11) Lower and raise the jack supporting the
brake drum until. distance "Ll" between the NOTE:
mark scribed on the fender (in step 7 above) Apply a coat of cemedine to the plug before
and the center of the wheel is obtained. At this installing.
point, the amount of adjustment (a)should be
added to, or subtracted from, dimension "L" 20) Apply a coat of cemedine t o the end of
as necessary, the trailing arm, and then install Che plug.
(Examples)
1) If height "H" of the torsion bar above NOTE: .

ground before adjustment i s 270 mrn, Recommended seajant: Cemedine 11 15

difference "a" is determined by the Cernedine 540 or the
following: equivalent
a = 2 9 5 - 270=25 mm
Where a:Amount t o be adjusted
21) Tighten bolts and nuts to the specified
The distance' between the mark on the torque settings.
fender.and the center o f the wheel is also
determined by:
L1 - L + 25 IIXII
2) If height "H" of the torsion bar above
ground before adjustment is 325 mm.
difference "cr" is determined by the
following:
a = 295 - 325 = -30m m -Torsion bar lock 3.0 - 4.4 kg-m
Thc distance between the mark on the bolt (22 - 3 2 ft-lb)
fender and the center of the wheel is also
determined by: Trailing arm stop I.1 - 2.6 kg-m
L1 = L - 3 0 m m bolt ( 8 - 19 it-lb)
12) With distance "L1" adjusted as above,
engage the serration of the torsion bar with Shock absorber 1.8 - 2.6 kg-m
that of the crossmember and trailing a m . attaching nut (13 - 19 ft-lb)
. 13) Properly align the V grooves on each sidc
of the torsion bar with the lock bolt holes on 3.6 - 5.4 kg-m
the trailing arm and crossmember. Then tighten Wheel nut
(26 - 39 it-lb)
the lock bolts.
2. Rear posture adjustment 5- 9. ADJUSTMENT OF WHEEL
ALIGNMENT
1) Park the vehicle on a flat surface, and
adjust the front and rear tires t o the specified 7. F r o n t wheel alignment
pressure.
2) Measure height "H" of the torsion bar at Carnbtr and caster need not be adjusted.
its end to determine difference "a" from the Toe-in alone i s adjustable.
standard value. Check the condition of the following items.
a = 285 - H I f necessary, adjust or replace parts, then
Where a: Amount t o be adjusted adjust toe-in.
285: Standard value a) Height above ground
b) Tire pressure
c) Play at tie rod end ball joint
d) Trailing arm-to-crossmember play
e) Wheel play due t o wear of kingpin bush-
ing or wheel bearing
f ) Deformed traiIing arm
1) Set the steering wheel in the straight-ahead .
position.
2) Loosen the lock n u t on each side of the
tie rod turn-buckIe.

NOTE:
The turning direction is quite different for
each of the two lock nuts.

Fig. S 6 4 Measuring vehicle height

3) To adjust the rear height above ground,

turn the center arm adjusting bolt as required.
One clockwise turn of the adjusting bolt
increases the height above ground by 4.5 mm.

F k . s t 5 6 Loosening lock nut

3) Adjust the length of the tie rod by turning

the turnbuckle. Lengthening the tie rod increase
toe-in, and vice versa.

NOTE:
Turn the turnbuckle equally on each side
until tfie steering angle o f the left and rear
Pig. S 6 5 Vehicle height adjusting bolt wheels are within the specifications.
 Inner wheel: 37" i 2"
Steering
Outer wheel: 33.5' * 2"

1 Lock nut
2 Turn buckle

.. .-
- :.-
Fig. S 6 7
t;.

:. . q,.
4) Measurc toe-in or side dip to see5f i t is
within the specifications. Then tighten the
turnbuckle lock nuts in the following sequence:
a. Tighten tie rod end nut and turnbuckle.
b, With the tie rod push all the way backward,
tighten the tie rod nut and turnbuckle.
r
I
NOTE:
a. Use two wrenches when tightening the lock
n u t Failure to do so can cause the tie rod to
be dislocated from its end.
b. Holding the turnbuckle with ' a wrench,
tighten tfie nut and then lock.
Torque 8 - 8.5 kg-m (58 - 6 1 ft-lb)
 1 Tie rod
2 Turn buckle (19 rnm in
width rcmss flats) Fig. S 6 9 Tightening lock nut
3 Tic rod end
4 Nut (22 rnm in width across
flats)
5 Holding spanner (do not turn)
6 Tightening spanner
7 Nut (left-hand screw) c. After tightening the lock nut, move the tie
(22 mrn in width across flats)
. 712-036 rod to the front and back t o see that it
moves equally from side to side more than
Fig. S 6 8 35 rnrn (1 -38 in).

Fig. 63-70

tP - 30
2. Rear wheel alignment
Toe-in can be adjusted by changing the
number of shims at the inner trailing arm
bracket.
Check the following items and, if necessary,
adjust or replace parts. Then adjust toe-in.
a) Tire pressure
b) Height above ground (Ground clearance)
c) Be'aring play
d) Deformed trailing arm

2) Loosen the two 10 mm bolts securing the

inner arm bracket t o the crossmember.
3) To adjust toe+, add o r remove shims as
requi;ed ,between the inner arm bracket and
crossmember.

NOTE:
Fig. B-71 Toe-in adjusting shim Use the same number of shims on both sides.

4) Tighten the two 10 mm bolts securing the

inner arm bracket t o the crossmcmbcr.

Torque 3.5 - 4.5 kg-m (25

- .
- 33 ft-lb)
1) Measure the rear wheel toe-in. To obtain
the specified value, select the necessary number . 2.
of shims from among those of0.6 rnm,0.8 mm 5) Again measure-toe-in or sidg slip t o see if
and 1.2 mm in thickness. it is within the specifications. '
r- . T i
i:
5~ 10. TROUBLESHOOTING

A. Unstable running
When the vehicle is driven along a flat surface at a constant speed and the hands arc released from the
steering wheel, it pulls t o one side.
The vehicle wanders immediately after a lane change, even though the steering wheel is held in the
straight-ahead position.

Probable cause Remedy

b- -
(1) lmproper tire pressure. Inflate properly.
(2) Wheels out. of alignment. Align.
(3) Brake dragging or not properly adjusted. Adjust.
(4) Trailing arm not properly installed (substantial Reinstau.
difference in reaction between left and right
arms).
(5) Broken torsion bar. Replace.
(6) Wheel bearing worn or not properly adjusted. Adjust or replace.
(7) Ray or wear in steering system parts. Adjust or replace.
(8) Front trailing arm bearing or crossmember Replace.
sleeve worn.
(9) Loose wheel nuts. Tighten.
(10) Deformed tie rod or trailing arm. Replace.
(1 1) Play in tie rod end ball joint. Replace.
(12) Worn kingpin bushigg. Replace.
(13) Loose trailing arm o r steering system installing Tighten.
bolts.
(14) Improper tire (wrong brand). ' Replace.
(15) Fatigued o r deformed rear suspension outer Replace.
bushing.

. .
.%
B. Incorrect vehicle posture or ground clearance
? '

Probable cause Remedy

(1) ' Fatigued or broken torsion bar. Replace.

(2) Shock absorber not functioning properly. Replace.
(3) Trailing arm not properly installed. Reinstall.
(4) Deformed traiIing arm. Replace.
C. Hard or rough ride
Large shocks i s transmitted to the seat from the wheels.
Shocks d o not dampen o u ~quickly after the wheels have run over obstacles.
Large shocks are felt when wheels run over concave spots.

Probable cause Remedy

(1) Broken torsion bar. Replace. .

(2) Helper i s excessively deformed or-has dropped ... Replace. .
off.
(3) Tires excessively inflated. Reduce to specified pressure.
I ' .

(4) Improper ground clearance. Adjust.

(5) Shock absorber not functioning properly. Replace.
(6) Damaged or deformed shock absorber rubber Replace.
bushing.
(7) incorrect shock absorber travel strokes. Replace.
(8) Rear suspension outer bushing is deformed or Replace.
has dropped off.

D. Rear (Drive) wheels run idle

I Probable cause
I Remedy
I
1 (I) incorrecr &ound clearmu. I Adjust.
. ,
1
(2) Insufficient shock absorber extension. Replace.
(3) Broken torsion bar. Replace.

1
(4) Insufficient swing angle of double offset joint
(D.O.J.).
(5) Excessively deformed trailing arm.
II Correct engine installation or replace.

Replace. I
E. Unusual noire

Probable cause Remedy

(1) Worn or damaged shock absorber parts. Replace.

(2) Deformed or damaged shock absorber rubber Replace.
bushing.
(3) Worn wheel bearing. Replace.
(4) Worn double offset joint. Replace:
(5) Worn brake drum splines. Replace.
(6) Front trailing arm not properly installed. Reinstall.
(7) Worn front trailing a r m bearing or crossmember Replace.
sleeve.
(8) Front trailing arm bcaring insufficiently Lubricate.
lubricated.
(9) Play o'r wear in tie rod end ball joint. Replace.
(10) Loose rear suspension outer bushing lock bolt. Tighten.

-
( 1 1) Deformed or dislocated rear suspension ann Replace.
bushing.
( 1 2) Play in rear suspension inner arm bracket. Replace.
(13) Incorrect shock absorber travel strokes. Replace.
(14) Helper is dislocated or has dropped off. Correct or install.
(1 5) Steering angle not properly adjusted. Adjust.
(16) Broken torsion bar. Replace.
 .. CHAPTER 6: IJHEELS AND AXLES

6- 1. FRONT WHEELS AND AXLES . . . . . . . . . . 2

6- 2 . REARMHEELSANDAXLES . . . . . . . . . . . . . . . 7
6- 3 . TIRES AND RIMS ................... 16
6- . I . FRONT WHEELS AND AXLES

1. General description

L d t side-

1 Knuckle (RH.) 8 Kingpin 15 . Brake drum mmplctc (Front)

2 Knuckle (LH.) 9 Knock pin 16 Washer
3 0-Ring 10 Shim 17 Lock washer
4 Covtr 1 1 Plug 18 Cap (RH.)
5 0-Ring 12 S p a a r 19 Cap (LH.)
6 Thnut washer (Upper) 13 Taper rolbr tearing 20 Oilsell
7 Thrustwuhcr(Lower) (Outer) 21 A x k n u t
14 Trpcr rollex beadng
finer)

Fig. Ptl Construction offront wheel and axle assembly

The tire is installed on a 3.50 D x 10 split
'type rim which is attached t o the brake drum.
The brake drum is provided with two taper
roller bearings, which rest on the knuckle
spindle. Since these taper roller bearings are
used with specified preload, special care should
be taken during installation. T h e knuckle is
connected to the trailing arm by m a n s of a
king pin. T h e king pin connection is designed as
a maintenance-free type, consisting of an upper
and lower bushings made of resin, two thrust
washers of high wear resistance, and four
O-rings and two plugs. The oil seals prevent the
entry of foul water and consequent rusting, so
that removal and installation are easily per-
formed.
2. Brake drum
1) Removal
a. With the wheel o n the ground, loosen the
four 10 rnm wheel nuts attaching the rim to
the brake drum.
b. Raise the vehicle with a lift or jack and, in
either case, assure the safety by locking the
lift or using safety stands.
c. Remove the wheel nuts and pull the wheel
off.
b. If the inner bearing remains attached on t h e
spindle when the drum is removed, install
Special Tool (BEARING REMOVER:
922120000) as shown in Fig. a-3 and
remove the bearing by turning the handle.
2) Disassembly (bearings and oil seal)
a. Tap the inner bearing outer race out of the
drum by using a brass rod etc.
Remove the oil real a t this time. (Fig. B - 4 )
' b. Tap the outer bearing outer race out of the I

d. Remove the three 5 mrn screws attachhg thc drum by using a brass rod etc. using care not
cap t o the drum and remove the cap. t o damage the race.
NOTE:
Since the left-side cap is provided with a pin
t o drive the speedometer cable, be careful
not to bend the pin when removing the cap.

e. Spread the lock 'washer and remove the 30

rnrn (width across flats) nut, lock washer,
and washer.
f. Remove the drum using care not to drop the
outer bearing. (Fig. Rl-2) Inner bearing Special tool
BEARING REMOVER
NOTE: 922120000
f 1s o 0 2
a. If the drum is difficult to remove by hand
because the bearings stick to the knuckle
Fig. t0-3 Rcmwing inner baring from spindle
spindle, install Special Tool (ATTACH-
MENTS: 921420000) t o the wheel mount-
ing bolts on the drum using wheel nuts.
Then, hook the pawls of a puller to the
recesses of the attachments, align the lead
screw with the knuckle center hole, and
remove t h e drum by turning the lead screw.
I n place of the standard tool, Special Tool
(BRAKE D R U M PULLER: 921 120000)
may also be used. .
. .
.

Fig. S 4 Tapping out inner beoring

3) Inspection
Wipe off the grease in the bearing mounting
bore in the brakc drum. Clean the bearing in
cleaning solvent.
Inspect the disassembled parts and replace
Fig. #-I Removing w h e r defective parts with new ones.
 NOTE:
When it is necessary to replace one of the
bearings, always replace both the inner and .
outer bearings as a set.

a. Brake drum
I ) Check the drum bolts for damage.
2) check the innsr surface of the brake
'drum for wear and damage. .

3) Check the outer races of the bearings for

correct installation.
b. Check the bearing inner races, retainers and
roUen for damage, wear, seizure, rust and
correct fitting in'thc knuckle arm. Fig. f9-6 Packing drum with pears
c. Check the oil seal for damage or deforma-
tion, the oil seal lip for wear, and the spacer d. After installing the rollers and inner race of
for damage and wear. the inner bearing and packing it with grcase,
d. Check the cap gasket for damage. press the oil seal, with its Up and inner
e. Check the cap for damage and deformation. surface coated with grease, into position.
f. Check the knuckle spindle for 'damage and e, Install. the outer bearing rollers and inner
deformation. race packed with grease.'
4) Reassembly (bearings and b i seal)
5) Installation
Wipe off foreign matters, dust, etc. on the a. With the bearings installed in the drum,
drum surface with clean cloth, 5 install the spacer and drum on the knuckle
a. Place the drum on a support and install the spindle, and tighten them with the 30 rnm
outer bearing outer race into the drum with (width across flats) nut, washer and lock
Special Tool (INSTALLER:9221 10000) by - washer.
tapping it with a hammer.
b. Place the drum on a support and install the NOTE:
' After having fully tightened the nut to seat .
inner bearing outer race into the drum with
Special Tool (INSTALLER:925080000) by the parts, back off about 118 to 1/10 turn so
! that the wheel rotates with the following
tapping it with a hammer. .
starting torque. (Fig.m-7) rn

b. Lock the nut by bending the lock ~ a a e r .

c. Install the cap with the gasket'%nd three
screws.
d. Install the wheel, tightening the wheel nuts
Fig. m-s Instatting benrings
.
finger-t ight
'
e. Lower the vehicle to the ground.
c. Pack the drum with grease as shown in Fig. f. Tighten the wheel nuts t o the specilication.
p - 6 . Appropriate amount of grease to be
packed in the drum and applied on the Wheel nut 3.6 - 5.3 kg-m
bearing surface is 35 t o 39 g (1.23 to 1.38 tightening torque (26 - 39 ft-lb)
02).
 c. Remove U l c upper' plug on the trailing arm
yoke.
i. Removing the king pin
1nstaU the body @ of Special Tool (KING
PIN PULLER: 92 1 14 1000) on the trailing
arm yokt and then install the stopper @
and insert pin @ as shown in Fig. s - 1 0 .
A l j y the lead screw @ with the king pin
and turn the screw to remove the king pin.

Fig. W-7 Meusuring starting torque

g. Adjust the brake shoe clearances after de-

pressing the brake pedal 2 to 3 times.

3. Knuckle (King pin)

1) Removal and disassembly
a. Remove the brake drum in accordance with
3 a\
3. 1). . .
.
b. Unscrew the four 8 mm bolts attaching the Fig. B - 9 Removing pin at knuckle
back plate t o t l y knuckle and remove the
back plate.

. ;..
.-.
b.
. . L Fig. i U l O Removing king pin
F& S 8 Removing bcck pkztc

'i'
-
:-. +.
c. Remove *e trailing arm in accordance with
a - 1 in Chapter NOTE:
d. Remove the pin at t h e center of the knuckle For the removal and installation of the king
by tapping it from the spindle side. (Fig. pin bushing on the trailing arm, refer l a
b B-9) Chapter U&d
2) Reassembly
NOTE:
Be sure to keep the parts free from dust
during this job.
a. Put the cover, upper md lower h s t
washers and O-ring jogether as shown in
Fig. m-11, with sufficient grease applied
between the upper and lower thrust washers
and on the O-ring. . .
b. Coal the bushing inside surface with grease
and also fill the oil groove in the bushing
with weau. . Fig. H-14.
c. Cost the king pin hole in the knuckle with
grease.
e. Apply r thin coat of pease on theking pin
surface.
f. Tap the king pin into the upper yoke
bushing from the tap of the yoke.
g. Hold the parts assembled in a. under the
upper yoke and press the king pin ,down
until its lower end becomes flush with the
thrust washer as shown in Fig. B-13.
h. Place the knuckle fitted with O-rings be-
tween the thrust washer and lower yoke and
align the king pin with the king pin hole in
h e knuckle while pressing the king pin
down by hand to the position shown in
NOTE:
Be sure to press the king pin by hand when
aligning. Driving the king pin with a hammer
will break the 0-rinp on the yoke if tha king
pin and the hole in the knuckle are not lined
UP.

hrust washer(lower )

T 13-006

Fig. l3-ll Assembling cover, t h a t washer

and O-ring

d. Apply grease on the O-rings,and install them

on the upper and lower yokes and both ends
of the king pin hole in the knuckle. Fig. Sf
3 Tapping king pin into upper bushing

3 Thrust warha (Upper)

Fig. -12 Assembled components Fig. JZi4 Aligning king pin with knuckle

a - 6
i. Direct the cut in thc king pin SO that it will k. Apply sealant to *e knock pin and drivc it
fit on the knock pin, and tap the king pin into the knuckle.
with a plastic hammer down t o a position
slightly above the O-ring installed at &e NOTE:
bottom o f t h e knuckle as shown in Fig. Alwayr use a new knock pin for reessembly.
m-15.
' \

NOTE: .., . ,

Be sure t o stop the kin# pin above the

O-ring, othewise t h e protruded O-ring might
hinder theinstallation of shirns-or-the-O-ring--
might be cut by the shim when it is inserted.
1. After applying grease on the top and bottom
-- o f the king .pin,-install plugs- on .both the
ends. Hit the center of the plug to spread it
and stake the yoke at three poinls arodnd
the plug to secure it. '
m. Apply sealant o n the circumference 01 each
plug t o perfectly seal the gaps.

NOTE:
Before applying sealant, wipe grease, oil, etc.
away with clean cloth.

Fig. m-15 Tapping kins pin into knuckle

j. Install proper shims between the knuckle 6-.2. REAR WHEELS AND AXLES
and lower yoke so that the knuckle end play
and rotating resistance are as specified be- 1. General description '

low. The engine output is transmitted t o the rear

wheels through t h e axle shafts. The inner end
0 - 0.1 mrn o f the axle shaft is connected through splines to
Knuckle end play
(0 - 0.004 in) the differential side gear on the engine side, and
the spline connection is locked with a spring
Approx. pin. The outer end of the axle shaft is sup-
Knuckle rotating
2.5 - 3.7 kg-m
resistance ported by two ball bearings housed inside the
(18 - 27 ft-lb)
. hub and cunncctcd through serrations t o the
brake drum, which transmit the driving power
t o the wheel. The brake drum, bail bearing,
spacer and ccnter piece are tightened at the
same time by a castle nut. The ccnter piece
makes i t easier t o remove and install the brake
drum.
 18 Cotter pin
3 A x k shaft I I Oil sell (A) 19 Circtip
4. Outer r a a 12 Ball 20 Snap ring
5 Spring pin 13 Cage 21 Boots
6 Hub 14 Spring wuhcr 22 Cap
7 Spaazr 15 Nut
8 Bdbcuing 16 e n t e r pierr (Axle) T13-011

Fig. S - 1 6 Construction of rear wheel and a l e assembly

shaft.
2. Brake drum
g. Make the shoe clearances larger.
I ) Removal h. Put a flat blade screwdriver against the slot
a. Loosen the four 10 mm wheel nuts attaching of the center piece and tap the screwdriver
I the rim to the brake drum. . . + i t h a hammer to remove the center piece.
w
b. Raise the vehicle with a lift or jack and, in
either case, support the vehicle by the
rigid rack or lock the fif! f o ~
safety.
c. Remove, the wheel nut6:an'd pull the wheel
off.
d. Unscrew the two 10 rnrn bolts retaining the
diagonal member and the eleven 6 mm bolts
retaining the under cover and remove the
diagonal member and under cover.
e. Remove the center cap with the three
attaching screws.
f. Pull the cotter pin and remove the castle nut
(27 mm in width across flats) on the axle F k . Ef-17 Removing center piece
 i. P U U the drum off the axle shaft. If it is
difficult t o remove the drum by hand, inslall Torque (Castle nut) 16.0 kg-m ( 1 16 it-lb)
Special Twl (ATTACHMENT;921420000)
on the drum by utilizing the wheel nuts and NOTE: ,

pull the drum with r puller as shown in Tighten the cnrtle nut to tho above torque
Fig. 11-18. firrt and retighten further until a slot of the
... - castle nut is aligned to the hole in the axle
NOT€: shaft - . !.- . .
In place of the standard puller, Special Tool
(BRAKE ..DRUM ...PULLER: 921120000) . c. I ~ c kthe castle nut with a new cotter pin.
may also be used. (Fig. f3-19) d. Install the under cover and wheel.
. .
3. Hub and axle shaft assembly
Spacial twl: ATTACHMENT 1) Removal
"
921420000 a. Rcmove the brake drum in accordance with
Conventional 2.1).
puller
b. Disconnect the axle shaft assembly from the
engine b y driving out the spring pin with a
4.8 mm (0.1 9 in) diameter bar.
c. Rcmove the parking brake return spring and
the cotter pin and disconnect the parking
brake cable.
.?
~13012'

Fig. S f 8 Removing brake.dmm

Fig. m-20 Dirconneciing parking brake c a h t

d. Remove the bleeder screw and remove the

brake pipe joint nut from the wheel cy!.
inder.
t. Remove the back plate by unscrewing the
. , Fig. =-I9 Removing brake drum four 8 rnrn attaching bolts.
f. Unscrew the four I2 mm bolts attaching the
hub to the trailing arm.
2) Installation g. Remove the axle shaft assembly togcther
a. Before installing the brake drum to the axle with the hub.
shaft, coat the splined portion of the shaft
with grease t o prevent corrosion. NOTE:
b. Install the brake drum, center piece and Be careful not to damage the inner and outer
castle nut and tighten the nut. boats.
 2) Disassembly
a. Place the hub and axle shaft assembly on a
press and press the shaft down out of the
hub as shown in Fig. m-21.

NOTE:
Do not uw a hammer since the threads at
the shsft end may be'crushed.

b. To remvoc the bearing (hub, inner) from the

axle shaft, pull the bearing with a puller by
inserting the pawls between the bearing and
oil d.
Fig. #-23 Removing bearing (hub, outer)

3) Inspection
Check t h e disassembled parts as follows.
a. Bearing
Wash the bearing in a cleaning solvent and
check the inner and outer races for cracking
and other damage, and also check if the
outer race rotates smoothly without noise
when the inner race is supported.
b. Spacer
Wash the spacer in a cleaning solvent and
check for damage and deformation.
Fig. #-21 Removing uxk shaft from hub c. Hub
Wipe the inside surface with clean cloth and
1 NOTE: check for cracking and other damage.
Do not reuse the oil seal. A damaged or 4) Reassembly
! worn oil seal will allow the entry of mud and a. Apply 9 g (0.33 oz) of grease to the inner
I
I
water into the hub, and shorten the life of bearing and position the bearing in t h e hub.
1 the bearing. With the 30 mrn (1.2 in) diameter end of
Special Tool (HUBBEARING INSTALLER:
921350000) inserted in the inner race of the
bearing, press the bearing into the hub.

Special twl:
H U B BEARING INSTALLER
921350000

II bearing Y6206C4

Fig. W 2 2 Remuving bearing (hub, inner)

T13-015
c. T o remove the bearing (hub, outer) from the
hub, use a 50 m m (0.2 in) diameter drift and
press as shown in Figure 5)-23. Fig. # - 2 4 Installing inner bearing

10
b. Coat the oil seal with grease and position it
in the hub. With the 30 mm (1.2 in)
diameter end of Special Tool (HWB BEAR-
ING INSTALLER: 921 350000) inserted
into the oil seal, press the oil seal against the
bearing.
Special tool:
HUB BEARING INSTALLER
Cross rmion
of oil raal
713-016
Fig. 3Z25 lnrtalling oil surl
NOTE:
Press the oil seal fully u d i l it bonorns. If
clearance exists a t A, it will cause the oil seal
lip t o wear.
c. Invert the hub and apply 14 t o 18 g (0.51 t o
0.65 oz) of grease to the inside surface of
the hub.
d. Install the spacer in the hub. Apply 5 to 6 g
(0.18 to 0.21 oz) of grmse to the outer
bearing and position it over the bearing hole.
With the 25 mm (1.0 in) diameter end of
Special Tool (HUB BEARING INSTALLER:
921 3500G0) inserted into the inner race of
the bearing, press the bearing into the hub.
Special tool: HU8 BEARING INSTALLER
921350000
8sll bearing 16305C4
TI3017
Fig. -26 ~nrtallingq c e r and outer bearing
e. Apply a coat or'grease to the oil seal to be
installed on the outer bearing side. Press the
oil seal into the hub using a 65 mrn (2.56 in)
diameter bar or block as shown in Fig.
8-27.
Cross r a i o n
00 oil teal
T13-018
NOTE:
Using more grease than specified may result
i n grease leakage from the outer bearing into
the brake drum, causing brake failure.
f. Installing the axle shaft into hub
Prepare Special Tool (HUB INSTALLER
CAP: 922320000) 0 ,and the lead scrcw
@ and handle @ of Special Tool (HUB
INSTALLER: 921360000). Insert the axle
shaft into the hub by hand as far as possible
and secure the shafkin3 vise. Install the lead
scrcw @ I the &c ;haft end, and install
onto
the cap @ and handle @ J as shown in
Fig. 13-28 so that the cap @ presses the
bearing and n o load is applied to the oil seal.
Pull the axle shaft until it stops by turning
the handle while holding the lead screw with
a wrench.
5) Installation
Install the hub and axle shaft assembly in
the reverse ordcr of the removal.
NOTE;
a. When connecting the axle shaft to the
engine.
1) Install each axle shaft on the correct side
as the lengths of the right-hand and
left-hand axle shafts are different. The
right-hand axle shaft is provided with a
Spacial 1001 921360000
Special tao1.922320000
Hub installer cap
Fig. IS-28 Inctal11ing axle shaft into hub
Fig. &Z-29 Axle skaft identijhztion
4. Axle shaft (D.O.J.)
1) General descript ion (Fig. B - 31)
The rear axle is of a floating type using two
constant velocity joints (D.O.J.) at both ends of
Broom for identification. (Fig. S 2 9 )
2) B e careful not to damage the boot,
3) U s r new spring pin.
b. The two upper bolts attaching the back plate
. . are slse used to secure the parking brake
bracket
Axle shaft
<
TlJ-019
the axlc shaft. This D.O.J.axle shaft transmits
power without fluctuation in rotational speed.
Furthermore, since the balls inside the D.0J.
make a smooth rolling motion, the stiding
resistance . i s smdf and there is almost no
mechanical loss, thus permitting unnoisy opera-
tion and compact construction with little un-
balancing factor. Since grmse is packed in the
scaled spacer, the D.0J. rarely requires greas-
. . -. e
ing... . .
2) Disasembly
a. Removing the boot band
1) Straighten the bent end of the band.
2) h o s e n the band by tapping its end. Pry
up the band with a screwdriver and
remove it from the boot with a pair of
pliers.
 b. Rcmoving the circlic
I ) Remove the boot from the D.O.J.
2) Pry off the round-section circlip installed
at the end of the outer race of the D.O.J.
with a screwdriver. (Fig. P - 3 2 )
c. Removing the outer race and balls
1) Remove the D.OJ. outer race from the
-. -- axle shaft assembly.
2) Wipe off the grease, take out the balls and
move the cage towards the boot.
, . Band

Fig. mf0 Rcmoving boot band

1 D.O.J. ass'y (Inner) 5 Boots (Outer) 8 Snap ring

2 D.O.J. ass'y (Outer) 6 Clip 9 Circlip
3 Shaft 7 Clip 10 Seal pkrc
4 Boots (Inner) T13-020

Fig. a - 3 1 Cross section of axle shuft (D.O.J.)!

NOTE
a. To remove the cage from the inner race, turn
the-cage by a half pitch of the ball tracks
aftei,r$moving the balls and pull the cage.
h. Exeyke care not t o loss the balls.

d. Rcmoving the snap ring and inner race

1) Remove the snap ring retaining thc inner
race on the shaft by using special pliers.
Fig. 0 - 3 2Rcmoving circlip 2) Pull the inner race off the shaft.
 4) Rtassemblmg
a. Install the b wt o n the shaft.

I
!

1
FQ. -33 Removing s m p ring

t: Take off the cage from the shaft and remove

the boot.

NOTE:
Be careful not to damage the boot with the Fig. S 3 5 Installing circlip and cage
squaresection circlip on the shaft.

f
b. Place the cage on the shaft with its direction
as shown in Figure S 3 5 .
c. Install the inner race on the shaft and lock it
with the snap ring using special pliers.

NOTE:
Make sure that the map-ring is completely
inserted in the shaft groove.

d. Install the cage on the inner race by digning

the protrusion of the cage with the track in
the inner race. Then turn the &ge by a half
Fig. w34 Disassembled D.O.J.
to line up the holes in the cage with
the inner race tracks.
3) Inspccrbn
Clean all the parts and check for defects as
NOTE: ..'i: .-
C

Apply grease to the cage holes. Use molyb-

follows. Repair or replace as necessary.
denumhasa grease for the D.O.J.
a. D.O.J.
. Check for seizure, corrosion, wear, excessive
play and other damage.
b. Shaft
Check for excessive bending, twisting, wear Constant vclocity joint
and other damage. grease (Molytex No. 2
c. Boots or equivalent)
Check for wear. warping and breakage.
 Fig. M-36 Installing cage on inmr race Fig. &8-38 Applyinggrcase to outer race

e. Insert the six balls into the cage holes. (Fig. g. Install the outer race on the assembly of the
B - 37) inner race, cage and ball assembly.
h. Install the circlip in the groove in'the outer
race.

Fig. U-37 Instalting balls

Fig. &-39 Installing outer race

f. Apply grease in the outer race as indicated in NOTE:

. ... .
Fig, U 3 8 .
.- a. Make sun that the balls, cage and inner race
are completely housed within the interior of
the outer race.
Constant velocity joint b. Do not position the ends of the circlip in the
Grease grease (hlolytex No. 2 track in the outer race.
or equivplent) c. Lightly pull the axle shaft to check that the
circlip is securely installed in the groove.
 i. Pack the inside of the D.O.J.with grease. NOTE:
When tightening the boot, exercise care that
- the mir remaining in the hoot is neither
Conslanl velocity joint excessive nor insufficient.
Grease grease (Molytex No. 2
or equivalent) 3) Further tighten the band by using Special
Tool (BAND TIGHTENER:925090000)
lnner D.0J. 50 g (I .8 oz) until the band. cannot be moved with
Amount figcrs.
Outer D.OJ. 100 g (3.5.02) 4) Lightly strike the band with the punch
1
provided at the end of the tool.

j. Install .the boot on the D.03. NOTE:

Be sure to strike lightly so as not to damage
NOTE: the boot.
Clean the boot groove in the shaft and outer
race so that they are free from grease and 5) Cut off the surplus part of the band,
other substance. ' leaving about 10 mm (0.4 in) after the
clip t o bend it over the clip.
k. InstaUing the boot bands
I 1) Wind the band twice around the boot
groove, passing the band through the clip. 6- 3. TIRES AND R I M S
? 1. Specifications
NOTE:
Use a new band. See the table for the tire and rim specifics-
lions.

2. Wheel (tire and rim)

1) Removal
a. Apply the parking brake and loosen the four
wheel nuts. ,

b. Jack up the vehicle.

NOTE:
Be sure to place the jack straight. The
vehicle is provided with four jacking points,
one near each wheel. , .
-.
b

Fig. W 0 ~ ~ t d lboot
i h bond
~ c. Remove the wheel nuts and washers, and\
take off the whpel;...
2) Tighten the band by pulling the end of 2) Installation :k'
the band with pliers while hojding the Install the wheel in the reverse order of the
clip. removal.
 T ~ r eand Rim Specifications

Rim size 3.50D x 10

Tire size 5.00-10-6PR ULT

Valve TR244A

Front
h p h t Load 45 lbs. I
Full Load 45 lbs.
Tire inflation
pressure Light Load 45 lbs.
kg/cm2 (psi) Rear
Full Load 45 lbs.

Spare 45 lbs.

Tlre w ~ d t h mm (In) Approx. 136 (5.4) with inflation pressure of 2.4 kg/cm2 (34.1 psi)

Tire outer
diameter mm (in) Approx. 5 18 (20.4) w ~ t hinflation pressure of 2.4 kg/cm2(34.1 pd)
>

outer rim half. Also use care that the drum

3. Inner tube
1) Removal
Deflate the tire. Since the rim is of the two
piece type, the tube can be taken out by
removing the four rim connecting bolts and
separating the two halves of the rim It is
unnecessary t o remove the tire from the rim.
2) Installation
a. Check the interior surface of the tire and
repair if necessary. Remove any foreign
matter from the surface.
b. Before installing the tube, tighten the tube
valve and inflate the tube. Check the tube
~ n dvalve thoroughly for leaks by putting
the tube in water.
c. Insert the tube through the rim gap into the
tire and align the valve with the valve hole.
d. Inflate the tube sufficiently so that it will
not be caught between the two rim halves
when reassembling the rim.
e. Match the two rim halves and join them
together with the bolts, spring washers and
nuts. Be sure t o insert the bolts from the
bolt holes in the rim halves are correctly
aligned. T h s . will make the brake drum
installation easier.
f. Inflate the tire t o the specified pressure and
attach the valve cap.
4. Tire
To remove the t ~ r efrom the rim, remove the
four run connecting bolts and separate the rirn
,halves If it is difficult t o remove the tire, insert
a large screwdriver between the rim and tire and
pry the tire off the rim. Repeat this operation
around the rim and the tire will be easily
removed.
5. Tire damage and possible causes
1) Damage due t o flex, fatigue and heat
The side walls of the tire flex as the tire
rotates. If the tire pressure is insufficient or the ,
vehicle is excessively loaded, the side wall
flexing will become abnormally large, leading to
separation of the cords from the rubber and

6-17

-%Lz_
 CHAPTER 7 : BRAKE SYSTEM

7- 1 . ...............
GENERAL D E S C R I P T I O N 2

7- 2 . BRAKEASSEMBLY . . . . . . . . . . . . . . . . . . 4

7- 3 . MASTER C Y L I N D E R . . . . . . . . . . . . . . . . . 11

7- 4. BRAKE FLUID LEVEL WARNING SYSTEM ........ 14

7- 5. PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . 14
 s

7- 1. G E N E R A L DESCRIPTION service brake syslem intd the front-wheel brake

systcm and rear-wheel brake system. This
1. Outline ensures safety. coupled with the aulomatic
adjuster of the front brakes. The front brakes
The brakc system consists of a service brake are of t w o leading shoe type and the rear brakes
system and parking brake syslcrn. The service --are of leading and trailing shoe type. The
brake system employs dual hydraulic circuit parking brake system is operated mechanically,
with a tandem master cylindei, splitting the applying the braking force t o the rear wheeb.
.
2. Specifications

Service brakes
Item Parking brake
Front brakes Rear brakes

Hydraulic, internal Hydraulic, internal Mechanical, inter-

expansion, two expansion, leading nal expansion,
TYPC leading shoe type, and trailing shoe leading and trailing
foot -operated type, foot-operat- shoe type, hand- .
ed operated

Brake drum material Cast iron Cast iron . Cast iron

Brake drum inside diameter 180 mm (7.09 in) 170 mm (6.69 in) 170 mm (6.69 in)

Brake lining material Molded resin Molded resin Molded resin

Lining dimensions 3 5 x 5 x 173mm 30 x 4.4 x 181 m m 30 x 4.4 x 181 mm

(Width x thickness x length) (1.4 x 0.20 x 6.8 in) (1.2 x 0.17 x 7.1 in) (1.2 x 0.17 x 7.1 in)

Lining surface area

6 0 =m2 (9.30 in2) 54.0 crn' (8.37 in2) 54.0 cm2 (8.37 i n 2 )
(One piece of lining)

Wheel cylinder inside 23.8 mm 19.0 mrn

diameter (0.94 in) (0.75 in)
3. Brake piping components

DETAIL 'c'

DETAIL 'H'

1 Tube (Brakc pipc) Brake pipe Spring washer

2 Brrke hose (F) Brake pipc Nut
3 Tubc Tube (Secondary) 3-way conneclor
4 Brake pipe Tubc (Primary) Stop lamp switch
S Brake pipe Brakc pipe 3-way conncclor
6 Bnke pipe Maatcr cylinder au'y Clamp (Brakc hose)
7 Brake pipe Clip Cap (Ruid levcler)
8 Brrkc pipc Sloppcr Grommet
9 Brake hose Spring washer Rclervoir au'y
10 BraLe pipe Bolt 2-way conneclor

Fig. m-1

a-3
7- 2. B R A K E ASSEMBLY

1. Front brake assembly

12
14

14

1 S h o c hold d o w q pin 8 Back p l a l ~(F. LH) 13 Brakc hot a d y (LH)

2 Spring w r l h c r 9 Whctl cylinder I4 Spring scxt
3 ' Nut (F.UPPER. RH) IS Shoc hold down r p r i n ~
4 Tube 10 Whcclcylindcr 16 Whccl cylindcr
5 Nut (F. UPPER. LH) (F.LOWER. RH)
6 Spring vrrshcr 1 Return spring 17 Wheel cylinder
7 Back p l a t e (F. RH) 12 Brakc shoe aw'y ( R H ) (F. LOWER. LH)

Fig. m-2 Exploded view offront brake ussembfy

1) Disassembly
a. Raise the front o f the vehicle and install
safety stands.
b. Remove the center cap. (Fig. R-3)
c. Spread the lock washer and unscrew the
spindle nut. Remove the spindle nut, lock
washer, and washer. (Fig. B4)
d. Rcmovc the plug from the brake drum.
Using a'screwdriver, force the shoes in the
directions of the arrows shown in Figure
13-5 t o make the shoe clearances wider.
Cenle? cap - -
-- -,/? \

e. Pull the drum and wheel off the knuckle

spindle.
I
Fig. m-3 Rcmovifig center cap
 g. Remove the shoe return springs from the
wheel cylinders.
h. Remove the brake shoes with the automatic
adjusters installed o n them.

NOTE:
To make the work easier, remove both the
primary and secondary shoes from the wheel
cylinder adjuster wheel sides first and then
from the wheel cylinder piston sides.

i. Remove the shoe return springs from the

Fig. m-4 Spreading lock washer primary and secondary shoes.

NOTE:
NOTE: Do not disassemble t h e automatic adjuster
When removing the brake drum, be careful because its nut is staked.
that the wheel bearing will not fall off.
2) Inspection, repair and adjustment
a. Measure the Iining wcar. If the thickness of
the lining is less than 1.7 mrn (0.07 in),
replace the shoe assemblies. Always replace
the primary and secondary shoes on both
sides of the vehicle at the same time.
b. Replace the shoe return springs if they are
weak.
c: Replace the back plate if warp or wear is
evident.
d. In case the inside surface of the brake drum
is scored, correct with No. 60 sandpaper.
Also correct or replace the brake drum if
irregular wear or tapered scoring is evident,
or if the drum exterior is damaged.
Fig. m-5 Removing plug

f. Rcmove the shoe set springs. inside

182 m m (7.17 in)

3) Assembly
a. Apply a small amount o f brake grease to the
sliding surfaces between the back plate and
brake shoes, and contact points between t l ~ c
brake shoes and wheel cylinders.
b. Install the shoe springs on both primary and
secondary shoes, and install them onto the
wheel cylinder ends.

NOTE:
Be sure t o install the shoe return springs as
Fig.-#-6 Removing broke purrs shown in Fig. S3-7.
 c. Hook the mid-point or the spring l o the approxirnalley 0.3 mm (0.012 in). Therefore,
wheel cylinder as shown in Fig. a4. pedal travel will not change even the linings
d. Install the shoe set pins. wear out.
e lnstall the brake drum o n t o the knuckle
Y!
spindle after wiping off the oil o n the brake
lining surface and brake drum inside surface.

Fklurn spring
Brake shoe

. -.

/
Fig. 13-7 Installing shoe return spring Fig. a - 9 Cross scction o ~ a u f o m o r i c
adjuster
/ .'
f. Install the washer, lock washer, and nut o n
the spindle and adjust the preload for the
When the clearance between the brake shce
bearings. (% R)See h p 6s and brake drum is more than t h e designed
g. Test drive the vehicle at about 10 km/h (6
mph) and' apply the brakes forcefully t w o o r clearance S, namely when the clearance is S +
three times. Check the pedal travel and make .AS,automatic clearance adjusting action takes
sure that there is n o abnormality in braking p!ace as fo!lows.
operation. As the brakes are applied, the brake shoes,
which have been stopped by A'of the adjusting
1 4) Automatic adjuster block, arc forced toward the brakc drum and at
1
t h e same time the adjuster bolts (4) installed o n
!I I- - I the shoe webs move away from A and coatact
B, travelling the distance S. As the pistons
further force t h e shoes outward overcoming the
frictional resistance produced b y the friction
springs (6), sliding occurs between the shoe web
(1) and the friction plate (5) to compensate the
surplus cleararlce A S and eventually the shoes
contact and press the brake drum.
When the b;akes a r t released the sI~ocsmove
off the drum and are retnrned inwards b y the
return springs until the aGjuster bolts (4) are
stopped by A. The shoes d o not move inward
more t11a.n that since the frictional resistance of
the friction spring is set greater t h a n the pulling
Fig. #i9 L.ocntion ojarrtomntic adjuster
force of the rcturr? spring, thus maintaining the
shoc ciearance S.
The front brakes are equipped with the 5) Front wheel cylinder
automatic adjuster that automalically keeps the The front wheel cylinder components are
I
clearance between the brake shoe and drum at shown in Fig. R-I0.
1
a. Rcasscrnbly
I ) Thoroughly clean the wheel cylinder
body and install the bleeder screw, with a
rubber cap o n it, into the cylinder body.
2) Wash the piston and cup in alcohol,
carefully -wipe them with clean cloth and
soak them in clean brake fluid.
3) 111staH the cup into the piston, being
careful about the c u p direction. If the
cup i s damaged or deformed, replace it
with a new one.
4) Insert the piston into the wheel cylinder.
Be careful not to damage the lip of the
cup.
5) Install the rubber boot on the cylinder
body.
2. Rear brake assembly
The components of the rear brake assembly
are shown in Fig. U-1I .
1) Disassembly
a. Raise the rear pf the vehicle and place it on
the stands.
b. Rcmove the wheel and brake drum as
described in a - 2 , Chapter -5
c. Release the parking brake and loosen the
cable adjusting nut at the rear end of the
parking brake rod. Remove the cable return
spring from the lever.

b. Torque specifications

1.3 - 2.0 kg-m

Wheel cylin-
dcr to back -
8 mrn
(9 - 14 ft-lb)
plate (Nut) 6 mm 0.6 - 1.1 kg-m
(4 - 8 ft-fb)

Back plate to knuckle 1.2 - 2.4 kg-m

(Nut) (9 - 17 ft-lb)

I Boo1 4 Cup spacer

2 Piston 5 Return spring
3 Cup 6 Wheel cylinder body
Fig. a - 1 0 Components of front wheel cylinder
 RCAR

( I ) Boo1 (8) Spring

(2) Nut (9) Levcr complctc
(3) Spring washer (10) Anchor block assembly
(4) Adapter (11) Back p k t e complete
( 5 ) cap (12) Pin
(6). Wheel cylinder arrcrnbly i13) Scat
(7) Brakc shot complctc (14) Spring

Fig. S - 1 f Exploded view ofrear brake arsembly

d. Remove the shoe set springs.
e. Return the brake shoe adjuster wheel of the
anchor block so as to make the spring
tension smaller.
g. Remove the shoe return springs from the
brake shoes.
2) Inspection, correction and replacement
a. Check the linings for wear. When the lining
-

thickness is less than 1.7 mm (0.07 in;

replace the brake shoe. Always replace the
Icading and trailing shoes on both sides of
the vehidc together wirh the slme return
springs a t the same time.

Adjuster
Fig. a - 1 2 R crnoving brake parts
f. Remove the brake shoes from the anchor
block first, and then from the wlleel cyl-
indcr.
Allowable 1.7 mm
lining thickness (0.07 in)
b. Replace the shoe return springs if the ten-
sion is insufficient.
c. Replace the back plate, brake shoes, and
lcvcr if deformed or worn.
d. Rcplace the lever if excessively worn.
e. Correct the inside surface of the brake drum
with No. 60 sandpaper if scoring is evident.
Also correct or replace the brake drum if
irregular wear, tapered scoring, or external
damage is found.
 d. Install the brake shoes together with the
Drum Standard 170 m m (6.69 in) return springs, by fust instatling the upper
inside ends of the trailing shoe and leading shoe in
diameter Limit 172 mm (6.77 in) this order to the wheel cylinder and then the
lower ends of the trailing shoe and leading
f. Replace the boot (dust seal) and adapter if shoe in this order to the anchor block.
defective. e. Install the shoe s'et springs.
3) Assembly f. Check the brake drum Tor abnormality and
a. Install the lever t o the back plate. Check t o carefully install it over the brake assembly,
see if the lever is installed on the correct Refer to 5 2 , Chapter for the installing t
side, as the left-hand and right-hand levers procedure. S 1

are different in shape. If installed on the 1

wrong side, the lever will contact the wheel 1
.cylinder and spring and may cause damage.
NOTE: 1
a. Be careful that nothing falls into the brake !
assembly.
b. Do not smear grease on the inside surface of
t h e brake drum.

g. Adjust the brake shoe clearance in accord-

ance with "4) Adjustment of shoe clear-
ance".
h. Adjust the parking brake cable at the park-
ing brake rod end so that the cable does not
pull the Iever on the brake assembly. Install
the pin, washer, cotter pin and return spring
as shown in Fig. B-15. 1
Fig. 13-13 Installing lever i. Readjust the parking brake cable in accord- .
I
ance with -5. in this Chapter.
b. Assemble the brake shoes and return springs. 4) Adjustment of shoe clearance I
Pay attention t o the directions of the brake a. Raise the rear of the vehicle so that the rear
shoes and return springs. (Fig. B-14) wheels turn freely.
c Apply a thin coat of brake grease to the b. Align the adjustment hole in the brake drum . .
surfaces of the back plate, wheel cylinder with the adjuster at the anchor block and
piston ends and anchor shoe supporters insert a sctewdrivcr through the adjustment ,
hole to reach the adjuster. i
which the brake shoes contact. !

Hang rht return spring

lrom back p l a ~ eside.

Fig. Sf
4 D i r e c t i o n of spring Fig. m-f5Connectirrg parking brake cable

Fig. =-16 Adjurtmcnt hole in brake drum
\ rubber cap on the bleeder screw and
Fig. =I 7 Adjusting rhoc clearance
c. Turn the adjusters on both sides in t h e
direction that decreases the shoe clearances
until the wheel cannot be rotaled with o n e
hand.
d. Then back off the adjuster b y 8 riotches.
c. After centering the shoes in the brake drum
by depressing the brake pedal 2 or 3 times,
turn the wheel t o see that it rotates easily
and n o noticeable noise is made between the
shoe and drum.
f. Perform the above adjustment for t h e lead-
ing and trailing shoes on both rear wheels.
NOTE:
a. Before starting the brake adjustment, fully
release the parking brake.
b. Be sure to back off t h e adjuster by 8 notches
otherwise the brakes may drag.
c. When the wheel i s heavy t o turn or noise is
distinctly audible, readjust the shoe clear-
ance.
5)
.
Rear wheel cylinder and anchor block
"
Boo1 Piston Cylidcr body COMPL
1 I I . .
/ ?w
d ;$r o w + 8 .
Piston head Cup
" "r*;s'r'-
Adjuster
Block COMPL
Fig. W-18 Components ofrear wheel
c y E d c r and anchor b b c k
Reassembly
a. Rear wheel cylinder
I ) Clean the wheel cylindcr, attach the
install the cap into the wheel cylinder.
2) Soak the piston and cup in clean brake
fluid.
3) Install the cup to the piston, being careful
about the cup direction. When inserting
the piston into the cylinder, use care not
to damage the lip of the cup.
b. Anchor block
1) One of the two supporters of the anchor
block has right-handed screw threads and
the other has left-handed ones. If warpage
or wear is evident on the threads, replace
the supporter together with'the adjuster.
2) The adjusters arc expected t o be rotated
lightly with fmgers. Replace tht adjuster
if its teeth are excessively deformed or
worn.
3) Replace the anchor block body if the
mounting bolt is defective.
4) Before assembling, clean the inside sur-
face of the anchor block, iht outside
surface and threaded hole of the adjuster,
and the threaded part of the supporter,
and apply a generous amount of grease to
these parts.
7- 3. MASTER CYLINDER
1. Operation
1) Normal operation
When the brake pedal is depressed, the
primary and secondary pistons are maved i n by
the force transmitted from the pedal through
the push rod. As soon as the return port is
closed b y the secondary piston, the hydraulic
pressure begins to rise in [he secondary cham-
ber, consequently applyiag pressure t o the rear
wheel cylinders, and then the pressure in the
primary chamber also rises, applying pressure to
thr front wheel cylinders. (ReTcr to Fig. B-20.)
2) Operation when secondary (rear wheel)
brake Line leaks
Since there is no pressure rise in the sccond-
ary chamber even if the push rod moves, the
secondary piston reaches the inner end of the
master cylinder. However the primary piston
compresses-the fluid in the primary chamber,
thus keeping the front brake system operative.
3) Operation when primary (front wheel)
brake line leaks
Sincc there is no pressure rise in the primary
chamber even if the push rod moves, the
primary piston comes into contact with the
secondary piston and pushes it, thus keeping
the rear brake system operative. (Fig. U-22)

I P

1 Nipple 6 Check vdve 12 R e t u r n spring

2 Nipple 7 Secondary pircon rtoppcr 13 Pbton rrl'y
3 Master cylindcr rcpair 8 Spring 14 Stop warher
kit (A) 9 T u b e scat 15 Stop ring
4 Masrcr cylinder repair 10 Cap 16 Boots
k i t (B) 11 Cyiindcr body 17 Push rod
5 Gasket

Fig. PT-19 Component parts of muster cylinder

SrC- 11
 Secondary
Fronr our1.1

econdary piston

Return port

~ i g M-20
. S e c t i o m l view of master cylinder

2. Removal 2) Right-hand drive vehicles

I) Left-hand drive vehicles
a. Remove the under cover.
b. Disconnect the brake pipes from the master
NOTE:
cylinder. (Fig. SU-2 1) He careful that brake fluid does not spill
c. Disconnect the tube, connecting the reser- /
over painted surfaces during removal.
voir t o the master cylinder, from the nipple.
d. Remove the pin on the push rod.
.
e. Remove t h e master cylinder from the chassis
frame by unscrewing the two attaching
bolts.

Fig. P 2 2 Operation when setondary

- ~ i g f.a 2 1 Removing muster cylinder

(rear-wheel) broke line leaks

a. Ren~ove !he brake fluid reservoir from the

reservoir holder and empty the reservoir.

Fig. H - 2 3 Removing brake fluid reservoir
b. Remove the f l a ~ enuts connecting the brake
pipes t o the master cylinder.
c. Remove the cotter pin from the brake
pedal-to-push rod connecting pin and
separate the master cylinder from the brake
pedal.
/
pin
?'
! the primary piston into the cylinder body.
Fig. a - 2 4 Removing master cyIinder
3. Disassembly
I) Remove the boot from t h t cylinder body.
(Fig. S-19)
2) Remove the snap ring and stop plate.
3) Remove the primary piston and the return
spring.
4) Remove the piston stop and gasket and
then remove the secondary piston.
5 ) Remove the cap and seat, and then remove
the check valve.
4. Preparation for reassembly
The inside surface of the master cylinder
must be smooth and perfectly round. Replace
the master cylinder if irregular wear or defects
are evident. Never* correct ... the inside oi the
master cylinder with sandpaper or other abra-
sive material.
I) Before assembling, wash the inside surface
of the master cylinder with clean brake fluid.
Be careful that dust or other foreign matter
does not enter the master cylinder during
assembly.
2) When washing the cylinder and inserting
the piston, use case not t o damage the inside
surface.of the cylinder and piston cup.
NOTE:
Replace the cylinder and the piston if the
clearance exceeds the specified limit.
Piston-tocylindcr clearance
I Standard
I 0.020
(0.0008
- 0.105 mm
- 0.004 1 in)
Limit 0.15 mrn (0.0059 in)
5. Assembly
1) Insert the secondary piston into the cyl-
inder body with the secondary return spring.
2) Insert the primary return spring and then
3) Install the secondary-piston stop with the
gasket.
4) Install the s t o p plate and secure it with the
snap ring.
5) lnsert the check valve' spring into the
cylinder block,
6) Install the seat end cap.
7) Install the push rod, with the boot pre-
viously installed o n the push rod, to tile
cylinder body.
6. Installation
I) Install the master cylinder in the I , ierse
order of the removal.
2) Alter installing, bleed the brake system
and check the operation of the master cylinder.
 3) Torque specifications 1. Operation %

In normal condilion, the float is above the

Master cylinder to 'reed switch; the magnetic field from the perma-
chassis frame on Ieft-
8.0 - 12.0 kg-m nent magnet placed in the float does not permit
handdrive vehicle
(58 - 87 it-lb) the reed switch to operate, the indicator light
being unlighted. As the brake fluid level drops

Brake pipe flare nut

1.5 - 2.0 kg-rn the float is also lowered, and when i t reacher
(1 l - 14 fl-lb) the prescribed level the reed switch operales t o
turn on the indicator light, warning the driver
of dropping of brake fluid level.
The indicator,. circuit is connected .to the
charge relay so that the light glows when the
ignition-starter switch is turned t o ON position
7- 4. B R A K E F L U I D LEVER and goes out when the engine is started, in or-
WARNING SYSTEM der t o provide a means of checking the circuit
for disconnection and the bulb for burning out.

2. Replenishment of brake fluid

If the indicator light glows during operation,
immediately replenish the reservoir,with brake
fluid t o the embossed level line.

NOTE:
The brake fluid level drops as the brake
lining wear develops as well as when the
brake system leaks. When the vehicle jolts
along a rough road, the indicator light may
flicker because the float moves u p and d o w n
Fig. B - 2 5 Cornponenfs of brakc fluid with the waving fluid surface.
level warning syrtem

?- 5. PARKING BRAKE SYSTEM

Checking circuit added
The components of the parking brake sys-
tem are shown i n Fig. R27.

1. Parking brake lever and rod

Brake fluid lewl rn
I ) Removal
a. Raise the vehicle and loosen the nut at the
turn on position rear end of the rod. Disconnect the rod from
t h k parking brake lever by removing the
clevis pin. (Fig. S-28)
I I b. Remove the two 8 mm lever attaching bolts.
(Fig. 1 - 2 8 )
Fig. #-26 Sectional view r l j brake fluid c. Separate the rod and cable by reinoving the
reservoir nuts at the rear end of the rod. (Fig. B-29)
 DETAIL ' O m DETAIL 'Em

1 Rod assy (Hand brake) 1 1 Hand brake lever assy 21 Grommet (Hand brake)
2 Nut 12 Button (Hand brake lever) 22 Clamp
3 Washer 13 Spring (Hand brake Icvcr) 23 Bracket (Hand brake RH)
4 Pipe (Hand brake) 14 Screw (Pan head) 24 Bracket (Hand brake LH)
5 Joint (Hand brake) 15 Hand brake switch t s s y 25 Spring (Hand brake cable)
6 Cable u s y (Hand brake) 16 Cord assy (Hand brake switch) 26 Clevh pin
7 Spring washcr 17 Bolt (8x18) 27 Clamp (Hand brake cable)
8 Bushing 18 Spring washer 28 Bolt
9 Clamp (Hand brakc) 19 Clevis pin
10 Boltauy 20 Cotter pin

Fig. -27 Components of brake system

m- 15

Fig. B-28 Rcrnoving parking brake lever
a n d rod
Fig. B - 2 9 Separating rod and cable
2) Inspection
a. Check the parking brake lever for operation.
b. Check the ratchet and hook for wear.
c. Check the rod for damagc and wear.
d. Check the clip and joint for damage and
wear.
3) Installation
a. Install the parking brake lever t o the bracket
on the floor.
Torque (Lever arrach- 0.6 - 1.4 kg-m
ing bolts) (4 -, 10 ft-lb)
b. Connect the rod t o rhe lever.
c. Install the joint, with the cable inserted in it,
t o the rear end of the rod, being careful
about the installing order of the nuts,.
washers and pipe.
d. Install the clip on t h i r o d and attach the clip
t o the bracket on the crossrncmbcr.
c. Adjust the cable in accordance with "2.
Parking brake cable".
2. Parking brake cable
1) Removal
a. Release the parking brake lever fully.
b. Disconnect the cable from the leven on the
rear brake assemblies.
c. Remove the four.cable clamps.on the. cross-
member and hub by unscrewing the 6 mm
attaching bolls.
d. Remove the cable from the rod by removing
the joint.
e. Remove the cable grommets on the outer
trailing arms and extract the cable.
2) Inspection
a. Check the parking brake cable for operation.
b. Check the inner wire of the cable for rusting
and damage.
c. Check the outer sheathing of the cable for
wear, tear and other damage.
d. Check the boots for tear and other damagc.
e. Check the clevis pin for wear.
3) .Installation
a. Insert the cable into the hole in the outer
trailing arm o n each side.
b. Install the four clamps, tightening the at-
taching bolts t o the specified torque. (Fig.
m-27)
-
Torque (Clamp at- 0.3 - 0.6 kg-m
taching bolts) (2 - 4 ft-lb)
c. Connect t h c cable end t o . t h e lever at the
brake assembly.
NOTE:
Change the cotter pin with a new one and be
sure t o bend it into anchor shape.
d. Install the cable return spring on the bracket
which is attached t o the hub.
e. Insert 'the cable into the joint and install the
joint on the rear end of the rod with the
nuts, washers and pipe in thc correct order.
f. Install the clip on the rod and attach the clip
t o the bracket o n the crossrnembcr.
g. Adjust the cable as described i n the follow-
ing item.
4) Adjustment
a. Prior t o the cable adjustment, complete the
brake shoe clearance adjuslment.
b. Adjust the cable t o the specification below
by changing the joint position on the rod.

Norchcs
Standard lever travel
[when pulled with approx. 3 notches
25 kg (55 Ib) of force]
Fig. st-30 Parking brake lever ratchet
Limitof travel
[when pulled with approx. 5 notches -
25 kg ( 5 5 lb) o f force]
Joint
Total notches provided 8 notches

Torque -
0.3 0.6 kg-m
(Joint lock nut) (2 - 4 ft-lb) Lock nut
1
I
1
c. Make sure that the wheel rotates lightly alter i
adjusting the cable. Fig. m-31 Joint and lock nut3 iI

i
I
 CHAPTER 8: S T E E R I N G SYSTEM

GENERAL DESCRIPTION . . . . . . . . . . . . . . . 2

S T E E R I N G SYSTEM .
. . . . . . . . . . . . . . . . 3

STEERING WHEEL .
. . . . . . . . . . . . . . . . 4

S T E E R I N G SHAFT .
. . . . . . . . . . . . . . . 5

BEVEL GEAR BOX .. . . . . . . . . . . . . 8

S T E E R I N G GEAR BOX . . . . . . . . . . . . . . . . 10

TIE-RODEND . . . . . . . . . . . . . . . . . . . 15

TROUBLESHOOTING . . . . . . . . . . . . . . . . . 16
8- 1. G E N E R A L DESCRIPTION
1. Outline
The steering gcar box employed is of the
rack and pinion type, which is simple and
rcliablc. As the pinion rotates, thc rack moves
laterally. pulling or pustung the tic rods that
connects the rack and the knuckle a r m . Thus
both the front whcels are turned right and left
2. Specifications
to steer the vehicle. 'Th: tie rods are ball.jointed
to the knucklt am and l o the rack. The
backlash between the rack and pinion is set to 0
using a spring installed in the slecve adjuster. In
this sleering system, t h e bevel gcar box is
locaied in front of the sltering gear box;
therefore, the iorquc from t h e steering wheel is
reversed by the bevel gear and is transmitted
through the torque rod and rubber joint to the'
pinion on the steering gear box.
- -
I
-

Minimum turning c~rcle 7.2 rn (24 ft)

Inner 36O
Turning angle
Oulcr 3S0 .
Steering ratio 22.5

S~ccringwhcel d i a m c ~ c r 380 m m ( I 5.0 in)

TYPC Rack and pinion

Pinion 7 teeth
Steering Scar assembly
Rack 28 tecth

I Backlash I L c s than 0.05 mrn (0.002in) 1

Thread diameter and pitch 18 mrn x 1 .SP (Lcft-hand screw)

Nut width across flats

Tic .rod
Turnbuckle width across flats 13 rnrn

Tie-rod end ball stud 12 mm dia. x 1/10 taper

Pinion 15 teeth

Gear 21 ~ c e ~ h

Bevel gear assembly Gear ratio 1.40

I

Backlash Lrss than 0.05 m m (0.002 in) I

Axial play of bevel pinion Less than 0.035mm (0.0014 in)

Toe-in (with vehicle unloaded) 8 - 13 m m (0.32 - 0.51 in)

Sidc slip (with driver) IN 3 mm (0.1 i n ) to OUT 3 m m (0.1 in)

 Fig. *-I Installing steering system components

Since this stecring system cmploy s the bevel
gcar assembly, it is very important to obtain
correct alignment bctwcen the bevel gcar box.
stccring gear box a n d steering wheel which are
installed a n the vchiclc. Whcn installing the
steering system c o m p o n e n t s , first temporarily
tighten their attachi;;g bolts a n d nuts. Then
fully tighten t h e m t o the specifications in thc
o r d e r of @ to @ as indicated in Fig. 14-1,
ensuring that the c o m p o n e n t s are aligned cor-
rectly with each other.
1) Tighten t h e bolts attaching t h e stccring
shaft b r a c k e t t o thc instrument panel.
2) Secure t h e s ~ c c r i n ggear box b y tightenin?
t h e attaching bolts in t h c order o f @, @.@
artd @ .
3) Sccurc the bcvcl gcar box with the rubber
bushing and clamp by tigh~cningthc allaching
bolts to the specified torque. The construction of thc stccring wheel is
shown in Fig. fd-3.

Torque l .O - 2.2 kg-m (7 - 16 it-lb) 1. Removal

1) Remove the two screws at the back of the

4) Tighttn the clamp securing the torque rod steering whcel and remove the cover.
ro thc bcvel gcar b o x .

Torque 2.5 - 3.3 kg-m (18 - 24 TI-lb)

5) Tighten the clamp securing the steering

shaft fo t h e bevel gear box.

Torque 2.5 - 3.3 kg-m (18 - 24 ft-lb)

NOTE:
When tightening the clamp, pull the steering
shah up so that the gap between the steering Fig. S 2 Removing cover (steering whcel)
wheel and shafi cover becomes as follows.
2) Remove the s!cering wheel retaining nut
1 - 3 m m (0.04 - 0.12 in) and rcmovc the stecring wheel from the shaft.
Gap
(Fig. sa4)

Fig. s 3 Construction of steering wheel

m-4
2. Inspection 3) Install rhe cover o n t h e sleeting wheel by
tightening t h e t w o screws from t h e back of the
Check all the parts for damage a n d poor steering wheel.
operation, and if necessary replace defective
4) Check the horn operation by pushing the
parts with new ones.
horn key.

Fig. 81-6 Inttalling steering whect

8-4. S T E E R I N G SHAFT
3. Reinstallation
The construction o f the steering shaft is
I) C l e m t h e horn contact points and slide shown in Fig. L-8.
plarc.
1. Removal

1) Remove the bolt or the clamp securing the

steering shaft t o the bevcl gear.

Clamp

Fig. H-5 Cleaning contact points

2) With the front wheels in rhc straight-ahead
install the stecrir~g whcel with the washer,
lock wasller a n d n u t o n t o l h c shaft and tighten
thc nut to the spccific;ltion with t h e steerirrg
spoke in the horizontal position. (Fig. FI-6)
2 . 2 - 2.8 kg-rn
-
Fig. 8 - 7 Removing c b m p bolt
2) Disconnect t h e c h o k e cable from t h e
stccririg bracket b y removing t h c c h o k e knob.
3) Removc the t w o bolts attaching t h e steer-
ing brackct to the instrument panel.
4) Disconnect the c o m b i n a t i o n switch a n d
ignition-starter switch harncsses from thc main

5) Pull t h e steering shaft o f f t h e bevel shaft.

2. Disassembly the steering shaft placed in its installed direc-
tion),
1 ) Separate the slcering whecl from the shaft 3) Remove the screw on each side of the
assembly. sleering column cover t o remove the steering
2) Pull out the steering shaft downward (with bracket out of the steering column cover.

1 Steering wheel
2 Cover (Column)
3 Combination swi~ch
4 Hazard warning switch knob
5 Brackt~complete
6 Shaft complete
7 Bearing

Fig. I3 Corutrvction ofsteering shaft

4) Remove the hazard warning switch knob

and lake out the combination switch. (Fig.
ra-10)

Fig. R-9 Removing steering bracket
3. Inspection
1) Check t h e steering shaft for bend and
other damage.
2) Check the bcaring for wear, and for noise
and smoothness when thc steering shaft is
rotated in t h e bearing.
 tighten with the clamp. At this time, adjust the
gap between the bottom of the steering wheel
and the t o p o f the shaft cover to 1 t o 3 rnm
(0.04 to 0.12 in). (Fig. m-1 1) '

Fig. S - I 0 Removing combination switch

3) Check t h e o t h e r p a r t s f o r d e f e c t .

4. Reassembly Fk. S f 1 Installing steering shaft

1) Before reassembling, clean [he sliding parts

and apply new grease.
2) Install t h e combination switch in the Torque . 2.5 - 3.3 kg-m
steering column cover and install the hazard (Clamp bolt) ( I 8 - 2 4 Ct-lb)
warning switch knob. - 1
3) Pass the combination switch harness
through the hole in thc bracket, install the
steering bracket in the cover and temporarily 2) Install the stecring shaft assembly to the
'instrument panel with the two attaching bolts.
tighten the attaching scrcws.
4) Insert the shaft into position and install
the stecring wheel on the shaft. I .O - 2.2 kg-m
Torque
5) Tighten the bracket attaching screws on (7 - 16 ft-lb)
both sides of the cover.

Torque 0.06 - 0. 12 kg-m 3) Connect the combination switch and igni-

(Screw) ( 0 , 4 - 0.9 It-lb) tion-starter switch harnesses t o the main har-
I ness and clip them o n the steering bracket.
4) Install the choke cable and knob on the
5. Installation steering bracket.
5) Make sure that the steering wheel spoke
I ) Press the steering shaft o n t o the bevel gear pisition is correct and install the steering wIlcel
shaft with the notches correctly aligned, and cover.
8- 5, BEVEL GEAR BOX
The construc!ion or rhc bevel gear box is
shown in Fig. q - 1 2 .

(1) Gcu box

(2) Bevel g e u (pinion)
(3) Bevel g w (gear)
(4) Cover
( 5 ) Retainer.
(6) Buring
(7) Buring .

( 9 ) Dust r u l
(10) Oil r u l
(11) Adjusler

(1 3) Grounding cord
(14) B u r i n g

Fig. S - I 2 Construction of bevelgear box

1. Removal
1) Raise the vehicle or place i t on a pit. 4) Remove the two bolts at the rubber
2) Remove the clamp bolt connecting the coupling and disconnect the torque rod from
stccring shafi t o the bevel gear box and pull the the pinion shait of the steering gear box
steering shafr off the bcvcl gear box. ascmbly.
3) Remove the front bumper and under
cover. It is unnecessary t o remove the radiator
and protector.

Fig. @-I4 Dirconnecting torqtre rodfrorn

Fig. B - 1 3 Rcmoving under cover pinion shaft
5 ) Remove (he two bevel gear box clamp
bolts with the ground wire, and detach the
bevel gear box from the chassis frame. (Fig.
la-15)
6 ) Remove the torque rod from the bevel box
gear b o x by removing the clamp bolt.

Rubber bushing

Fig. S f 6 Installing rubber bushing

3) Place the clamp on t h e rubber bushing and

temporarily install the bevel gear box on the
chassis frame with the two bolts. washers and
spring washers. Be sure to connect the ground

Fig. *-I5 Renloving bevelgear box
i
wire t o t h e upper bolt.
4) Connect the torque rod ,to the rubber
coupling with the two bolts, spring washers and
nuts.

2. Disassembly and assembly

Since the bevel gear box is designed to be Torque
0.9 - 1.5 kg-rn
(7 - 1 I ft-lb)
used without maintenance or adjustment,
no1 diusscnlble the unit unless it is to
do
be
.
discarded. If it is dcfective replace as an
assembly. 5) Connect t h e steering- shaft to the bevel I

L
gear shaft and temporarily tighten the clamp
bolt.
3. Installatian 6) Fully tighten the clamp bolts attaching the
bevel gear b o x t o the chassis frame, after
1) Install t h e clamp .on the torque rod and establishing the bevel gear box position in
temporarily connect the torque rod to the bevel which the steering wheel turns rnost,lightly. TO
I

gear shaft with the bolt. spring washer and nut.

i
check the rotating torque o f the steering wheel,
2) Install the rubber bushing to the bevel gear rotate t h e rubber coupling with hand.
box, with the marked end downward.
!I
!
!
 2) Remove the under cover.
Tor quc 1 .O - 2.2 k g - ~ n 3) Remove t h e r d o bolts connecting the
(Clamp bol I) (7 - 16 [I-lb) pinion shalt of the srcering gcar box t o the
rubber coupling and leave the rubber coupling
atlached la the torque rod.
i 7) Fully tighten the clamp bolls connecting
1 the lorquc rod and steering shaft t o the bevel
I
gcar box assembly.

- -

Toryuc 2.5 - 3.3 kg-m

(Clamp boll) (18 - 24 TI-lb)

8) Turn the steering wheel from lock t o lock

and check for operation. The condilion is
satisfactory if the tangential force o n the
sreering wheel is less than 1.8 kg (4.0 Ib) with
one pcrson on the seat (front).
Fig. PI-18 Removing rubber coupling bolts

4) Loosen the 16 mm nuts of the turnbuckle.

The t i t rod has 1ef1-hand screw thread and the
tie rod end has righ-hand screw thread.

! Fig. S - 1 7 Checking steerirlg wheel oprrration

i
9 ) Adjust t h e stecring wheel position so that
the spokes are horizontal when the front whcels
are in straight-ahead position.
Fig. a - 1 9 Loosening turnbuckle lock nutr

Ei. S T E E R I N G G E A R BOX
The construction of the steering gear box is 5 ) Separate the tie rod and tie rod end by
shown in Fig. W-20. turning the turnbuckle.
1. Removal 6) Remove the iour 8 m m bolts attachjng the
steering gear b o x t o t h e crossmember ,and
I ) Raise the vehicle and place i t on safcty remove the stecring gear b o x by shifting it
stands. rearward. (Fig. M-21)
 1 N U ~ ( I D X ~ )
2 Lock washer (Rnck)
3 Stopper (Rack)
4 Rack compl
5 Cap (Rack)
6 Snap pin
7 S p a a r ( G ubox)
8 Clip (Gear box)
9 Boot (Steering gcar box)
10 Scat ( G a r box spring)
I! Spring (Gear box ball)
12 Seat (Gear box ball)
13 Tic r o d end au'y
14 Nut
15 Turn buckle (Tie rod)
16 Nut (18 x 10)
17 Tic rod
18 Clip (Tic rod)
19 Boot (Gear box)
20 Gcar box unit
2 1 Bushing (Gear box)
22 Bushing (Gear box)
23 Bushing (Slcering pinion)
24 Bushing (Steering pinion)
25 Oil scal(l9 x 26 x 6 )
26 ' ~ o l t
27 Spring washer
28 Covcr (Pinion)
29 Packing ( G a r box)
30 Reraincr (Pinion)
3 1 Lock nut (Steeling gcar)
32 Adjuster (Gear box)
33 Spring (Ccar box)
34 Sleeve (Gcar box)
35 Boot (Gcar box)
36 Pinion tss'y (Gcar box)

FQ. Sir-20 Construction of steering gcar bor

2. Disassembly

1) Hold the steering gear box in a vise a n d

remove the covers a t both ends of the gear box.
2) Remove the s n a p pin installed i n the
groove in the rack by using a flat blade screw
driver. (Fig. kU-22)
3) Remove the cap from the rack, leaving the
spacer, spring, etc. in the rack.

Fig. U - 2 1 Removing s t e c r i n g g e a r box

B-11
 6) Turn the pinion shaft clockwise t o pull the
rack out of the gear box. '
7) Take out the spacer, spring and ball
retaining seats from the rack.

NOTE:
Be careful not to damage the sliding surfaces
of the rack.

8) Remove the boot retaining clips and re-

move the boot from the gear box.

Fig. @-22 Removing smp pin NOTE:

D o not pull the boot forcefully.

4 ) Remove the tie rod clips from r h t boots

and extract the tie rods from the gear box.
Remove the clips from the tie rods. (Fig. 1 - 2 3 )
5) Spread the lock washer at the rack end
and remove the rack stopper, lock washer and
nut. (Fig. 1824)
9) Rcrnovc the pinion wver and gasket by
removing the two attaching nuts. (Fig. S 2 5 )
10) Remove the retainer and take out the
pinion.
11) Loosen the adjuster lock nut and remove
the adjuster, spring and sleeve from the gear
box.

3. Assembly

1) Thoroughly wash all the parts in cleaning

solvent.

Fig. 8-23 Removing t i e rods

Fig. PI-25 Removing pinion cover

2) Hold the steering gear box in a vise and

install the boot with the retaining clip at each
end.
3) Apply a sufficient unounl of grease to the
pinion and the inside of the pinion bore in the
gear box. Insert the pinion into the gear box
and install the retainer, Also apply grease to the
F*. 1-24 Removing rack stopper retainer.

tp-12

Fig. tl-26 Knrtallinx pinion
Install the pinion cover with the gasket,
4)
two 6 rnm bolts and spring washers.
.-
Torque 0.5 - 0.7 kg-m
(Bolt) (3.6 - 5.1 ft-lb)
5 ) Apply a sufficient amount o f grease lo the
rack.
6) Insert the rack into the gear box from the
side opposite t o thc pinion. Engage the tceth'of
the rack and pinion, and turn the pinion
counterctockwise.
7) Apply grease to the adjuster sleeve and thc
inside o f the adjuster bore in the gear box, and
insert the sleeve into position.
8) Apply grease t o the adjuster spring and
inscrl i t in the sleeve.
9) Apply sealant t o the adjuster threads and
screw in the adjuster into the gear box.
10) Install the stopper, lock washer and nut
in this order o n the rack end.
11) Adjust the rack-to-pinion backlash by
fully tightening t h e adjuster and then back off
about 1/15 turn.
Turn the pinion from lock t o lock to see its
rotating condition. If the rotation i s smooth,
back off the adjuster less.than 1/15 turn, ---.-.
12) Measure t h i rotating torque of the
pinion. The torque from the slraight-ahead
position should be 0.01 to 0.09 kg-m (0.07 t o
0.65 ft-lb), and the maximum torque through
the whole range o f travel should be less than
0.22 kg-m(1.59 ft-lb). (Fig. a - 2 8 )
After the above condition is satisfied, lock
the adjuster with the lock nut.
13) lnsert the two gear box ball seats, spring,
spring scat, spacer and rack cap into the rack
holc in this order.
14) Install the tie rods after applying grease
o n the ball scats and tie rod ball ends.
15) Insert the tie rods into the holes in the
boot and install the rubber clips in position.
(Fig. Qr1-23)
Lever
Gear box
-
L
'
Spr'w scale
Fig. W 2 8 Measuring pinion torque
16) Fully tighten the rack cap and back it off
until its groove is first aligned with the snap pin
hole in the rack.
To check that-the cap is properly tightened.
measure the force t o move the tie rod as shown
in Fig. m-29, which should be about 0.3 to 1.5
kg (0.7 t o 3.3 Ib).
 coupling with the IWO bolts, spring washers and
nuts.

Torque 0.9 - 1.S kg-m (7 -ll TI-lb)

4) Connect the tie rod t o the tic rod end by

positioning the turnbuckle between them and
turning it in. Be careful in engaging the threads
so that the exposed thread lengths of the tic
rqd and tie rod end are not noticeably different.
5) Turn the steering wheel from lock t o lock
to check its operation.
Fig. H-29Checking tightne~so j t i e rods
6) Adjust the toe-in to the specification by
turning the turnbuckle, and tighten the 18 mm
17) Install the covers on both ends of the Jock nuts a f ~ e raligning the mark o n the tie rod
gear box.
with the mold parting l i n t on the tic rod end.
(Fig. LI-30)
4. Installation
-
1) Inst all the rubber bushings on the steering Toe-in (with vehicle IN 8 - 13 mm
gear box and position it on the crossmember unloaded) (0.32 - 0.5 1 in)
bracket.
2) Place the clamps on the bushings and
secure the gear box with the four 8 mrn bolts.
using care that t l ~ cpinion shaft a n d torque rod
a r t aligned. I Torque
(Lock nut)
8.0- 8.5 kg-m
(58 - 61 ft-lb) I
3)
Torque
(Bolt)
2.0 - 3.0kg-m
(14 - 22 ft-Ib)

Connect the pinion shaft to t h e rubber

I 7 ) Adjust t h e steering wheel position so that
the spoke is horizontal with the l'ront wheels in
the straight ahead position. For removal znd
installation of the steering whcel, refer to
" -3. STEERING WHEEL".

and at1 lor checking

Turn buckle movement.

Movement of lie-rod rhould '

b e even both front and rear

Fig. B - 3 0 Checking t i c r ~ movement

d

111 - 14
8- 7. TIE-ROD END
1. Removal ' castle nut. Tighten the castle nut t o 2.5 t o 3.0
1) Raise the front of the vehicle and place
it on the safety stand,-.-
2) Loosen the lock nuts of the turnbuckle
and remove the turnbuckle.
3) Pull the cotter pin off the castle nut
connecting the tie rod end t o the knuckle arm,
and remove the castle nut.
4) Press the baU stud of the tic rod end o u t
of the knuckle arm, using Special Tool (BALL
STUD REMOVER: 921 240000).
Fig. S - 3 1 Removing bat1 stud
2. Disassembly and assembly
T h e tie rod end cannot be disassembled.
Replace it as an assembly if defective.
3. Installation
I ) Connect the tie rod end t o the tie rod by
positioning the turnbuckle between them, a n d
turning it in. Be careful in engaging the threads
so thnl thc exposed thread lengths of the t i t
rod and tie rod end are not noticeably dif-
ferent.
2) lnsert t h e ball stud of the l i e rod end into
the hole in the knuckle arm and inslatl the
kg-rn (18 to 22 ft-lb) first, and then further
tighten within 1 / 6 turn t o align a slot in the
cotter pin with the hole in the baU stud.
- - -
Castle nut 2 . 5 - 3.0 kg-m
lightening torque (18 - 22 ft-lb)
3) Lock the castle nut with a new cotter pin.
4) Turn the stcering wheel; from lock t o lock
t o check its operation.
5) Adjust the toe-in t o the specification by
turning the turnbuckle, and tighten the 18 mm
lock nuts after aligning the mark on t h e tie rod
with the mold parting line o n the tie rod end.
(Fig. 1 - 3 0 )
Toe-in(with vehicle IN 8 - 13 mrn
unloaded) (0.32 - 0.5 1 in)
Torque 8.0 - 8.5 kg-m
(Lock nut) (58 - 61 It-lb)
6 ) Grip the tic rod and check that it moves
t h e same distance forward and rearward with
the front wheels in the straight-ahead position
as shown in Figure m-32. If it moves unequal-
ly, readjust. It is permitted that the tie rod
marking is found to be out o f alignment with
the tie rod end when this fore and air adjust-
ment of the tic rod has been cornpl;eted.
7) Adjust the steering wheel position so that
the spoke is horizontal with the front wheels in
the straigi~t.ahead position. For removal and
installation of the steering wheel, refcr t o
"m-3. STEERING WHEEL".
8- 4. TROUBLE SHOOTING

1.
Trouble and possible cause

Steering wheel is heavy.

I Corrective action

Raise the front of the vehicle until both front wheels clear the ground. Then turn the steering
wheel. If i l becomes lighter than the case that the front wheels arc on the ground, the tire
p r a s u r c or t h e suspension may be responsible and if it is still heavy the steering syslem may
have some trouble.

I) Ere pressure too low. .Adjust to correct pressure.

2) Incorrect front wheel alignment. Adjust toe-in,
3) Stuck ball joint. Replace.
4) Insufficient lubrication. Lubricate all parts.
5) Sruck king pin and bushing. Replace.
6) Worn out tires. Replace.

2. Steering wheel vibrates.

This trouble takes place mostly at high speeds, or rough roads.

I) Improper tire pressure. Adjust t o correct pressure.

2) Incorrecl front wheel alignment. Adjust toe-in.
3) Unbalanced wheels and tires. Correct.
4) Loose wheel nuts, drum nuts o r Tighten t o correct torque.
rim nuts.
5) Distortedwhcel. Correct or replace.
6) Damaged or worn wheel bearing. Repair or replace.
7) Uncven tire pressure. , Adjust t o correct pressure.
8) Damaged or worn trailing arm Replace.
bearing.
9) Worn king pin. Replace.
10) Unbalanced brakc drum. Replace.

3. Shocks at steering wheel,

1) I n c o r r e c ~front whcel alignment. Adjust t oc-in.

2) Excessive tirc pressure. Adjust t o correct pressure.
3) Defective shock absorber. Replace.
4) incorrect engagement or steering Correct.
gear or bevel gear.
5) Excessive backlash. Correct.
 Trobuble and possible cause Corrective action

4. Steering wheel pulls to one side.

This condition is very dangerous t o vehicles, and often atlributable to defective front
. suspension.
r
1) Uneven tire pressure. Adjust to correct pressure.
2) Incorrect front wheel alignment. Correct.
3) Damaged or worn wheel align- Replace.
ment bearing.
4) Brake dragging, Adjust.

5. Abnormal noise.

I) Loose conncclions or insuffi- Tighten t o specified torque.

c i c r ~ ttightening.

2) Damaged or warn wheel bearing. Replace.

3) Damaged or worn trailing arm Replace.
bearing.
4) Defective shock absorber. Replace.
5) Damaged or worn king pin and Replace.
bushing.
 CIlAPTER 9 HEATER

Page

DESCRIPTION--ESPAR MODGLS D1L & . . . . . . 9-2

B1L
TROUBLESHOOTING DIAGRAfl . . . . . . . . . . . . 9 - 5

W I R I N G DIAGRAM . . . . . . . . . . . . . . . . 9-6
 9- 1. DESCRIPTION
1

Beating C a p a c i t y

Fuel - Diesel o r C o m b i n a t i o n D i e s e l
Kerosene o r Gasoline

I Fuel Consumption + 5%
0.19 l/hr -

I Electric Power Consumption - 40 W +

- 10%
Voltage - 12V

Hot A i r 'I'hrouqhput a t Noted

V o l t s without C o u n t e r P r e s s u r e - 110 k g / h r - 108
+
F u e l a t low t e m p e r a t u r e s :
For t e m p e r a t u r e s above 0 ° C ( 3 2 ° F ) a n y k i n d of d i e s e l oil o r e x t r a
light fuel oil may be u s e d . F u e l oil m u s t , h o w e v e r , not be u s e d for
t e m p e r a t u r e s b e l o w 0°C (32°F). I f for temperatures below O°C
( 3 2 O F ) no special winter d i e s e l o i l b u t a normal summer or
w i n t e r d i e s e l oil i s u s e d , kerosine o r g a s o l i n e s h o u l d b e added
according t o the following t a b l e :

TEMPE RRTURE SUMMER KEROSINE WINTER KEROSINE

DIESEL + OR DIESEL + OR
01 L GASOLI NE OIL GASOLINE
from O°C t o - 1 5 ' ~ 50% 50% 100% --
from - 1 5 O C to - 2 5 O C -- -- 505 50%
from -25'C t o -30°C -- -- -- 100%"
*or special w i n t e r diesel oils

Fuel l i n e s a n d f u e l m e t e r i n g pump have to be filled with the new

fuel by o p e r a t i n g t h e heater f o r 1 5 m i n u t e s .

--
ESPAR MODEL -
B1L- P : C O Y ' f

Specifications--

Heating Capacity - 1400 +

1.J - 108

Fue 1 - Gasoline
F u e l Consumption - -022 l/hr +- 10%

Electric Power Consumption - 35 W +

- 102
Vol tag@ - 12 V

Hot A i r Throughput at Noted

Volts Plithout C o u n t e r P r e s s u r e - 100 kq/hr +- 10%
The Espar heater is located in the front center of the vehicle
inside the frame in front of heater unit attached to the vehicle's
ventilating and heating systems to rear of front bumper. To remove,
jack front end of vehicle, remove four bolts from plate across
underside of frame rear of bumper. Two bolts are on front and back
of right and left side of plate. Plate and heater will drop down.
Knob is rubber covered on heater case next to control unit.
Design and Method of Operation
The complete heating system consists of a basic heater and mounting
parts, air-flow and exhaust pipes, fuel supply system and controls.

The heater is switched on by means of a switch or optional timer,

with which the switch-on time can be preselected up to 22 hours
in advance. When the heater switches on, a pilot lamp lights up,
the heating-air blower begins to advance the heating air and the
combustion air blower begins to advance the combustion air.
At the same time, the fuel metering pump advances a precisely
metered quantity of fuel into the combustion chamber. Here, fuel
and combustion air are combined to form a combustible mixture,
which is ignited at the glow plug.
The combustion gases now flow through the heat exchanger and over
the temperature switch, which switches off the glow plug. The
heating air is heated at the heat exchanger and then flows out
into the area to be heated.
When the heater switches off, the pilot lamp extinguishes; however,
the blower motor continues to run until the heater has cooled off.
It is then automatically switched off by the temperature switch.
Controls and Safetv Eauiwment
The flame is monitored by the temperature switch. This switch acts
on the safety switch in the control unit, which shuts down the
heater in the event of a malfunction.
Sequence after being switched on:
a) After a stable flame has been attained, the temperature switch
switches off the glow plug. In addition, a f t e x the heater has
been switched off it automatically stops the blower when the
heater has cooled off.
b) If the heater fails to ignite, it switches off automatically
not more than 3 minutes after switching on.
The heater can be switched on a g a i n by briefly switching the.
off and on. Do not switch on the heater again more than
 twice. I f it s t i l l f a i l s t o ignite, remedy t h e m a l f u n c t i o n i n
accordance with the TROUBLESHIOTPNG and R E P A I R I N S T R U C T I O N S .
C ) S h o u l d t h e f l a m e e x t i n g u i s h spontaneously d u r i n g o p e r a t i o n , t h e
h e a t e r w i l l automatically switch off after not more t h a n f o u r
minutes. It can be s w i t c h e d on a g a i n a s described under b ) .

d) T h e s a f e t y thermal cutout s w i t c h s t o p s t h e fuel metering pump

i f t h e h e a t e r overheats ( e . g . , i n t h e event the heating air
ducts cloq). T h e heater then s w i t c h e s o f f automaticaLly a s
described u n d e r c).
all meaeuremente are in m
P a r t 11 Electric Power System
Drawing A
Drawing B
Chapter 1--BATTERIES/ELECTRICAL WIRING SYSTEM
I- 1. Specifications of Batteries Used
1- 2. Specifications and Description
1- 3. Removal

Chapter 2--SCR CONTROL SYSTEM

2- 1. Description
2- 2. Circuit Operation
2- 3. Control
2- 4. General Maintenance Instructions
2- 5. Troubleshooting

Chapter 3--ELECTRIC MOTOR

3- 1. Description
3- 2. Maintenance
3- 2a. Bearings
3- 2b. Insulation
3- 2 c . Brushes
3- 2d. Commutator
3- 2e. Cleaning
3- 2f. Mechanical
3- 3. Disassembly Instruction
3- 4 . Repair
3- 5. Renewal Parts

Chapter 4--CHARGER
4- 1. Description
4 - 2. Schematic Wiring Diagram
4- 3. Troubleshooting
 50A FUSE MAIN

EV-1 CONTROL

COLOR CODE

I
I
I

I
I

I
 CHAPTER I: BATTERIES/ELECTRICAL W I R I N G SYSTEM

1- I . SPECIFICATIONS OF BATTERIES USED ............ 1

1- 2 . . . . . . . . . . . . .
SPECIFICATIONS AND DESCRIPTION 1
1 - 3 . REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 2
 BATTERIES/ELECTRICAL WIRING SYSTEM -q,
d
w/

WARNING--Dropping metal objects on top of the battery pack could

cause the batteries to short, result in an explosion, and cause
injury to body and property.
Batteries are toxic. They also have the same properties as any
exposed'electrical appliance - they can s:lock and ignite. Wear
safety goggles or glasses when servicing the batteries. Do not -
smoke when the battery power pack hatch is off. Do not put tools
on the battery pack, even a single light tool. Sparks and shocks
'i may result when it is picked up or moved around on the batteries.
1- 1. Specifications of Batteries Used
a. SGL -- Main Power Pack
Type: 2HGC-HC, Lead Acid Plates: 51
Weight: 69 lbs. 20 hr. Rating: 210 Length: 10-5/16
Width: 7-1/8 Height: 10-1/4 Reserve Cap. 25 AMP: 390 mins.
Minutes at 75 Amps: 100 mins.
b. SGL -- Accessory Battery
Type: 24Ht, Lead Acid Plates: 54
Weight: 55 lbs. 20 hr. Rating: 75 Length: 10-7/32
Width: 6-3/4 Height: 9-7/8 geserve Cap. 25 AMP: 100 mins.
Minutes at 75 Amps: 15 mins.
li-
I
or
i
t Type: 27HT, Lead Acid Plates: 54
Weight: 62 lbs. 20 hr. Rating: 90 Length: 11-3/4
Width: 6-3/4 Height: 9-7/8 Reserve Cap. 25 AMP: 115 mins. 1
8j
Minutes at 75 Amps: 26 mins.
1- 2. Specifications and Description
'Seventeen 6 volt and one 12 volt battery comprise the ELECTRA VAN'S
power pack for the various drive trains and auxiliary power systems.
The batteries are under warranty for 12 months. When the batteries
start to need replacement one by one, it is recommended that the
total battery pack be replaced, in,order to assure even operation of
the power pack.
Installation --
The battery compartment and all hold-downs should
be free of corrosion and rust. Corroded, frayed or overheated cable
connections must be replaced. Clean battery terminals before cables
are tightened.
 BATTERIES/ELECTRICAL WIRING SYSTEM

WARNING-- A l w a y s u s e c o m p l e t e l y i n s u l a t e d t o o l s when w o r k i n g o n b a t t e r i e s
o r t h e - - ~ l e c t r i c a lS y s t e m s . D r o p p i n g metal objects on top of t h e b a t t e r y
pack c o u l d c a u s e t h e b a t t e r i e s t o s h o r t , r e s u l t i n a n e x p l o s i o n , and c a u s e
i n j u r y t o body a n d p r o p e r t y .

T h e y a l s o h a v e t h e same p r o p e r t i e s a s any e x p o s e d e l e c t r i c a l a p p l i a n c e -
t h e y c a n s h o c k a n d i g n i t e . B a t t e r i e s c o n t a i n s u l f u r i c a c i d and can c a u s e
severe b u r n s . A v o i d c o n t a c t w i t h skin, e y e s , a n d c l o t h i n g . I n c a s e of
c o n t a c t with a c i d , i m m e d i a t e l y f l u s h s k i n o r e y e s w i t h w a t e r for f i f t e e n
minutes, for e y e s , i m m e d i a t e l y g e t m e d i c a l a t t e n t i o n . ALWAYS WEAR
P R O T E C T I O N WHEN WORKING NEAR B A T T E R I E S . D o n o t s m o k e when t h e B a t t e r y
Fewer P a c k l i d s a r e o p e n . Do n o t p u t tools on t h e b a t t e r y pack, even a
single light tool. S p a r k s a n d s h o c k s may r e s u l t w h e n i t i s p i c k e d u p o r
moved around on the batteries.

1- 1. s p e c i f i c a t i o n s o f B a t t e r i e s Used

a. E x i d e -- 102 Volt Power Pack

Type: XPV 2 3 , Lead Acid Weight: 65 l b s .
Dimensions Length: LO-3/8" Lqidth: 7-3/16" Height: 11-7/32"
Zlectrolyte: S p e c i f i c g r a v i t y f u l l y c h a r g e d 1 . 3 1 5 grams p e r c c at 7 7 F
XPV 2 3 - 2 - 1 . 3 0 0 g r a m s p e r cc
XPV 2 3 - 3 - 1 . 3 0 0 g r a m s per cc
Rating D i s c h a r g e a t 7 5 AMPS t o 5 . 2 5 V o l t s a t 7 7 F - 1 2 5 M I N S .

b. 12 V o l t Auxiliary Battery

Exide: HC 2 4 , Lead A c i d W e i g h t : 5 0 lbs.

Dimensions Length: 11-1/4" Width: 6-13/16" Height: 10"
Reserve Capacity: 1 2 0 M I N . t o 1 . 7 5 Volts per cell at 2 5 LIPS.
Amp H o u r s a t 2 0 Hour R a t e 90 AMP Hours

1- 2. Description

S e v e n t e e n 6 v o l t and o n e 1 2 v o l t b a t t e r y c o m p r i s e t h e ELECTRA V A N ' S

power p a c k f o r t h e v a r i o u s d r i v e t r a i n s a n d a u x i l i a r y power systems.
The batteries are under w a r r a n t y f o r 12 months. When t h e batteries
start t o n e e d r e p l a c e m e n t one b y o n e , i t i s recommended t h a t the t o t a l
b a t t e r y p a c k be r e p l a c e d i n o r d e r t o assure e v e n o p e r a t i o n of the power
pack.

I n s t a l l a t i o n - - T h e b a t t e r y c o m p a r t m e n t a n d a l l h o l d - d o w n s s h o u l d be
f r e e of c o r r o s i o n a n d r u s t . C o r r o d e d , f r a y e d o r overheated c a b l e con-
n e c t i o n s must b e r e p l a c e d . C l e a n b a t t e r y t e r m i n a l s before cables a r e
tightened.
 BATTERIES/ELECTRXCAL W I R I N G SYSTEM

1-1. S p e c i f i c a t i o n s of B a t t e r i e s Used

a. SGL -- Main Power Pack

Type: 2HGC HC - Lead A c i d B C I Group: GC - 2 Volts: 6
Length: 1 0 5/16" Width: 5 1/8" Height: 10 3 / 4 "
Weight: 69 l b s . AH 2 Hours:

b. SGL -- Accessory B a t t e r y
Type: 24H - Lead Acid BCI Group: GC 24 Volts: 12
Length: 10 1/6" Width: 7 1/16" Height: 8 17/16''
Weight: 45 l b s . AH 2 Hours: 90

1-2. S p e c i f i c a t i o n s and D e s c r i p t i o n
S e v e n t e e n 6 v o l t and one 1 2 v o l t b a t t e r y c o m p r i s e t h e E l e c t r a
V a n ' s power p a c k f o r t h e various d r i v e trains and a u x i l i a r y
power systems. The b a t t e r i e s a r e under w a r r a n t y f o r 1 2 months.
A t t h e end of t h a t p e r i o d , s h o u l d t h e b a t t e r i e s start t o n e e d
replacement o n e by one, i t is recommended t h a t t h e t o t a l b a t t e r y
pack b e r e p l a c e d , i n o r d e r t o assure e v e n o p e r a t i o n o f t h e power
pack.
WARNING--Dropping m e t a l objects o n top o f the b a t t e r y pack
c o u l d c a u s e t h e b a t t e r i e s t o s h o r t , result i n a n e x p l o s i o n , a n d
c a u s e i n j u r y t o body and p r o p e r t y .
Batteries a r e toxic. They a l s o have t h e same p r o p e r t i e s a s
any exposed e l e c t r i c a l a p p l i a n c e - t h e y c a n shock and i g n i t e .
Wear s a f e t y g o g g l e s o r g l a s s e s when s e r v i c i n g t h e b a t t e r i e s .
D o n o t smoke when t h e b a t t e r y power p a c k h a t c h i s o f f .
Do n o t p u t t o o l s on t h e b a t t e r y pack, even a s i n g l e light t o o l .
Sparks a n d shocks may r e s u l t when it i s p i c k e d u p o r moved
a r o u n d on t h e b a t t e r i e s .
 Controller

.gency Disconnect
Switch

Batteries s h o u l d b e s e r v i c e d only when fully charged. The water

l e v e l s h o u l d be checked every two weeks and a log s i m i l a r t o t h e
o n e m e n t i o n e d i n the Owner's Manual (pg. 41) should be maintained.
The battery t e r m i n a l s should b e tightened e v e r y t h r e e months and
torqued t o 120 lbs. I f a w h i t e c o r r o s i o n powder forms o n any o f
the terminals, t h e y shoula be cleaned w i t h w a r m w a t e r a n d baking
soda, wiped dry and c o a t e d w i t h a l i g h t f i l m of n o n m e t a l l i c grease
t o minimize c o r r o s i o n .

D I S T I L L E D WATER o n l y s h o u l d b e u s e d t o s e r v i c e t h e b a t t e r i e s . One
by one, e a c h cap s h o u l d be removed a n d distilled water added. The
e l e c t r o l y t e level should be b r o u g h t u p t o 1 - 1 / 1 6 inch b e l o w the
l e v e l of t h e i n s i d e c a p , a t the bottom of t h e r i d g e . It should
n e v e r be so high t h a t when t h e c a p i s replaced i t forces t h e water
u p and o u t of t h e battery cell nor should it be allowed t o d r o p
below the top e d g e s of t h e p l a t e s .
\
I n case o f a c i d s p i l l a g e o r d i r t a c c u m u l a t i o n , b a t t e r y tops s h o u l d
be b r u s h s c r u b b e d w i t h a s o l u t i o n o f baking s o d a -- one-half pound
per pail of warm water -- a n d thoroughly r i n s e d .

1- 3 . Removal

To remove b a t t e r y p a c k , d i s c o n n e c t a l l cables a n d c o n n e c t o r s ,
l i f t o u t by h a n d . When r e p l a c i n g , b a t t e r i e s s h o u l d be torqued to
120 pounds.
 BATTERY PACK b AUXILIARY

Controller

Disconnec
ch

Batteries s h o u l d be servicea o n l y when f u l l y c h a r g e d . The

water l e v e l s h o u l d be c h e c k e d every t w o w e e k s . a n d a log m e n t i o n e d
i n t h e owner's manual. The battery t e r m i n a l s should be t i g h t e n e d
-%-
e v e r y t h r e e m o n t h s and t o r q u e d t o 1 0 0 l b s . If a white corrosion
powder f o r m s o n any of t h e . t e r m i n a l s , they should be c l e a n e d
w i t h warm w a t e r a n d ammonia, t h e n wiped d r y . D I S T I L L E D WATER
9
o n l y s h o u l d be used t o service t h e b a t t e r i e s . One by o n e , e a c h
cap s h o u l d be r e m o v e d a n d distilled w a t e r added. The l e v e l ..
should be b r o u g h t u p to 1-1/16" b e l o w t h e l e v e l of t h e i n s i d e
c a p , a t t h e b o t t o m of t h e r i d g e .
The water l e v e l s h o u l d n e v e r
be s o h i g h t h a t when t h e cap i s r e p l a c e d i t f o r c e s the w a t e r u p
and o u t o f t h e b a t t e r y cell.

1-3. Removal
To remove b a t t e r y p a c k , d i s c o n n e c t a l l cables a n d c o n n e c t o r s ,
5
lift o u t by h a n d . When r e p l a c i n g , b a t t e r i e s s h o u l d be t o r q u e d
t o 75 pounds.
 1, EXAMINE BATTERIES, CABLES, ETC.

BATTERIES DEFEC- CABLES DEFECTIVE

_t:
IVE (broken post, ( c h a r r e d , corroded,
broken case, brok- sulfated, etc. )
en cover)
Repair or replace,
Repair cr replace c l e a n terminals
Go to 4 . Go to 4 .

4 I

BATTERIES & CABLES

APPEAR OK
Check Voltages (open
circuit)
/-I
7
5
\
6
> JJ7 8
Approximately Less than 5.8 to 6.29 v o l t s
0 , 2 , 4 volts 5.8 volts 6.1 volts or h i g h e r
per battery
O n e or more Check e l e c t r o l y t e Check e l e c t r o - Battery f u l l y
defective cells, levels. I f OK, lyte levels. recharged, .
repair or replace Recharge, Go t o 4. I f OK,. Recharge. possibly w i t h
G o to 4 . P o s s i b l y a defect- G o to '4. Probab " s u r f a c e charge1'
ive cell. P r o b a b l y ly o n l y disch- Go t o 9 . Can
Zero volts may a c e l l with l o w
indicate a "dry" arged. Possibly also u s e a "load
cell.
electrolyte level. a cell w i t h low t e s t e r k Tt o dete-
electrolyte ct possible
level. d e f e c t i v e cells.

0m
-I CHARGING TEST

Connect charger to AC lines. Read

i n i t i a l c h a r g e c u r r e n t , and current
a f t e r 1 5 minutes. I f you have a
s i n s i t i v e volt-meter, connect t h i s
from post t o post in p a r a l l e l w i t h
each c o n n e c t i o n cable. V o l t a g e drop
should b e l e s s than .010 v o l t s (10 mv)
p e r c a b l e w i t h charge c u r r e n t - 2 0 amps.

INIT-over 25 INIT-over 25 INIT-over No Readinq.-

amps, 1 5 Min- amps, 15 Kin- 15 amps, 1 5
over 1 0 amps 5 to 10 a m p s Min-less t h a n Check charger
5 amps
AC and DC
B a t t e r i e s dis- Batteries f u l l y circuits
charged. Give c h a r g e d . ~ a t t e r i e s B a t t e r i e s fully
f u l l charge. old; possibly a c h a r g e d . Batter-
Possibly a defective cell. ies a r e a l l pro-
d e f e c t i v e cell bably OK.
 14, EXAMINATION AFTER RECHARGE

Check e l e c t r o l y t e gravity and

temperature, b a t t e r y voltage.

Gravities Low Gravities-Vary Gravities-Vary Gravities-High

6 Uniform Temp-Ambient Temp-Vary & uniform
Temp-Ambient Temp-Slightly
Check l e v e l s , add "Hot" cells may above
Cells overfilled, water to low cells be defective.
flushed or spilled. g i v e an equalizing Batteries
Insufficient rech- charge. probably OK
arge, g i v e an equal-
izing charge.
 CHAPTER 2 : S C R CONTROL SYSTE?l
Page

DESCRIPTIOi4 . . . . . . . . . . . . . . . . . 2-2

CIRCUIT OPERATION . . . . . . . . . . . . . . 2-3

S C R COIITROL FEATURES . . . . . . . . . . . . . 2-5

GENERAL ,MAINTI?MAYCF TNSY'RUCTIONS . . . . . . . 2-6

TROUBLESHOOTING . . . . . . . . . . . . . . . 2-6
2- 1. Description

The n e a r t of the c o n t r o l system is a silicon controlled rectifier

(SCR). The SCR is a semi-conductor rectifier used as a latching
switch; i.e., it may assume either a conducting or nonconducting
state ( O n or Off),

CAlHODE (PIGrP

GATE

ANODE (51IUD')

The SCR can be turned ON by a momentary application of control

current to the gate. To turn it OFF, it is necessary, i n a d d i t i o n
to removing the t u r n - o n signal from the g a t e , e i t h e r to remove a l l
power from the SCR or to a p p l y momentary reverse voltage b e t w e e n
c a t h o d e and anode.

PHOTOS OF CONTROL

Fig. I . Typical SCR stotic pone) Fig. 2. Typical conlactor

2-2
 i";
-

Fig. 3. Typical accelerator switch with cover

removed

2- 2. Circuit Operation ( S e e Fiq. 4)

The control circuit is energized by closing the Key switch,

and then depressing the accelerator, thus closing the Start
switch. T h i s applies power to the control card and, if the
pulse monitor trip requirements are satisfied, turns on the
PMT driver, which will close the main contractor, completinc
the circuit to the traction motor.

T h e c o n t r o l card s u p p l i e s a q a t e p u l s e t o 2 R E C ,
turning it on
to a c a n d u c ' t i n g state, allowing current to flow from the battery
t h r o u q h lC, 2REC, lX, notor field, motor armature, current sensor,
and back to the battery. After 1 C charges, 2REC shuts OFF due to
lack of current. The control card c h e c k s that IC is charged and
u n l o c k s the gates to 1 WEC and 5 REC.

T 5 e control card than supplies a gate pulse to 1 XEC, turning it

ON to a conauctinq state, allowinq current to flow from the
b a t t e r y through L REC, nGtor field, motor armature, sensor, and
back to the battery. 5 REC t - u r n s O N a n d allows current to flow
T4-T3, lC, I R X , 5 REC L a c k to T4-T3. This current charges 1 C
positive ( c a r d ternLt?al 7 i s now positive) .
This charge is now
stored on t h e capacitor u n t i l i t is time to turn OFF 1 3 E C . T h i s
charging c y c l e o c c u r s i n less t h a n 1 millisecond ( 0 . 0 0 1 seconds)
and 5 REC s h u t s O F F .

Current continues to flow in 1 .?EC until the control card turns

ON 2 REC. !jlhen 2 ZCC conducts, capacitor 1C discharges around
the c i r c u i t composed of IT, 2 9 E C , 1 X and 1 3EC. This discharge
current opposes the 1 ) a t t c r y current through 1 ?EC until the
resulant current is zero.
 100'h- - - PEA%
CURRENT

-
,oo/,- -.-- - - - -. -i
., AVERAGE
CURRENT

ON OFF O H OFF ON O F F
TIME

Fig. 5. Battery current

W i t h reverse voltage a c r o s s 1 REC, 1 REC i s t u r n e d OFF. Current

c o n t i n u e s t o f l o w i n lC, 2REC, motor and t h e b a t t e r y l o o p u n t i l
the c a p a c i t o r (card t e r m i n a l 7 ) is fully charqed negative. This
charge e x c e e d s b a t t e r y v o l t a g e by a n a m o u n t w h i c h i s a f u n c t i o n
of m o t o r c u r r e n t , a n d 2 QEC t u r n s OFF. Figure 5 i l l u s t r a t e s t h e
p u l s i n g o f c u r r e n t f r o m the b a t t e r y .

D u r i n g t h e OFF t i m e , t h e energy stored i n t h e m o t o r , by v i r t u e

of i t s i n d u c t a n c e , w i l l cause c u r r e n t to c i r c u l a t e t h r o u g h the
m o t o r a r o u n d the loop formed by 3 R E C , t h u s p r o v i d i n g w h a t i s
called "flyback current." F i g u r e 6 s h o w s the nature of t h e m o t o r
c u r r e n t , w h i c h i s c o m p o s e d of b o t h b a t t e r y current a n d t h e
inductive flyback c u r r e n t . I t s h o u l d b e noted t h a t t h e average
motor current measured w i l l be g r e a t e r t h a n the a v e r a g e battery
current. The SCR control, in effect, c o n v e r t s b a t t e r y c u r r e n t
a t battery v o l t s i n t o a h i g h e r motor current a n d a l o w e r m o t o r
volts. T h e t i m e f o r t h e n e x t On and O f f c y c l e t o s t a r t i s
determined by the t i m e that t h e c o n t r o l c a r d t a k e s t o oscillate.
T h e o s c i l l a t i o n times are c o n t r o l l e d by the potentiometer i n t h e
accelerator. S l o w s p e e d i s o b t a i n e d by h a v i n g maximum ohms i n
t h e potentiometer. A S t h e resistance i n the p o t e n t i o m e t e r
decreases, t h e speed of t h e motor i n c r e a s e s .

--
ON OFF ON OFF OM OfF
TIME

Fig. 6. Motor current

2- 3. S C R C o ~ t r o lFeatures

oSCTLLATOR--The oscillator section of the card has two adjustable

features, creep s p e e d and controlled a c c e l e r a t i o n , and one fixed
feature, top speed.

I q ON
5 50 95 TIME
CS SCR range TS

Fig. 7. Oscillator irequency curve

When the accelerator potentiometer at maximum ohms, the c r e e p

s p e e d c a n be adjusted w i t h a trimpot on the card. Top speed is
f i x e d b y card design, and is obtained w i t h the a c c e l e r a t o r
potentiometer at minimum ohms.

T h e r a t e a t which the oscillator nay increase its percent OW

tine is limited by "Controlled Acceleration." The minimum
time required to g o from creep speed to maximum percent o n
time m a y be varied b y an indexed trimpot ( C / A ) on the card,
adjustable from approximately 0.5 seconds to 1.0 seconds.

T h e p e r c e n t ON t i n e h a s a r a n q e o f a p p r o x i m a t e l y 5 t o 9 5 percent.
The center operating condition of the o s c i l l a t o r i s a t 5 0 p e r c e n t
O?l time w i t h a n o m i n a l 1 . 7 milliseconds ON time and 1.7 milli-
second OFF time. This corresponds to a maximum operating
frequency o f a b o u t 3 0 3 h e r t z . A t creep the 0 l J time will decrease
to a p p r o s i m a t e l y 0 . 8 milliseconds while OFF time will become i n
t h e o r d e r of 2 0 milliseconds. A t f u l l SC!? operation, t h i s
condition will be r e v e r s e d (short OFF time, long ON tine). T h i s
variatioc of ON a n d OFF time of t h e oscillator produces the
optixum frequencies t h r c u g h t h e SCR r a n q c . See F i g u r e 7.
C U R R E K T LIMIT--This circuit m o n i t o r s motor current by utilizing
a sensor in series with the armature. The information detected
<?cross the s e n s o r is f e d back to t h e c a r d s o current may be
l i n i ! - : d to a maxirnum safe v a l u e . If heavy Load currents a r e
#N
I
l4
!
d e t e c t e d , this c i r c u i t o v e r r i d e s t h e o s c i l l a t o r and l i m i t s t h e
t-
a v e r a g e c u r r e n t . An i n d e x e d t r i m p o t for t h e c u r r e n t l i m i t ( C / L )
a d j u s t m e n t i s p r o v i d e d t o m a i n t a i n t h e peak v o l t a g e o n t h e
I - capacitor within i t s r a t i n g when u s e d o n high source i n d u c t a n c e
i a n d / o r l o w motor r e s i s t a n c e a p p l i c a t i o n s . B e c a u s e o f t h e fly-

iI1l I
back c u r r e n t t h r o u g h 3 REC, t h e m o t o r c u r r e n t u s u a l l y r u n s 2 t o
3 times t h e b a t t e r y c u r r e n t .

2- 4. General Maintenance I n s t r u c t i o n s

The SCR c o n t r o l , l i k e a l l electrical apparatus, does have some

t h e r m a l losses. The s e m i c o n d u c t o r j u n c t i o n s have f i n i t e t e m p e r a -
t u r e l i m i t s a b o v e w h i c h t h e s e d e v i c e s may b e damaged. For t h e s e
r e a s o n s , normal m a i n t e n a n c e s h o u l d g u a r d a g a i n s t a n y a c t i o n
which w i l l e x p o s e t h e c o m p o n e n t s t o excessive h e a t , s u c h a s
s t e a m cleaning; o r w h i c h w i l l r e d u c e t h e h e a t d i s s i p a t i n g a b i l i t y
of the c o n t r o l , such a s r e s t r i c t i n g a i r f l o w .

The f o l l o w i n g D O ' S a n d D O N ' T S s h o u l d be o b s e r v e d :

--Any c o n t r o l s that w i l l be used i n a m b i e n t s o f 1 0 0 ° F (40°C)

o r o v e r s h o u l d be brought t o the a t t e n t i o n of the manu-
f acturer .
--All e x t e r n a l c o m p o n e n t s h a v i n g i n d u c t i v e c o i l s must be
filtered. Refer t o v e h i c l e m a n u f a c t u r e r for s p e c i f i c a t i o n s .
--The c o n t r o l s h o u l d not be steam cleaned. I n d u s t y a r e a s ,
u s e l o w - p r e s s u r e a i r t o b l o w o f f the c o n t r o l . I n o i l y or
g r e a s y a r e a s , a mild s o l u t i o n of d e t e r g e n t o r d e n a t u r e d
a l c o h o l c a n b e used t o wash o f f the c o n t r o l a n d t h e n b l o w
completely dry w i t h l o w - p r e s s u r e a i r . The c o n t r o l c a n
a l s o be c l e a n e d with F r e o n TF degreaser.
1 2- 5. TROUBLESHOOTING I N S T R U C T I O N S

i T h e p u l s i n g o f the main SCR i s too fast f o r c o n v e n t i o n a l i n s t r u m e n t s

t o measure. When t h e c o n t r o l i s f u n c t i o n i n g p r o p e r l y , a l o w hum c a n
be h e a r d .

M a l f u n c t i o n s of t h e SCR w i l l g e n e r a l l y f a l l i n t o o n e o f t w o
categories. They a r e either n o power ( T a b l e 1 ) o r f u l l power
(Table 2 1 , when operating i n the SCR c o n t r o l r a n g e .
These simple and e a s y - t o - f o l l o w t a b l e s outline t h e various symptoms
and t h e c o r r e c t i v e a c t i o n t o be t a k e n .

T h e same d e v i c e d e s i g n a t i o n s h a v e b e e n m a i n t a i n e d on d i f f e r e n t
c o n t r o l s but the w i r e n u m b e r s may v a r y . Refer t o the e l e m e n t a r y
and wiring diagrams f o r your s p e c i f i c c o n t r o l . The w i r e numbers
shown on the elementary diagram will have identical numbers on
the c o r r e s p o n d i n g wiring d i a g r a m s f o r a specific vehicle but
thcse numbers may be different from the numbers referenced in
this publication.
WARNING : BEFORE TROUBLES HOOTING, JACK UP WHEELS,
DI SCONNECT THE BATTERY AND DISCHARGE CAPACITOR 1 C .
RECONNECT THE BATTERY A S NEEDED FOR THE S P E C I F I C
CHECK.

If capacitor 1C terminals are not accessible, discharge capacitor

by connecting from SCR POS terminal t o 2 REC anode. Check resistance
on RXlOOO scale from frame to SCR power and control terminals. A
resistance of less than 20,000 ohms can cause misleading symptoms.
Resistance less than 1000 ohms should be corrected first.
Before proceeding, visually check for loose w i r i n g , maladjusted
linkage to accelerator switch, signs of overheating of components,
etc.
Tools and test equipment required are: (a) 6-volt lamp, 6-volt
battery, two A 1 4 diodes ( 1 Amp 400V), clip leads, volt-ohm meter
(20,000 ohms per volt) and general hand tools, or ( b ) EV-1 System
Analyzer, volt-ohm meter (20,000 ohms per volt) and general hand
tools. If the system a n a l y z e r is used, refer to the analyzer
instruction book.

F U N C T I O N OF EV-1 CARD TERMINALS FOR IC36450SC5 A N D E 5 CARDS

TERYI: NALDESCX PTION CONDI TION NOMINAL

(Voltage measurements with respect to negative, VOLTS
SCR power t e r m i n a l . )

L3,4,5,7 Card power supply Key open

i n p u t m u s t be l o w Key closed
to satisfy PMT
reset.
L6 M o t o r current No c u r r e n t 1.8
sensor output
500 Amps average motor 3.3
c u r r e n t model " B "

Start switch Key Open 0

input Key closed, BV
Accelerator depressed
Card power s u p p i y Key off
K e y on
TERMINAL DE SCRI P T I O N CONDI TI ON NOMI NAL .
VOLTS

R2 1 A thermal h o l d o f f
c o n t r o l jumper t o
R4 to disable 1 A
thermal holdoff
Output to PMT
Driver
Key o n , c o l d T / P 0
Key o n , t h e r m a l 0 . 6 6 o r more
cutback
Key off 0 Volts
Key c l o s e d , 5-10 rnilliamps
accelerator depressed.
See Note 1.

Common r e t u r n t o Key o f f , u s e VOM and Less t h a n 1

card for accele- read from TBR4 to "Neg. " ohm
rator p o t and 1 A
switch

A c c e l e r a t o r pot Xey o n and accelerator 3-4

input at "creep."
Key on and a c c e l e r a t o r 0-.2
at top s p e e d .

R7 8 ON time o u t p u t . C r e e p speed
Top speed

NOTE I : C o n n e c t m i l l i a m r n e t e r f r o m t e r ~ i n a lto R4. I f contactor

picks up d u r i n g t h i s test replace d r i v e r . If z e r o
milliamps open lead and recheck t o e l i m i n a t e possible
d r i v e r s h o r t from t e r m i n a l 1 to 2 ,

ALL TESTING SHOULD BE DONS WITH VEHICLE JACKED UP.

TABLE 1

FAILURES WHXCH CAUSE REDUCED OR NO IIOTOR TOFQUE

WITH SCR CONTROL

Trouble s h o o t i n g i s based on using t h e v o l t m e t e r t o d e t e r m i n e i f

the proper voltages a r e a v a i l a b l e t o p e r m i t the c o n t r o l t o o ~ e r a t e
properly.
SYMPTOM PROBABLE CAUSE

1A. C o n t a c t o r s do not p i c k - O Check power a n d control fuses.

up. No c o n t r o l voltage
from positive t o nega- O C h e c k battery for l o w s p e c i f i c
tive. g r a v i t y and c o n n e c t i o n s f o r
looseness or broken f i t t i n g s .
SYMPTOM PROBABLE CAUSE

LB. C o n t a c t o r s do n o t pick- O Plug i n battery w i t h Key s w i t c h

up. Control v o l t s OFF. Volts on L3 s h o u l d be l e s s
p r e s e n t from p o s i t i v e than 4 v o l t s .
t o n e g a t i v e with proper
polarity. O Close Key switch.
C h e c k v o l t s a t T2 ( p i n 10). Should
be about 5 0 8 of b a t t e r y v o l t s . Above
7 0 % locks o u t 1 REC. ( C o n t r o l card
c o n t a i n s a 1 0 K bridge from p i n 5 to
L3 and pin 6 . ) I f near b a t t e r y v o l t s ,
check f o r s h o r t e d 1 REC. I f near z e r o
v o l t s , check for s h o r t e d 3 REC ( 4 G ) .

O Close B r a k e . V o l t s on L 3 , L S , L7
should be battery volts. V o l t s on L9
should b e n e a r z e r o . Wait f o r one
I second, t h e n depress a c c e l e r a t o r .
V o l t s a t L9 and L9 side of F c o i l
should be battery v o l t s . I f not,
check w i r i n g and s w i t c h e s .

" Connect milliarnetex ( L O m a s c a l e )

from R 3 t o R 4 . Should read 5-10
milliamps. I f n o t , open Key switch,
open lead from R 3 t o PMT d r i v e r , r e -
-
c l o s e k e y s w i t c h , wait over o n e
second and d e p r e s s a c c e l e r a t o r s w i t c h .
I f r e a d i n g i s n o t 5 - 1 0 milliamps,
r e p l a c e c o n t r o l card. I f reading i s
good, the c o i l o r wiring t o t h e PYT
d r i v e r i s open o r t h e PNT d r i v e r i s
defective. Check d r i v e r ($El.

1C. C o n t a c t o r s c l o s e . NO
power and NO S C R hum
w i t h a c c e l e r a t o r i n SCR
range.
O Check v o l t s a t S C R p o s i t i v e .
S h o u l d be b a t t e r y v o l t s . If n o t ,
c h e c k power f u s e .
O Check v o l t s a t T 2 . Fhould be z e r o .
I f n o t , c h e c k v o l t s a t S 1 , 52, A l ,
a n d A 2 t o l o c a t e open circuit.

O Check volts at P5. S h u u l d be 3-4 at

creep reducing to 0.2 o r less a t t o p
speed. I f R 5 remains about 4 v o l t s ,
check accelerator. I f R 5 i s zero,
check v o l t s at 81. Should be 8 - 8 . 5
v o l t s . I f Rl i s above'l0 or near z e r o
a n d L3 i s battery v o l t s , replace -
c o n t r o l card and c h e c k PXT d r i v e r f3r
s h o r t (4E).
SYNPTOM PROBABLE CAUSE

1C. Contactors close. NO " Check volts at R7. Should be 2-2.3

power and >!O SCR hum when Xey s w i t c h closed.When accel2-
with accelerator in SCR rator is depressed, should increase
range. to about 6 . 2 volts. I f r e m i n s near 2
(Cont'd.) volts, check volts at 1C ( g r e y wire or
2 REC anode). If more than 0 . 1 2 5 BV
check if 2 E C will gate on ( 4 G ) . If
less than 0.125 B V , check if 1 REC w i l l
g a t e on (45). Check current sensor
green lead to card input pin 1 3 -
1D. Contactors close. Little " Check 3 E C f o r open c i r c u i t ( 4 H ) .
or no power. ?;orma1 SCR
hum. " Check 4 REC for short ( 3 H ) .
" Check for open thermal protectpr (43).

1E. Contactors c l o s e . Little O Check 2 REC for short ( 4 ~ ) .

or no power. Abnormal
SCR hum. O Check 5 REC for short ( 4 G ) .
O Check 22 PEC and 2 5 REC (4M).
NOTE: A 2 5 REC which checks good with
an ohmmeter can cause a misoperation
of 5 REC under load.
IF. Contactor closes, little O Check 1C for low resistance ( 4 8 ) .
power, no SCR hum.

TABLE 2

F A I L U R E S W H I C H CAUSE FULL MOTOR TORQUE WITH SCR CONTROL

WMPTOM PROBABLE CAUSE

2A. Contactors close. Full O Key switch on.

SCR speed immediately Check volts at R5. Should be 3-4 volts
w i t h a u d i b l e hum. NO at creep position. If n e a r zero, check
PMT trip. Accelerator potentiometer (4D).
O Replace control card ( 4 A ) .

2B. Contactors close once or O Check 5 W C for open circuit or open

twice and then remain gate ( 4 G ) .
open. PHT trips.
Check 1C for open and connections (4B).
C h e c k 1C for dead short ( 4 8 ) .
SYMPTOM PROBABLE CAUSE

28. Contactors close once or O Check 5 RE€! f o r short.

twice and t h e n r e m a i n
open. PMT trips. O Check 2 REC f o r s h o r t .
(cont'd.
O Check 1X c h o k e and transformer
T3-T4 (4N).

O Replace c o n t r o l c a r d ( 4 A ) .

C o n t a c t o r s close, S t a l l " Check current s e n s o r yellow lead

currents, under SCR from negative end of s e n s o r to
o p e r a t i o n , higher than card i n p u t p i n 1 4 .
normal and u n c o n t r o l l a b l e
w i t h C / L trimpot. Con- a Replace c o n t r o l c a r d (4A).
t a c t o r s may o p e n o n c e
o r twice a n d t h e n remain
open.

TABLE 3

MI SOPERATI ON OF OTHER FEATURES

SYMPTOM PROBABLE CAUSE

3A. PMT does n o t open O Operate traction d r i v e .

contactor. Jumper R 3 t o R4. I f c o n t a c t o r does
n o t drop out, replace PMTD d r i v e r .
3B. Blown power f u s e . O Check 3 IiEC for s h o r t ( 4 H ) . (Possible
Very h o t power c a b l e s . damage a l s o t o 1 REC a n d transformer
module. )

TABLE 4

C H E C K I N G COMPONENT'S

4A. Main SCR Control C a r d

All troubleshooting is written to c h e c k all outside d e v i c e s a n d

e l i m i n a t e them a s the s o u r c e of s y m p t o m s . The conclusion being
then that the card is faulty.
 1. Instructions for Removal of C a r d

a . Remove k h e f o u r ( 4 ) screws shown in '+'i?!urc? 3 .

5 . J a c k out t h e r i g h t - and l e f t - h a n d ~ e ; & : i n a l b o a r d ,
r i s i n c ; 2 screwdriver i n the s l o t s , ;fI-.ea~rir-ir: t h e ..-;ires
i n t ~ c t )a s shown i n F i g u r e 1 0 .
c. P r y a p e n t h e l a t c h e s c a r e f u l l y w i t h (I .;cre;.v-iirivcr a s
shown i n F i g u r e 11.
d . .;ack o u t + h e bottom p l u g w i t h .A screwdriver 2s shown
i n P3i/:;ure 1 2 .
T h e c ~ r d::an
. .- be .$e:goW& by h i n g i n y 1 0 decr$&b -4rn'CI.~q&&.gn1~ out, OL-,
1; p a n e l C'ompon&i'k~e(:?bt r e l a t e d to c a r d :fi&$*'*06e5ri$;-;) a r e to be
r e p l a c e d , d lsrr?i-&'d-a.11 instructions abos~e:~ and the card
e.aY:Csefi,r;~'*:~~
will h i n c ~ eu s to 3 0 d e q r e s s .

Remove T B
Retarnrna Screws
Retarnrng

Card

Fig. 9. Fig. 71.

---3%- insert Screwdriver

and Tw~st

Fig. 70. Fig. 12.

 4B. Capacitor 1C
Disconnect battery and discharge capacitor. Measure ohms through
the capacitor using the R x 1 0 , 0 0 0 scale. Meter s h o u l d read zero
a n d then s w i n g slowly to above 300,000 ohms. Replace capacitor if
above reading i s not o b t a i n e d .
4C. Contactor
See GEH-4469

NOTE 1: Most contactor coils are polarity sensitive. The

left-hand terminal must be connected to positive.
4D. P o t e n t i o m e t e r in Accelerator
To check operation of the potentiometer, disconnect battery and
disconnect wires at card terminal R 4 and R5. Connect a VOM t o
wire removed with scale set to R x 100. With accelerator in
creep speed position, the ohms r e a d i n g s h o u l d be 4800 to 6000
ohms. With accelerator in top speed position, reading should be
.,>. 2 0 0 ohms or less. With wire disconnected as above, check for
resistance of 1 megohm or higher from pot w5res to truck frame.
4E. Driver Module
IC3G4 5CPMI RDB2

(a) Connect circuit as shown.

(b) Voltmeter should read battery
v o l t s with s w i t c h open. + 3 \+
( c ) C l o s e s w i t c h and meter Simpson
reading should be 3 volts or 50 volts d-c scale
less.
i d ) Move l o a d to terminal 4 a n d
repeat steps ( b ) and ( c ) .
4F. SCRs (1 RLC, 2 3 E C , 5 R E C )

These a r e silicon c o n t r o l rectifiers. Before checking, disconnect

battery and discharge capacitor 1 C . D i s c o n n e c t o n e power connection
o n the rectifier. Disconnect gate leads of SCRs at the card plug.

T o check a n S C R ,
it i s n e c e s s a r y to have a 12-volt battery, a 1 2 -
volt lamp and 2 A - 1 4 diodes.

C o n n e c t the positive l e a d to the anode (I), connect negative Lead

to t h e c a t h o d e ( 3 ) a s s h o w n i n F i g u r e 1 3 .
 A 1 4 O R ECIIJAL 203 V

Anode Cathoac Sdfa 12,

Gnre ,21

(Top V~e..v)

Fig. 13.

(a) The lamp should not light. I f t h e lamp does l i g h t , t h e

SCR i s shorted a n d must be replaced.
( b ) I f check ( a ) was satisfactory, test t h e SCR f o r its
ability to be turned on by the gate. Connect p o s i t i v e
through two diodes to g a t e ( p o i n t 2 ) . I f gate is
operative, the lamp will come on a n d s h o u l d remain on
when t h e gate i s r e m o v e d . Some S C R ' s w i l l operate
correctly even i f t h e lamp does n o t r e m a i n on, particularly
with a weak b a t t e r y .
( c ) I f lamp c a n n o t be l i t under s t e p ( b ) the SCR is o p e n and
must be r e p l a c e d .
( d l If the SCR is a stud-type device, check c o n t i n u i t y
between the red a n d black cathode l e a d s .

iL'OTE: I f you d o n o t h a v e a t e s t light t o c h e c k the SCR's a s

described a b o v e , t h e y may be checked f o r shorts o r o p e n s by
u s e of t h e VOM.

(1) Measure r e s i s t a n c e f r o m anode t o c a t h o d e ( R x 1 0 0 s c a l e ) .

If SCR i s s h o r t e d ( z e r o o h m s ) , i t must be r e p l a c e d .
( 2 ) Measure r e s i s t a n c e from g a t e lead (white l e a d ) to
cathode and t h e n from cathode to g a t e lead ( R x 1 s c a l e ) .
I f r e s i s t a n c e reads e i t h e r z e r o ohms (shorted) o r i n f i n i t y
ohms ( o p e n ) , r e p l a c e t h e SCR.

When reassembling S C R ' s , r e f e r t o TABLE 5.

4H. Rectifiers ( 3 REC, 4 Q E C , D i o d e Blocks)

When checking d i o d e s , d i s c o n n e c t b a t t e r y and d i s c h a r g e c a p a c i t o r

1C t o prevent burning out the ohmmeter. When r e p l a c i n g r e c t i f i e r s ,
r e f e r t o TABLE 5 . F o r 3 a n d 4 REC, disconnect one lead or f l e x i b l e
connection. 3 and 4 REC are d i o d e s w i t h a b o u t 7 to 12 ohms i n t h e
 d
conducting d i r e c t i o n ( + -) m e a s u r e d on
the R x 1 s c a l e , a n d 1 0 , 0 0 0 ohms o r ;igher, in t h e non-conducting
direction !- -----4--+ ) measured on the R x 1 0 , 0 0 0 s c a l e .

Anoae Cathode

Anode Cathode
Anode

Thick
End

45. Thermal Protector ( T P )

Remove both connections from TP and with a VOM r e a d less than

200 ohms terminal to terminal, if heat sink i s at room temperature.
Set VOM t o h i g h e s t O ~ Tscale and c h e c k p i n s t o heat sink, r e a d i n g
should be infinity.

4K. " F i l t e r Black ( W , 2 3 FIL, etc.

To check d i s c o n n e c t a l l w i r e s f r o m filter block. With VOK o n

R x 10,000 scale, touch the lead to the filter terminals to
charge the filter. After a f e w seconds, reverse the meter
leads a n d t o u c h t h e f i l t e r t e r m i n a l s . The VOM n e e d l e w i l l
deflect and r e t u r n t o i n f i n i t y . I f this capacitor action is
not observed, replace t h e f i l t e r b l o c k .

4L. Filter Block--23 RES, etc.

Should t h e s e filters fail, i t will be evidenced v i s u a l l y by

severe cracking.

4M. Filter Block--22 REC, 25 E C

?!>e c a p a c i t o r f i l t e r t e s t , a s i n 4 K , is v a l i d f o r 2 2 REC a n d 25
RCC only t o d e t e c t a n o p e n o r s h o r t e d f i l t e r . T f control h a s
s y m p t o m s a s in 16, interchange 22 REC and 2 5 RCC a n d t r y a g a i n .
I f problem is c o r r e c t e d the o l d 2 5 REC is mar4inal. If problem
is ~ o corrected,
t replace both f i l t e r s with k n o w n good filters.
4N. I X Choke--Transformer Secondary T3-T4

R e f e r to p a n e l wiring diagrams ( p a g e 1 6 ) to locate w i n d i n g s . With

VOM o n R X - 1 scale, check choke w i n d i n g or transformer secondary,
r e a d i n q s h o u l d be zero ohms.
 THERE IS NO
POLARITY ChR
i l THEP T E W I W L
Z A f . HC I 'F 2 .

WIRES \ mC CARD PLLG

7%
RE4R V l EW WI TG
CWER R M W E D

-
WIRE TLBLC

WIRE NO. YIRC COLID TO

0 3 512C DEVICE TCW MIICE TEsl
arS 4 r)EC A 3 9EC A
815 PTB T2 3 RfC C
BUS 4 1EC A P7B N
BUS I R f C C T Tt
BUS 1 'IEC 4 PTB P
BU5 3 8EC C T 71

:,{
ABWE
#8
*8
111
18
BLK
BLX
EL*
BLX
U R C C
2IIEC
2 REC
I RtC
A
A
1x1

A
T
1
2C
ZC
1x1
r)
I
2

4 RCC LEAD 4 9EC C PTB A1

2 9EC LEAD 2 9EC C Z IIEC 1% I
5 ICC LC~O 5 arc c 22 REC 74

SMWT LEAD EL SHT 2 TBZ 14

5"T I re2 13
$22 BLU 3 QEC A 782 6

N I 2 1 12
m, I .a 11
VIO 3 QCC C T E 10
2 IEC C T a 9
2 9 ~ ' LEAD )1T 2 RCC c TLP 8
$22 G-7 ZC 1 782 7

wlsl{ : BLK
WT/BLL
I REC
I KC
c
c
762
In7.
5
1

5 RE( L C 4 0 QED 5 -C C T B 3
TY,5T{
5 SEC '.FA: U T 5 m t TB1 2

ru WT/RED lc z ra I
,z2 WT/CIDI 23 FIL 12 3 SEC C
*
Fig. 18. Model C wiring diagram
 CHAPTER 3 : DC ELECTRIC MOTOR
Page

DESCRIPTION . . . . . . . . . . . . . . . . . . 3-2

BEARINGS . . . . . . . . . . . . . . . . . . . 3-2

INSULATION . . . . . . . . . . . . . . . . . . 3-3

BRUSHES . . . . . . . . . . . . . . . . . . . . 3-3

COMMUTATOR . . . . . . . . . . . . . . . . . . 3-3

CLEANING . . . . . . . . . . . . . . . . . . . 3-3

MECHANICAL . . . . . . . . . . . . . . . . . . 3-4

DISASSEMBLY INSTRUCTION . . . . . . a * . . . . 3-4

FAILURE . . . . . . . . . . . . . . . . . . . . 3-5

REPAIR . . . . . . . . . . . . . . . . . . . . 3-5

RENEWAL PARTS . . . . . . . . . . . . . . . . . 3-5

 DC E L E C T R I C YOTOR

3- 1. Description

S e r i e s Wound, C l a s s H I n s u l a t i o n , 2 0 h p a t 4 7 0 7 rpm, 4 :#lain i 3 n l c 2

and C o i l s , Shifted Nonadjusted Rrush R i g g i n g , B l o w e r Ventilak5d

The armature assembly consists of a s h a f t , armature core,

a r m a t u r e w i n d i n g s , a n d commutator. T h e c o i l e d f ramc c o n s i s t s o f
t h e m a g n e t frame, m a i n p o l e s a n d c o i l s , a n d the field t e r m i n a l s .
O t h e r b a s i c p a r t s of the motor include the d r i v e e n d b e a r i n g
b r a c ! < e t , c o m m u t a t o r e n d bearing b r a c k e t , b e a r i n g s , bearina s e a l s
(when s u p p l i e d ) , b r u s h h o l d e r yoke w i t h h r u s h h o l d c r s , b r u s h c s a n d
b r u s h h o l d e r s p r i n q s , and c o v e r s . O p e n i n g s o v e r the brushholders
p r o v i d e accessibility to t h e b r u s h r i g g i n g a n d commutator f o r
inspection and brush replacement.

90 NOT OPERATE A S E R I E S 1 0 T O R UNLOADEn AS

iJARNIi\!G:
EXCESSIVE S P E E D L N Y OCCUP P I H I C I I CAN C A U S E DAPIAGE 'r0
TIIE !!OTOR AND I N J U R Y T O PERSONNEL.

3- 2. Maintenance

WARNING: IF POSSIBLE, N A K E SURE MOTOR I S DISCONF!EC?'ED

FRObI POIqER SOURCE BEFORE PERFORMING ANY ?*IAINTENANCE
OPERATIONS ON THE MOTOR. WHEN POlJER IS REQUTRED TO
PERFOW1 A N Y MAINTENANCE, VIGILANT CARE A N D ATTENTION
SHOULD BE E X E R C I S E D .

S t a n d a r d B e a r i n g s a r e t h e s i n g l e row, d o u b l e d s h i e l d e d , C o n r a d
t y p e p r e - l u b r i c a t e d with h i g h t e m p e r a t u r e grease w i t h ABECl
t o l e r a n c e a n d AFMBA $ 3 i n t e r n a l r a d i a l c l e a r a n c e . Standard
b e a r i n g s do ' n o t r e q u i r e l u b r i c a t i o n . Under n o r m a l c o n d i t i o n s
the bearings f a i l after s e v e r a l years s e r v i c e d u e e i t h e r F r o m
d i r t y c o n t a m i n a n t i n the g r e a s e o r i n s u f f i c i e n t o i l in the yrease
New g r e a s e c o n s i s t s of a b o u t 8 0 % o i l , 2 0 % soap. When b l e e d i n g
r e s u l t s i n a r e d u c t i o n of oil t o a b o u t 6 0 8 , t h e bleed r a t e i s
r e d u c e d t o a l e v e l that may n o t s u p p l y s u f f i c i e n t l u b r i c a t i o n .
For t h i s r e a s o n when m a i n t e n a n c e o v e r h a u l s a r e performed a f t e r
s e v e r a l y e a r s of s e r v i c e , b e a r i n g s are a u t o m a t i c a l l y replaced a s
a routine practice. A b e a r i n g should b e r e p l a c e d with a n e s a c t
r e p l a c e m e n t c r o n e w i t h a l l interchangeable f e a t u r e s . It i s
especially i m p o r t a n t that t h e b e a r i n g h a v e high t e m p e r a t u r e
grease.
3- 2b. Insulation

I n s u l a t i o n r e s i s t a n c e s h o u l d be c h e c k e d d u r i n g e a c h m a i n t e n a n c e
inspection. Low r e s i s t a n c e m a y b e c a u s e d by e x c e s s i v e d i r t ,
x o i s t u r e o r impending f a i l u r e . A l t h o u g h motors c a n be s u c c e s s -
f u l l y r u n with i n s u l a t i o n r e s i s t a n c e a s l o w a s 1 / 4 megohm i t i s
well t o i n v e s t i g a t e t h e r e a s o n s f o r a n y i n s u l a t i o n r e s i s t a n c e
b e l o w 1 rnegohm. Low r e s i s t a n c e v a l u e s d u e t o d i r t c a n u s u a l l y
be c o r r e c t e d by c l e a n i n g f o l l o w e d by a v a r n i s h d i p a n d b a k e . Low
r e s i s t a n c e d u e t o m o i s t u r e c a n be c o r r e c t e d by b a k i n g t h e m o t o x
i n a 90°C o v e n u n t i l the i n s u l a t i o n r e s i s t a n c e r i s e s above t h i s
value a n d stabilizes t o a n e a r l y c o n s t a n t v a l v e . A new motor
s h o u l d withstand for o n e minute w i t h o u t b r e a k d o w n t h e a p p l i c a t i o n
of 6 0 Hertz potential 1 2 0 0 v o l t s . O l d motors s h o u l d be t e s t e d a t
7 5 % of t h e s e v a l u e s .

3- 2c. Brushes

B r u s h c o n d i t i o n a n d r e m a i n i n g b r u s h l i f e s h o u l d be c h e c k e d a t e a c h
maintenance inspection. i?hen i n s t a l l i n g new b r u s h e s , e a c h b r u s h
s h o u l d be s a n d e d i n t o t h e c u r v a t u r e o f the c o m m u t a t o r for m o s t
reliable performace. A m i n i m u m of 859- s u r f a c e c o n t a c t with 1 0 0 %
brush a r c i s recommended. R e p l a c e m e n t b r u s h e s s h o u l d be e x a c t l y
t h e same b r u s h grade a s o r i g i n a l .

3- 2d. Commutator

Commutator r u n o u t s h o u l d not exceed . 0 0 2 " t o t a l i n d i c a t e d r u n o u t

with a b a r - t o - b a r v a r i a t i o n of . 0 0 0 2 " . The m i c a b a r - t o - b a r
insulation s h o u l d a l w a y s be k e p t b e l o w t h e c o p p e r s u r f a c e . Khen
c o m m u t a t o r wear r e s u l t s i n f l u s h o r p r o t r u d i n g m i c a , the m i c a
s h o u l d be u n d e r c u t t o a d e p t h e q u a l t o t h e t h i c k n e s s o f the mica
o r about .025", The u n d e r c u t s l o t s h o u l d be k e p t clean a n d free
of dirt.

3- 2e. Cleanina
B o t h t h e i n t e r i o r a n d exterior o f t h e motor should be kept c l e a n
a n d f r e e of d i r t a n d g r e a s e . Loose d i r t may be removed by vacuum
c l e a n i n g o r b l o w i n g with compressed a i r . '2acuurn c l e a n i n g i s p r e f e r r e d
because compressed a i r m a y d r i v e d i r t d e e p e r i n t o cracks a n d
v o i d s i n the i n s u l a t i o n s y s t e m . L o o s e d i r t c a n be removed w i t h
a c l e a n i n g rag or a s o f t b r i s t l e b r u s h . Clogged a i r o p e n i n g s
should be c l e a n e d o u t u s i n g c a r e n o t t o damage i n s u l a t e d p a r t s .
O i l a n d g r e a s e may be removed by w i p i n u w i t h a c l e a n cloth
dampened s l i g h t l y w i t h FREON TF (a fluorinated h y d r o c a r b o n s o l v e n t
made by D u P o n t ) o r P e r c h l o r e t h y l e n e .
 C A L I : 'FIE: CLOTF Si?OFLD NO'!' OF ::JET, PQR L I Q t ' I D
SOLVC?IT >!LAY CARRY E L E C T R I C ; I L C3?:LlXCTI>TC D I R T DEEP
INTO CRACKS A N D V O I D S I V T I E I N S U L A T T O S SVSTE.".I.
If insulation resistance is !ow a f t e r cleaninn it n a y be necessary
to either Sake the a r m a t u r e a t 3 0 ° C to remove moisture o r t c ,
varnish t r c a t a n d S a k e .

C h e c k f o r u n u s u a l n o i s e s or v i b r a t i o n which were not present when

the u n i t was o r i y i n a l l y i n s t a l l e d . Chcck all e l e c t r i c a l and
nechanical connections for tightness. C l e a n screen covers a n d
v e n t i l a t i n q ducts.

3- 3. -
3isassembly Instruction

The following instruction will describe t h e disassembly process of

a s t a n d a r d motor. I t s h o u l d be recognized t h a t s ~ e c i a lrequire-
ments and special a p p l i c a t i o n s require special construction and
there will be many variations to which standard instructions do
not a p p l y . The following s t e p s will serve a s a h e l p f u l g u i d e
w h e n disassembling a motor:

I. Remove the b r u s h h o l d e r s p r i n g s and brushes from t h e brush-

holders.
2. W i t h the motor i n a vertical position, drive end up, remove
t h e d r i v e e n d bearing bracket b o l t s .
3. Tap the bearing bracket loose and remove. Remove t h e armature
using a lifting eyebolt in the center hole in t h e shaft.
4. Disconnect all connections between the magnet frame a n d t h e
commutator end bearing bracket. Remove all bolts h o l d i n g the
commutator end b r a c k e t to the magnet frame. Remove t h e
bracket from the frame tapping it loose t o disengage the
rabbet .
5. F u r t h e r d i s a s s e m b l y or replacement of parts can n o w b e
accomplished a s required by the situation.
6. Peassembly is accomplished i n reverse order of steps 1 t h r o u q h
4.
3- 33. Failure

WARNING: IF AN ELECTRICAL F A I L U R E O R AN EXTREME OVERLOAD

O C C U R S , PERSONNEL SHOULD NOT BREATHE THE FUMES W H I C H
li('rVE BEEN GENERATED I N S I D E THE iVWCFJNE. TEE FEAT O F THE
FAILURE ARC OR OVERLOAD MAY GENERATE NOXIOUS FUMES B Y
PYROLYSIS OF THE I N S U L A T I O l J blATERIALS. ALL POWER SI-DULD
RE DISCONNECTED FRO?'! THE MOTOR BEFORE ANY I N V E S T I G A T I O N
OF TFE F A I L U R E I S ATTEMPTED. TEE AREA AROUND TEE FlOTOR
S fYOULD BE WELL VENT1 LATED.

k?ater should not be applied to a n y electrically energized equip-

ment because of t h e d a n g e r of electric s h o c k which can r e s u l t
in s e r i o u s o r fatal injury. I n case of f i r e , disconnect all
power a n d use a carbon d i o x i d e extinquisher to quench the flame.

3- 4. Repair

See \l1arranty .
3- 5. genewal P a r t s

T h e n o t o r s e r i a l n u m b e r completely identifies the yotor and e v e r y

part therein. It must be g i v e n when o r d e r i n g replacement p a r t s .
Any order f o r motor parts should g i v e the number of parts d e s i r e d ,
t h e d e s c r i p t i o n of t h e p a r t , the serial n u m b e r of t h e m o t o r , a n d
t h e ~ o d e lnumber.
 ELECTRIC MOTOR

3.1.1
--
Description

S e r i e s Wound, Type H I n s u l a t i o n , 2 0 h p a t 4 9 0 0 rprn, Main P o l e s

a n d Coils, ona adjusted Brush Rigging
T h e a r m a t u r e a s s e m b l y c o n s i s t s of a shaft, a r m a t u r e core,
a r m a t u r e windings, and commutator. The c o i l e d f r a m e c o n s i s t s o f
t h e magnet f r a m e , main poles a n d c o i l s , a n d t h e f i e l d t e r m i n a l s .
O t h e r b a s i c p a r t s of t h e motor i n c l u d e t h e d r i v e e n d b e a r i n g
b r a c k e t , commutator e n d b e a r i n g b r a c k e t , b e a r i n g s , b e a r i n g s e a l s
(when e q u i p p e d ) , b r u s h h o l d e r yoke w i t h b r u s h h o l d e r s , b r u s h e s a n d
b r u s h h o l d e r s p r i n g s , and c o v e r s . O p e n i n g s o v e r the b r u s h h o l d e r s
p r o v i d e a c c e s s i b i l i t y t o t h e b r u s h r i g g i n g and commutator for
i n s p e c t i o n and brush replacement. S t a n d a r d b e a r i n g s are t h e s i n g l e
row, d o u b l e d s h i e l d e d , Conrad type p r e - l u b r i c a t e d w i t h h i g h
t e m p e r a t u r e g r e a s e w i t h ABECl tolerance a n d AFMBA # 3 i n t e r n a l
r a d i a l clearance.
WARNING: DO NOT OPERATE A S E R I E S MOTOR UNLOADED AS E X C E S S I V E
SPEED MAY OCCUR W H I C H CAN CAUSE DAMAGE TO THE MOTOR AND
I N J U R Y T O PERSONNEL.

3.1.2 Maintenance

WARNING: I F POSSIBLE, MAKE SURE MOTOR I S DISCONNECTED FROM

POWER SOURCE BEFORF, PERFORMING ANY MAINTENANCE OPERATIONS
ON THE MOTOR. WHEN POWER IS R E Q U I F S D TO PERFORM ANY IHAIN-
TENANCE, V I G I L A N T CAFU AND A T T E N T I O N S H O U L D BE E X E R C I S E D .

S t a n d a r d b e a r i n g s are d ( 7 u b l e shielded a n d p r e - l u b r i c a t e d and

normally do n o t r e q u i r e l u b r i c a t i o n . Under normal c o n d i t i o n s t h e
b e a r i n g s f a i l a f t e r s e v e r a l y e a r s s e r v i c e due t o l a c k of p r o p e r
l u b r i c a t i o n , e i t h e r f r o m d i r t y c o n t a m i n a n t i n t h e g r e a s e or
insufficient o i l i n the grease. N e w g r e a s e consists o f a b o u t 8 0 %
oil, 2 0 % s o a p . When b l e e d i n g r e s u l t s i n a r e d u c t i o n o f o i l t o
a b o u t 6 0 % , t h e b l e e d r a t e i s reduced t o a l e v e l t h a t may n o t s u p p l y
sufficient lubrication. For t h i s r e a s o n when m a i n t e n a n c e o v e r h a u l s
are performed after several years of service, bearings are
automatically replaced as a routine practice. A bearing should
be replaced with an exact replacement or one with all interchange-
able features. It is especially important that the bearing have
high temperature grease.
3.1.2b. Insulation
Insulation resistance should be checked during each maintenance
inspection. Low resistance may be caused by excessive dirt,
moisture or impending failure. Although motors can be success-
fully run with insulation resistance as low as 1/4 megohm it
is well to investigate the reasons for any insulation resistance
below 1 megohm. Low resistance values due to dirt can usually
be corrected by cleaning followed by a varnish dip and bake. Low
resistance due to moisture can be corrected by baking the motor
in a 90°c oven until the insulation resistance rises above this
value and stabilizes t o a nearly constant valve. A new motor
should withstand for one minute without breakdown the application
of a Hertz potential of 500 volts for voltage up to 60 volts
or 1000 volts plus twice rated voltage for voltages higher than
60 volts. Old motors should be tested at 75% of these values.

3.1.2~. Brushes
Brush condition and remaining brush life should be checked
at each maintenance inspection. Each brush should be checked
for length and each spring for proper pressure. When installing
new brushes, each brush should be sanded into the curvature of the
commutator for most reliable performance. A minimum of 85%
surface contact with 300% brush arc is recommended. Replacement
brushes should be exactly the same brush grade as original.
3.1.2d. Commutator
Commutator runout should not exceed .002" total indicated
runout with a bar-to-bar variation of .0002". The mica bar-to-bar
insulation should always be kept below the copper surface. When
commutator wear results in flush o r protruding mica, t h e mica
should be undercut to a depth equal ot the thickness of the mica
or about . 0 2 5 " . The undercut slot should be kept clean and
free of dirt.
3.1.2e. Cleanin9

Both the interior and exterior of the motor should be kept

clean and free of dirt and grease. Loose dirt may be removed
by vacuum cleaning or dry compressed air. Vacuum cleaning is
preferred because compressed air may drive dirt deeper into
cracks and voids in the insulation system. Loose dirt can be
removed with a cleaning rag or a soft bristle brush. Clogged
air openings should be cleaned out using care not to damage
insulated parts. Oil and grease may be removed by wiping with a
clean cloth dampened slightly with FREON TF(a fluorinated
hydrocarbon solvent made by DuPont) or Perchlorethylene.
CAUTION: THE CLOTH SHOULD NOT BE WET, F O R L I Q U I D
SOLVENT MAY CARRY ELECTRICAL C O N D U C T I N G D I R T DEEP I N T O
CRACKS A N D V O I D S IN THE INSULATION SYSTEM.
If insulation resistance is low after cleaning it may be
necessary to either bake the armature at 900C to remove moisture
or to varnish treat and bake for reliable repair.
3.1.2f. Mechanical
Check for unusual noises or vibration which were not
present when the unit was originally installed. Check all
electrical and mechanical connections for tightness. Clean screen
covers and ventilating ducts.
3.1.3. . Disassembly Instruction

The following instruction will describe the disassembly

process of a standard motor. It should be recognized that special
requirements and special applications require special construction-
and there will be many variations to which standard instructions
do not apply. The following steps can still serve as a helpfu.1
guide when disassembling a motor:
1. Remove the brushholder springs and brushes from the brushholders.
2. With the motor in a vertical position, drive end.up, remove
the drive end bearing bracket bolts.
3 . a. On m c t o r s which do not have a restrained drive end bearing
t h e d r i v e end b e a r i n g bracket can be tapped loose and removed.
Next the armature can be removed using a lifting eyebolt in
t h e center, hole i n t h e s h a f t .
b. 3n m o t o r s w h i c h have a r e s t r a i n e d drive end b e a r i n g , l i f t
the armature and d r i v e end bearing b z a c k e t using--the lifting
e y e S ~ l tin the c e n t e r hole i n the shaft, t a p p i n g the
bracket loose from the magnet f r a m e a s it is lifted.
c, ~ c t h motors with and without restrained drive end hearings
may be disassenbled a s described in 3b. A f t s r rernoval t h e
drive end S r a k c e t may be slid off t h e bearing.
4. Disconnect a l l connections between the m a g n e t frame a n d the
~ ~ ~ m ~ u t end a t obearing
r Sracket. Remove all b o l t s h o l d i n g
?he ;om.nutator end bracket to t h e rnagnet frame. Remove the
b r a c . k e t from the frame t a p p i n g i t . l o o s e to disengage the rabbet.
5. Further disassembly or replacement of parts can now be accomp-
l i s h e d as required by the zituation.
6. 3es:$cevqblyis accomplished in reverse o r d e r of steps 1 through
4
-3
.- . 1 . J a . Failure

I\1,T4RYING: IF AN ELECTIXICAL F A I 1 , U R E OR ' A N EXTREME OVERLOAD

O C L S R S , ESPECIALLY I N A TOTALT.,Y ENCLOSEC MOTOR, PERSCFJNEL
S H O U L D NOT BREATHE THE F U M E S WHICi7 HAVE BEEN GENERRTED
I N S T D E THE MACHINE. THE HEAT OF THE FAILUIG ARC OR OVERLOAD
Y A Y GENERATE NOXIOIJS FUMES BY P Y R O L Y S I S O F THE I N S U L A T I O N
W.'?ERIALS. ALL POWER S H O U L D BE DISCONNECTED FROM THE MOTOR
FEFORE A i i Y INVESTT.C;.\'l'ION O F THE FATLURE IS ATTEMPTED. THE
AREA AROUND THE Y b T O R SHOU1,D BE WELL VENTILATED. L'ERSONNEL
StiG'JLD NOT BREATIIE THE T O X I C ?'UKES PRODUCED BY TI-IE F A I L U R E .
Tf.' POSSTBL.E, TI:= SHOULD BE ALLOWED FOR THE MOTOR T O COOL
AND F O R D I L U T I O N O F THE FUP'ES WITH AIR.
W;ter should not bc applied to a n y electrically e n e r g i z e d
e q u l l ~ : r \ c n tbecause of the d a n ~ e rof elrctric shock which c a n r e s u l t
i n s.::ious or f a t a l injury. 111 c a s e of fire, disconnect a l l
yuwex -and use a cazborl dioxide extinguisher to quench the flame.
-3.1.4. Repilir
See Warranty.

3.1.5.
--
R e n e w a l Parts

T h e m o t o r serial n u m b e r c o m p l e t e 1 . y i d e n t i f i e s t h e motor
and every p a r t t h e r e i n . I t m u s t be g i v e n when ordering replacement
parts. Any order fox motor parts should give t h e number of parts
desired, the d e s c r i p t i o n of t h e p a r t , t h e serial number of t h e
motor, and e i t h e r t h e model n u m b e r o r t h e OEM-customer i d e n t i f i c a t i o n
number.
 CHPATER 4 : CHARGER

4- 1 . DESCRIPTION . . . . . . . . . . . . . . . . . . . . 1
4- 2. SCHEMATIC WIRING DIAGRAM . . . . . . . . . . . . . I
4- 3 . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . I
 / 1, -
4- 1. Description Ffl.
1'
L e s t r o n i c B a t t e r y C h a r g e r , Model 3 4 5 8 - 'I'ype ' , 2 / 1 0 2 L C R 2 5 - i E T
Input: 115/230 v o l t s A.C. 60HZ
Output: 1 2 & 1 0 2 volts D.C., L 0 / 2 5 amps

4- 2. Schematic Wiring D i a g r a m

See page 3 .

4- 3. Troubleshooting

When o p e r a t i n g from 230 v o l t A . C . s o u r c e , the i n i t i a l c h a r g e rate

will vary from 18-30 amps, d e p e n d i n g o n t h e state o f discharge o f
the batteries.

I f not check: 1) C h e c k l o w v o l t a g e o u t p u t to charger

2) Check for dead battery ( i e s )
3) Check charger f u s e

When o p e r a t i n g from a 1 1 5 v o l t A . C . source, the i n i t i a l charge

rate will vary from 8 - 1 3 amps, d e p e n d i n g o n the state of
discharge of t h e b a t t e r i e s . I f not c h e c k a s above.

The charge r a t e of t h e 1 2 v o l t b a t t e r y w i l l v a r y g r e a t l y d e p e n d i n g
on the s t a t e of d i s c h a r g e of b o t h the 1 2 a n d 1 0 2 v o l t b a t t e r y
system.
 \" + > :4ALFUNCTION SYYPTOMS AND TIIETR REPIEDIES
?\
L s s t r o n i c Sat tery Chargers
Models 9 4 5 8 a n d 9575

No T r a n s f o r m e r Xum and ,Anmeters Do Not R e ~ i s t e r

I n t h e e v e n t n o hum i s d e t e c t e d f r o m t h e transformer, c h e c k t h e
AC. c o r d t o , b e s u r e I t i s s e c u r e l y p l u g g e d i n t o a live AC o u t l e t
( c h e c k line f u s e o r c i r c u i t b r e a k e r ) . Also c h e c k t o b e s u r e t h e
c h a r g e r DC o u t p u t l e a d s a r e c o n n e c t e d s e c u r e l y t o t h e i r r e s p e c t i v e
batteries.
XOTE: 9 e c a u s e t h e r e l a y , -dhlch c o n t r o l s the t u r n l n g
on and-61-f 'of-Ehe c h a r g e r , i s activat-eT%-$-the
_C__

I ' ~ T D + + ~ l E - ' b a t - ~ e r - ~ ~ the

~ ~ s t102
e m ;v o l t charger
i o u t p u t leads must Se c o n n e c t e d to b a t t e r i e s t o
i t u r n c harzer on.
Push a n d r e l e a s e "START" b u t t o n . IT, I n t h e p r e v i o u s c h a r g e c y c l e ,
t h e c h a r g e r was allowed t o t u r n o f f automatically the relay w i l l
c l o s e a p p r o x i m a t e l y t w o s e c o n d s after the b u t t o n I s r e l e a s e d and
only one "click" w i l l b e heard. If t h e p r e v i o u s c h a r g e c y c l e was
"
I n t e r r u p t e d b e f o r e t h e charger t u r n e d o f f a u t o m a t i c a l l y , t h e r e l a y
1 r i l l o p e n when the "START1' b u t t o n is d e p r e s s e d and r i l l c l o s e a f t e r
I the b u t t o n i s r e l e a s e d , thus p r o d u c i n g two "clicks". 'dhen t h e r e l a y
closes and the AC cord 1 s c o n n e c t e d , t h e c h a r g e r . ls o n a n d t h e
transformer s h o u l d hum.
If still no hum Is n o t i c e d , a c o n t i n u i t y c h e c k o f t h e A C c i r c u i t
i s necessary. Disconnect AC cord from w a l l o u t l e t b u t l e a v e
connected t o c h a r g e r r e c e p t a c l e . U s e a s u i t a b l e continuity t e s t e r
t o c h e c k t h e c i r c u i t a c r o s s t h e AC p l u g p r o n g s . Circuit should b e
c o m p l e t e when r e l a y i s c l o s e d . ( I f relay Is not already c l o s e d ,
push "START" button.) If not complete, i n d i v i d u a l l y c h e c k A C c o r d s ,
c h a r g e r A C i n p u t r e c e p t a c l e , r e l a y c o n t a c t s , primary t r a n s f o r m e r c o l l
and a11 c o n n e c t i o n s ,
If m a l f u n c t i a n s t i l l e x i s t s , c h e c k r e l a y c o i l v o l t a g e a t r e l a y

< /.
terminals using a suitable DC v o l b m e t e r . Voltage s h o u l d b e t h e
same a s t h e 1 0 2 v o l t b a t t e r y s y s t e m . If voltage is c o r r e c t c h e c k
the r e l a y c o i l resistance.
----.L

IMPORTANT: D i s c o n n e c t c o n t r o l c a b l e from E l e c t r o n i c
'-- , . T i m e r Assembly b e f o r e checking r e l a y c o i l
resistance. Damage t o E l e c t r o n i c T L m e r o r
meter w i l l result If c o n t r o l c a b l e remains
connected.
E r 3 a y c o i l r r s j s t a r l c c should bc* : ~ l ) p r o Jxl r ~ : i t t ~ I y6 , 0 0 0 o l l r n s . If
c o i l r e s i s t a n c e i s n o t correct, relay I s d e f e c t i v e a n d m u s t b e
rep1 aced.

I f r e l a y c h e c k s g o u d , check continuity o f h e a t sensor. C l r c u i t s b o u l

b e c o m p l e t e unless charger has o v e r h e a t e d , In w h l c h c a s e t h e h e a t
sensor will b e o p e n . If c l r c u l t i s n o t c o m p l e t e , r e f e r t o 'CHARGER
OVERHEATS" for further t e s t p r o c e d u r e s . If n o malfunction c a n be
found, refer t o "Charger Does Not T u r n O f f " for Electronic T l m e r
t e s t procedures.
. ..
Transformer Hums B u t No Ammeter I n d i c a t i o n
Check t h e c h a r g e r DC o u t p u t leads t o b e sure t h e y are p r o p e r l y
c o n n e c t e d t o t h e 1 2 v o l t and 1 0 2 volt b a t t e r y s y s t e m s . If t h e r e
i s s t i l l no ammeter i n d l c a t l o n , a c o n t l n u l t y t e s t o f t h e c h a r g e r
DC c i r c u i t m u s t be performed. Disconnect AC cord from charger
r e c e p t a c l e a n d DC o u t p u t l e a d s from batteries. Check f u s e s o n
charger f r o n t p a n e l . If one o r more fuses have blown, refer to
"Charger DC Fuse(s) Blowst1 f o r f u r t h e r t e s t s . If f u s e s c h e c k
good, use a l o w voltage c o n t i n u l t y t e s t e r t o perform t h e following
/
tests:
( a ) Connect t h e t e s t e r l e a d s t o charger 102 volt output
leads. Note reading a n d t h e n r e v e r s e tester l e a d s .
C i r c u i t s h o u l d c o n d u c t i n one d l r e c t l o n o n l y . Perform
same test on charger 1 2 volt o u t p u t leads.

If c i r c u i t does not conduct In e i t h e r direction, a n d

f u s e s a r e good, l n d l v l d u a l l y check t h e DC output l e a d s ,
ammeter, d l o d e a n d f u s e c o n n e c t i o n s ( e a c h may be checked
w l t h a contlnulty t e s t e r ) .

If clrcult conducts In both d l r e c t l o n s a "short" e x i s t s

i n t h e DC c l r c u l t . F l r s t c h e c k DC o u t p u t l e a d s for a
" s h o r t " b e t w e e n t h e t w o wires. More probably, one or
more d l o d e s have " s h o r t e d " . Refer t o "Charger DC Fuse(s)
Blows", p a r t ( b ] f o r c o n t l n u i t y t e s t o f d l o d e s .
( b ) If D C c i r c u f t t e s t I s good, a c h e c k o f t h e c a p a c i t o r s
I s necessary. W i t h AC cord and DC o u t p u t l e a d s d i s c o n n e c t e d ,
r e m o v e o n e t r a n s f o r m e r l e a d w i r e from c a p a c i t o r terminal
and c o n n e c t contlnuity tester l e a d s t o c a p a c i t o r t e r m i n a l s . .
If c l r c u l t I s complete, o n e or m o r e capacitors a r e " s h o r t e d "
a n d must be replaced.
 Charger DC ~ u s r ( s )B l o w s

T h l s condition m a y b e c a u s e d by:

( a ) R e v e r s e polarity between charger a n d b a t t e r i e s , s u c h

a s incorrect f n s t a l l a t l o n o f batteries o r v l r f n g o f
c ~ a r g e koutput leads.
(b) A short c i ~ c u l tfailure of one or more dlodes. First
d i s c o n n e c t AC c o r d and DC output l e a d s f r o m b a t t e r i e s .
Remove f u s e s (tour 30 amp and two 5 a m p fuses) to
I s o l a t e diodes. U s i n g a low v o l t a g e continuity tester
connect one lead t o diode m o u n t i n g plate a n d o t h e r
l e a d t o d i o d e w i r e lead. Note r e a d i n g and t h e n r e v e r s e
t e s t e r l e a d s and c h e c k e a c h d i o d e again. If diode
conducts current In both directions, the d i o d e is
shorted and aust Se replaced. Replace e f t h e r t h e
e n t i r e h e a l s i n k assembly o r o n l y t h e defective diode.
When replacing a single d i o d e , b e sure t h e new d i o d e
1s p r e s s e d s q u a r e l y i n t o the hole and that i t d o e s
not e x t e n d beyond t h e r e a r of t h e heat sink p l a t e .
( c ) E x c e s s i v e h e a t i n g of t h e fuse d u r i n g normal charging.
Be s u r e all fuse c o n n e c t i o n s are clean a n d t l g h t . Screw-
i n t y p e fuses can become corroded a t t h e fuse receptacle
contacts, c a u s i n g t h e fuse element to m e l t . Be sure
to keep fuses t l g h t and c o n t a c t s f r e e o f c o r r o s i o n . If
necessary, replace f u s e r e c e p t a c l e or cartridge.
Charqer Output Is Low

The most probable cause Is one d i o d e shorting and b l o w i n g o n e

fuse. Refer t o "Charger DC F u s e ( s ) Blows", part ( b ) to c h e c k
diodes. The c h a r g e r o u t p u t w i l l b e 1 to 5 amps when one f u s e
has blown,
.
Charqer Does Not T u r n O f f
The E l e c t r o n i c Tlrner c o n t r o l s t h e r e l a y whlch turns t h e c h a r g e r
both on and o f f . If batteries have been heavily discharged t h e
charger may r u n f o r u p t o 1 6 h o u r s in o r d e r to f u l l y c h a r g e t h e
batteries. In cold temperatures or when operating from 115 v o l t s
AC, e v e n more t i m e m a y be required.

IMPORTANT: F o r normal overnight charging, use only 230

v o l t AC input. L i m i t u s e o f 115 v o l t AC input
t o emergency s i t u a t i o n s a n d occasional charging
when vehfcle is n o t In u s e and 230 v o l t lnput
is not available, Continual use of 115 volt
lnput will lead t o u n d e r c h a r g i n g of the Satteries,
thus reducing performance and b a t t e r y life.
rf'
I
6' .
T h e Electronic Timer Assembly may be c h e c k e d b y measuring t h e
voxtages o f t h e c o n n e c t o r p i n s . The following t a b l e s h o w s t h e
c o r r e c t voltages o f t h e various p l n s . A l l voltages a r e measured
relative to pin #1 (battery negative).
1
 CAUTION: Use extreme c a r e when w o r k l n g internally on
charger. DO NOT allow meter probe to short
between pins or pcrrnancnt damage to Electronic
Timer may result. Charger c a p a c l t p y v o l t a g e
is approximately 630 volts, Use care when working
n e a r capacitors.

PIN P i n Voltage

NO, . .(Use m e t e r with at l e a s t 20,000

ohms per volt input impedance)
---

2 Same a s 102 volt b a t t e r y s y s t e m .

(Approximately 107 Vdc )

6 C h a r g e r ON - I Vdc
Charger OFF- Same as 102 volt battery s y s t e m

7 Charger ON - 78 V a c

8 "START" b u t t o n c l o s e d ( d e p r e s s e d ) - 0 Vdc
"START" button open (released) - 10 Vdc

10 "SUMMER-WINTER" s w i t c h - SUMMER 10 Vdc

WINTER 0 V d c

If all voltages a r e correct, check the c o n n e c t o r terminals t o

b e s u r e t h e y a r e making proper c o n t a c t w i t h p i n s . If no r n a l f u n c t l . o n
can be f o u n d , or v o l t a g e s a r e not correct, r e p l a c e E l e c t r o n i c T i m e r
Assembly and return d e f e c t i v e assembly t o f a c t o r y for r e p a i r .

T r a n s f o r m e r Short o r B u r n - O u t

F a l l u r e o f t h e t r a n s f o r m e r nay b e c a u s e d b y n a t u r a l aging o r
p r e m ~ t u r e shorting of e d j a c e n t coil turns. The transformer may
hum when A C and DC l e a d s a r e c o n n e c t e d , however, a low or c o m p l e t e
lack of o u t p u t would b e observed on t h e ammeter. To test trans-
f o r m e r , f i r s t disconnect AC cord a n d DC o u t p u t l e a d s a n d perform
DC c i r c u i t test a s d e s c r i b e d in "Transformer Hums But No Ammeter
Indication". If c i r c u i t t e s t s good, r e c o n n e c t AC cord and m e a s u r e
t r z n s f o r m e r output voltages. C o r r e c t voltages are shown in t h e
following t a b l e . Voltages will vary sllghtly If AC Input voltage
Is other than 115 or 2 3 0 Vac. If measured v o l t a g e s a r e substantially
lower t h a n t h o s e shewn, t h e t r a n s f o r a e r I s shorted a n d ~ u s tb e r e p l a c e
 T r a n s f o r n e r Ooen-Circui t Vol t a r e s

Models 9458 a n d 9575 - 102 volt s y s t e m s

I~ Transforaer
I
with
C O L ~V o l t a g e tVac)

without
~ coil capacitors
connected
capacitors
connected

ll5Vac 230Vac ll5Vac 230Irac

Secondary - leads 1 to 4 21 9 221 120 165

Secondary - l e a d s 9 to 1 2 308 312 167 232

Secondary - leads 5 t o 8 ' 27 28 14 20

- -- --

Capacitor C o i l 620 633 335 462

S

C h a r g e r Overheats/Charqer Coolinq Fan Does Not Ouerate

The c h a r g e r cooling f a n must operate t o p r e v e n t the u n i t f r o m

overheating. A heat sensor, mounted i n t e r n a l l y , is used to turn
the charger off should t h e unit overheat. SJhen t h e fan i s operating,
w a r m air should b e exhausted from the s i d e vent opposite t h e f a n
f u s e . If fan does not o p e r a t e check fan f u s e mounted on t h e s i d e
of the c h a r g e r . If f u s e 1s good, check AC voltage at fan connector.
Voltage s h o u l d be 80 to 100 Vac. If fuse and fan v o l t a g e c h e c k
good, t h e fan fs defective and must be r e p l a c e d .
 Battery Voltage T a b l e

Room Temperature 2 5 C = 7 7 F Flood M a x 130 F Sealed Max 150F

Spec. Gravity 1.170 1.200 1.230 1.260 0.015 Spread

#6V Nom. Fully 25% 50% 75% 100% Max. Gasing 30min.
Bats Volt Disch. Float C.Taper CnstCur

cell
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