Web 00ELB0011

Pub.No.
00ELB0011, FEBRUARY 2013
Shop Manual
chassis
GROUP INDEX
GENERAL ........................................ 00
CLUTCH ........................................... 21
MANUAL TRANSMISSION ............. 22
(EURO 3)
PROPELLER SHAFT....................... 25
Shop Manual FRONT AXLE................................... 26
REAR AXLE ..................................... 27
chassis WHEEL, TIRE................................... 31
FRONT SUSPENSION..................... 33
REAR SUSPENSION ...................... 34
FOREWORD BRAKE ............................................ 35
This Shop Manual is published for the information and
PARKING BRAKE ........................... 36
guidance of personnel responsible for maintenance of
Mitsubishi Fuso ROSA series buses, and includes proce- STEERING ....................................... 37
dures for adjustment and maintenance services.
We earnestly look forward to seeing that this manual is
made full use of in order to perform correct services with
FRAME ............................................. 41
HEATER, AIR-CONDITIONER,
no wastage. VENTILATION .................................. 55
For more details, please consult your nearest authorized
Mitsubishi Fuso dealer or distributors.
BODY ............................................... 63
Kindly note that the specifications and maintenance ser-
vice figures are subject to change without prior notice in
line with improvement which will be effected from time to
time in the future.
FEBRUARY 2013
Applicable models
BE
©2013 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

This Shop Manual contains the information classified into the following groups.
If any system or equipment has two or more variations with significantly different construction, the variations are
handled as different groups. These groups are identified by different alphabets preceded by the same number.
1. ENGINE volume (Pub.No.00ELB0010)
Group No. Group subject

00 GENERAL
11 ENGINE
12 LUBRICATION
13 FUEL AND ENGINE CONTROL
13E ELECTRONICALLY CONTROLLED FUEL SYSTEM
14 COOLING
15 INTAKE AND EXHAUST
17 EMISSION CONTROL
2. CHASSIS volume (Pub.No.00ELB0011)

00 GENERAL
21 CLUTCH
22 MANUAL TRANSMISSION
25 PROPELLER SHAFT
26 FRONT AXLE
27 REAR AXLE
31 WHEEL, TIRE
33 FRONT SUSPENSION
34 REAR SUSPENSION
35 BRAKE
36 PARKING BRAKE
37 STEERING
41 FRAME
55 HEATER, AIR-CONDITIONER, VENTILATION
63 BODY
3. ELECTRICAL volume (Pub.No.00ELB0012)

54 ELECTRICAL
GROUP 00 GENERAL
VEHICLE MODEL CODING SYSTEM ................................................ 00-2
EQUIPMENT TYPE CODES LIST ...................................................... 00-3
POWER TRAIN TABLE ...................................................................... 00-4
HOW TO READ THIS MANUAL ......................................................... 00-6

13A
CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE ........ 00-14 13E
PRECAUTIONS FOR MAINTENANCE OPERATION
1. General Precautions ................................................................... 00-16
2. Handling of Battery ..................................................................... 00-19
3. Handling of Sensors, Relays and Electronic Control Units ......... 00-19
4. Handling Precautions for Electric Circuits .................................. 00-20
5. Service Precautions for Alternators ............................................ 00-23
6. Intermittent Faults ...................................................................... 00-24
7. Precautions for Arc Welding ....................................................... 00-25
8. Precautions When Repainting .................................................... 00-25
JACKING UP THE VEHICLE............................................................ 00-26
DIAGNOSIS CODES
1. Diagnosis Codes ........................................................................ 00-28
2. Access and Clearing of Stored Diagnosis Code.......................... 00-28
TABLE OF STANDARD TIGHTENING TORQUES

1. Tightening Torques ..................................................................... 00-34
2. Table of Standard Tightening Torque .......................................... 00-34
00-1
VEHICLE MODEL CODING SYSTEM
1 2 3 4 5 6 7 8 9 10 11
B E 6 3 D J L M S H
1 Basic vehicle type B Front engine bus with frame

2 Drive system E 4 × 2 2WD Diesel
3 Development sequential number 6 Rosa
4 Suspension (front/rear) 3 Rigid leaf suspension/Rigid leaf suspension
5 Engine D 4M50T
E 3490
6 Wheelbase (mm) G 3995
J 4550
7 Steering position L Left-hand drive vehicle
M With air conditioner
8, 9,
Body arrangement S Standard
10
H High roof
11 Export specification
00-2
EQUIPMENT TYPE CODES LIST 00
Component Name plate marking Code description
Engine
4M50T7 4 M 5 0 T 7
Power version number

Turbocharged
Order of development within same series
Order of development among different series
Diesel engine
No. of cylinders (4)
Clutch
C5W33 C 5 W 33
Disc OD
Facing material (W: Woven)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the clutch
Transmission
M036S6 M 036 S 6
Forward speeds
Type of mesh (S: Synchromesh)
Initial letter of the transmission
Propeller shaft
P3 P 3

Initial letter of the propeller shaft
Front axle
F020B F 020 B
Vehicle type (B: Bus)

Initial letter of the front axle
Rear axle
R033B R 03 3 B
Vehicle type (B: Bus)

Initial letter of the rear axle
Reduction and differential
D033H D 03 3 H
Tooth profile (H: Hypoid gear)

Initial letter of the reduction & differential
00-3
POWER TRAIN TABLE
Propeller Reduction &
Vehicle model Engine Clutch Transmission Front axle Rear axle
shaft Differential
BE63DJLMSHNF 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DELSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DGLSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DJLMSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
00-4
00
M E M O
00-5
HOW TO READ THIS MANUAL
This manual consists of the following parts:
• Specifications
• Structure and Operation
• Troubleshooting
• Circuits
• Electrical Equipment Installation Positions
• Inspection of Electrical Equipment
• On-vehicle Inspection and Adjustment
• Service procedures
• Connector configuration chart
On-vehicle Inspection and Adjustment

• Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de-
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for
looseness, play, backlash, crack, damage, etc.
Service procedures
• Procedures for servicing components and parts off the vehicle are described centering on key points in their re-
moval, installation, disassembly, reassembly, inspection, etc.
Inspection
• Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given.
• Some routine visual checks and cleaning of some reused parts are not described but must always be included in
actual service work.
Caution
• This service manual contains important cautionary instructions and supplementary information under the following
four headings which identify the nature of the instructions and information:
DANGER Precautions that should be taken in handling potentially dangerous substances

such as battery fluid and coolant additives.
WARNING Precautionary instructions, which, if not observed, could result in serious injury or
death.
CAUTION Precautionary instructions, which, if not observed, could result in damage to or de-
struction of equipment or parts.
Suggestions or supplementary information for more efficient use of equipment or

NOTE better understanding.
Terms and Units

• Front and rear
The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred
to as the rear.
• Left and right

Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left
and right.
Standard value
• Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-
ance between two parts when assembled, and the standard value for an assembly part, as the case may be.
Limit
• When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must
be replaced or repaired.
00-6
00
Tightening torque
• Values are directly specified for out-of-standard tightening torques for bolts and nuts.
• Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
(Values for standard tightening torques are based on thread size and material.)
• When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.
Units
• Tightening torques and other parameters are given in SI* units with metric units added in brackets { }.
*SI: Le Système International d’Unités
Example: 390 N·m {40 kgf·m}
Metric unit
SI unit
Unit SI unit {metric unit} Conversion factor

Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}
Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}
Pressure kPa {mmHg} 0.133322 kPa {1 mmHg}
Vacuum pressure
Pa {mmH2O} 9.80665 Pa {1 mmH2O}
Volume dm3 {L} 1 dm3 {1 L}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Power kW {PS} 0.7355 kW {1 PS}
00-7
Illustrated Parts Breakdown and Service Procedures
Symbol Denotation Application Remarks
Specified values shown in table
Parts not tightened to standard torques
See Table of Standard Tightening Torques for
Tightening torque (standard torques specified where neces-
parts for which no tightening torques are speci-
sary for servicing)
fied.
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or Parts to be coated with lubricant or sealant Necessary lubricant and/or sealant, quantity re-
sealant for assembly or installation quired, etc. are specified in table.
Parts for which special tools are required for Tool name/shape and part number are shown in
Special tool
service operation table.
Parts associated with those removed/disas-
*a Associated part
sembled for servicing
00-8
00
00-9
How to Read Circuits (Electrical)
00-10
00
1.1 Index number: 100 to 999
• Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its
own index number.
1.2 Key number: A01 to Z99
• Key numbers indicate electrical equipment installation locations. The installation location of an electrical equip-
ment can be easily found using its key number shown in a circuit diagram.
All of the electrical equipment installation locations are listed in Gr54-10.
1.3 Part name
1.4 Connector type (type indication)
• A list of the connectors used is included in Gr54-14.
1.5 Connector terminal number
1.6 Major harness division

• Major harness divisions are shown.
1.7 Wiring variations between different specifications
• Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown.
1.8 Circuit number, wire diameter, wire color
1.9 Code number: #001 to #999

• Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspec-
tion procedure for an electrical equipment can be found using its code number shown in a circuit diagram.
1.10Grounding point: [1] to [99]
• Locations where wires are grounded to the vehicle. All of the grounding points are listed in 130 .
1.11 Harness connection
• The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity.
00-11
Wire color
Wire color Base color + tracer
Black/ Black/ Black/ Black/ Black/
BW BY BR Black/red BG BL BO
white yellow green blue orange
B Black
Black/ Black/ Black/
BP BV B Br
pink violet brown
Brown/ Brown/ Brown/ Brown/ Brown/ Brown/
BrW BrB BrY BrR BrG BrL
white black yellow red green blue
Br Brown
Brown/ Brown/
BrGr BrV
gray Violet
Green/ Green/ Green/ Green/ Green/ Green/
GW GR GY GB GL GO
white red yellow black blue orange
G Green
Green/ Green/ Green/
GGr GBr GV
gray brown violet
GrL, Gray/ GrR, Gray/ GrB, Gray/ GrG, Gray/ GrW, Gray/ Gray/
GrY
Gr, GyL blue GyR red GyB black GyG green GyW white yellow
Gray
Gy Gray/ Gray/
GrG GrBr
green brown
Blue/ Blue/ Blue/ Blue/ Blue/
LW LR Blue/red LY LB LO LG
white yellow black orange green
L Blue
Blue/
LGr Blue/gray LBr
brown
Light Light Light Light
Light
Lg LgR green/ LgY green/ LgB green/ LgW green/
green
red yellow black white
Orange/ Orange/ Orange/
O Orange OL OB OG
blue black green
Pink/ Pink/ Pink/ Pink/ Pink/
P Pink PB PG PL PW PGr Pink/gray PV
black green blue white violet
Pu Purple
Red/ Red/ Red/ Red/ Red/
RW RB RY RG RL Red/blue RO
white black yellow green orange
R Red
Red/ Red/
RBr Rgr
brown Gray
Sb Sky blue
Violet/yel- Violet/ Violet/ Violet/ Violet/
V Violet VY VW VR Violet/red VG VGr VB
low white green gray black
White/ White/ White/ White/ White/ White/
WR WB WL WG WO WV
red black blue green orange violet
W White
White/ White/
WBr WY
brown yellow
Yellow/ Yellow/ Yellow/ Yellow/ Yellow/ Yellow/
YR YB YG YL YW YO
red black green blue white orange
Y Yellow
Yellow/ Yellow/ Yellow/ Yellow/
YP YV YGr YBr
pink violet gray brown
00-12
00
M E M O
00-13
CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE
• Serial chassis (vehicle identification) and engine numbers are assigned to the vehicles and engines in manufac-
turing sequence. Every vehicle and engine has its own number. These numbers are required for registration and
related inspection of the vehicle.
• Chassis number <Type A>
• Vehicle identification number (VIN) <Type B>
J L B B E 6 3 D J C R
(1) (2) (3) (4) (5) (6) (7)
(1) Geographic area

J: Japan
(2) Manufacturer
L: Mitsubishi Fuso Truck & Bus
(3) Country
B: Peru
(4) Model Code
(5) Model year
C: 12M/Y
D: 13M/Y
E: 14M/Y
F: 15M/Y
(6) Plant
K: Kawasaki
R: Toyama
(7) Plant Sequential Number
00-14
00
• Name plate contains the following information.
• MODEL
• CHASSIS No. <Type A>
• Engine model
• Vehicle identification number (VIN) <Type B>
• An engine name plate indicates the following item.

• Engine model
00-15
1. General Precautions
• Before performing service operations, inquire into the customer’s complaints and ascertain the condition by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently.
• Check the location of the fault, and identify its cause. Based on
your findings, determine whether parts must be removed or dis-
assembled. Then, follow the service procedure given in this
manual.
• Perform service operations on a level surface. Before starting,

take the following preparatory steps:
• To prevent soiling and damage, place covers over the seats,
trim, floor and over the paintwork of the body.
• Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this man-
ual. Do not attempt to use other tools since they could
cause injuries and/or vehicle damage.
• Take extreme care when removing/installing heavy items such

as engine, transmission and axle. When lifting heavy items using
a cable etc., observe the following precautions.
• Identify the weight of the item being lifted. Use the cable that
is strong enough to support the weight.
• If lifting eyes are not provided on the item being lifted, tie a ca-
ble around the item taking into account the item’s center of
gravity.
00-16
00
• Do not allow anyone to pass or stay under a lifted item which
may possibly fall.
• Never work in shoes that have oily soles.

When working with a partner or in a group, use pre-arranged sig-
nals and pay constant attention to safety. Be careful not to touch
switches and levers unintentionally.
• Inspect for oil leakage etc. before washing the vehicle. If the or-
der is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
• Prepare replacement parts ready for installation.
• Oil seals, packings, O-rings and other rubber parts, gaskets, and
split pins must be replaced with new ones after removal. Use
only genuine MITSUBISHI replacement parts.
00-17
• When disassembling parts, visually check them for wear, cracks,
damage, deformation, deterioration, rust, corrosion, defective ro-
tation, fatigue, clogging and any other possible defect.
• To facilitate correct reassembly of parts, make alignment marks

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

gloves when necessary, and watch out for sharp edges and oth-
er items that might wound your hands.
00-18
00
2. Handling of Battery
2.1 Handling of battery cable
• Before working on the electrical system, disconnect the (–) bat-
tery cable to prevent short circuits.
CAUTION
• Make sure that the starter switch and lighting switches are
OFF before disconnecting or connecting battery cable.
(Semiconductor components may otherwise be damaged.)
• Disconnect the (–) battery cable, then insulate the (–) termi-
nal of the battery and (–) battery cable with insulating tape
or the like.
• If the (–) battery cable is not disconnected, battery voltage
will remain constantly applied to the B terminal, inviting
danger of electric shock.
3. Handling of Sensors, Relays and Electronic Control Units

• Carefully handle sensors relays, and other items that are sensi-
tive to shock and heat. Do not remove or paint the cover of any
control unit.
• When separating connectors, grasp the connectors themselves

rather than the harnesses.
• To separate locking connectors, first push them in the direction
of the arrows. To reconnect locking connectors, push them to-
gether until they click.
• Before washing the vehicle, cover electrical parts to keep them

dry. (Use plastic sheets or equivalent.) Keep water away from
harness connectors and sensors and immediately wipe off any
water that gets on them.
00-19
• When applying a voltage to a part for inspection purposes,
check that the (+) and (–) cables are connected properly then
gradually increase the voltage from zero. Do not exceed the
specified voltage.
Remember that control units and sensors do not necessarily op-
erate on the battery voltage.
4. Handling Precautions for Electric Circuits

CAUTION
• Do not pierce wire insulation with test probes or alligator
clips when performing electrical inspections. Doing so can,
particularly with the chassis harness, hasten corrosion.
4.1 Inspection of harnesses

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

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

(2.1) Inspections on female terminals
• Perform the inspection by carefully inserting a test probe into the
terminals. Do not force the test probe into the terminals since
this could deform them and cause poor connections.
00-20
00
(2.2) Inspections on male terminals
• Perform the inspection by applying test probes directly to the
pins.
.
CAUTION
• Be careful not to short-circuit pins together with the test
probes. With control unit connectors, short-circuiting of
pins can cause damage to the control unit’s internal circuit-
ry.
• When using a multimeter to check continuity, do not allow the

test probes to touch the wrong terminals.
4.2 Inspection of connectors

(1) Visual inspection
• Check that the connectors are fitted together securely.
• Check whether wires have been separated from their terminals

due to pulling of the harness.
• Check that male and female terminals fit together tightly.
00-21
• Check for defective connections caused by loose terminals, by
rust on terminals, or by contamination of terminals by foreign
substances.
(2) Checking for loose terminals

• If connector terminal retainers become damaged, male and fe-
male terminals may not mate with each other when the connec-
tor bodies are fitted together. To check for such terminals, gently
pull each wire and see whether any terminals slip out of their
connector housings.
4.3 Inspections when a fuse blows

• Remove the fuse, then measure the resistance between ground
and the fuse’s load side.
Next, close the switch of each circuit connected to the fuse. If
the resistance measurement between any switch and ground is
zero, there is a short circuit between the switch and the load. If
the resistance measurement is not zero, the circuit is not cur-
rently short-circuited; the fuse probably blew due to a momen-
tary short circuit.
• The main causes of short circuits are as follows:

• Harnesses trapped between chassis parts
• Harness insulation damage due to friction or heat
• Moisture in connectors or circuitry
• Human error (accidental short-circuiting of components)
4.4 Inspection of chassis ground

• A special ground bolt is used to tighten a ground terminal. When
servicing the ground point, be sure to follow the procedures de-
scribed below:
• When reinstalling the ground bolt
Tighten the ground bolt to the specified torque.
• When relocating the ground point
A special ground bolt must be used. Spot-weld a nut to a
frame and tighten the ground bolt to the specified torque. Be
sure to apply touch-up paint to the welded point.
00-22
00
5. Service Precautions for Alternators
• When servicing alternators, observe the following precautions:
• Never reverse the polarity of battery connections.
If the polarity of the battery connections were to be reversed,
a large current would flow from the battery to the alternator,
damaging the diodes and regulator.
• Never disconnect the battery cables with the engine running.

Disconnection of the battery cables during engine operation
would cause a surge voltage, leading to deterioration of the di-
odes and regulator.
• Never perform inspections using a high-voltage multimeter.

The use of a high-voltage multimeter could damage the diodes
and regulator.
• Keep alternators dry.

Water on alternators can cause internal short circuits and dam-
age.
• Never operate an alternator with the B and L terminals short-cir-

cuited. Operation with the B and L terminals connected together
would damage the diode trio.
00-23
• Disconnect the battery cables before quick-charging the battery
with a quick charger.
Unless the battery cables are disconnected, quick-charging can
damage the diodes and regulator.
6. Intermittent Faults
• An intermittent fault typically occurs only under certain operating
conditions. Once these conditions have been identified, the
cause of the intermittent fault can be ascertained easily. First,
ask the customer about the vehicle operating conditions and
weather conditions under which the fault occurs. Also ask about
the frequency with which the fault occurs and about the fault
symptoms. Then, reproduce the fault based on this information.
In accordance with the conditions under which the fault occurs,
determine whether the fault is caused by vibration, heat or other
factors. if vibration is a possible factor, see if the fault can be re-
produced by performing the following checks on individual con-
nectors and other parts:
• Gently move connectors up and down and to left and right.
• Gently move wiring harnesses up and down and to left and
right.
• Gently wiggle sensors and other devices by hand.
• Gently wiggle wiring harnesses on suspension systems and
other moving parts.
• Connectors and other parts to be checked are those included or

given as likely fault locations in inspection procedures corre-
sponding to diagnosis codes and/or fault symptoms.
00-24
00
7. Precautions for Arc Welding
• When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless ap-
propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses.
And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be
largely damaged.
• Current flows backward as shown below.

7.1 From battery (–) cable
To prevent damage to the battery and to electrical devices that are
connected directly to the battery, it is essential to disconnect the
battery’s (–) cable.
7.2 Procedure
• Turn the starter switch to the LOCK position.
• Disconnect the battery’s (–) cable.
• Cover all parts of the vehicle that may be damaged by welding
sparks.
• Connect the welder’s (–) cable to the vehicle as close as possi-
ble to the area being welded. Do not connect the welder’s (–) ca-
ble to the cab if the frame is being welded, and vice versa.
• Set the welding current in accordance with the part being weld-
ed.
8. Precautions When Repainting
• When repainting, cover the following electronic control components with a masking material. If paint get on these
components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal
circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti-
lation holes.
• Engine electronic control unit and other electronic control units
• Sensors
00-25
JACKING UP THE VEHICLE
<Front of Vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Jack up the front of the vehicle with a bottle jack or garage jack.
3 Support the front of the vehicle frame on jack stands.
WARNING
• Chock the wheels firmly to prevent the vehicle from rolling away.
• Do not attempt to remove the chocks until the operation is completed.
• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the front of the vehicle frame on jack stands.
• Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed.
00-26
00
<Rear of Vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Jack up the rear of the vehicle using a bottle jack or garage jack as illustrated above.
3 Support the vehicle frame on jack stands on both sides.
WARNING
• Chock the wheels firmly to prevent the vehicle from rolling away.
• Do not attempt to remove the chocks until the operation is completed.
• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the vehicle frame on jack stands on both sides.
• Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed.
00-27
DIAGNOSIS CODES
1. Diagnosis Codes
• The diagnosis code indicates the faulty location(s) of the vehicle.
• Reading the diagnosis code(s) and performing the corresponding remedy (troubleshooting) repairs the faulty lo-
cation(s).
• Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to
be diagnosed.
• Using a Multi-Use Tester
• Flashing of warning on meter cluster
• The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in-
dividual systems.
1.1 Systems and diagnosis code displaying methods

Diagnosis code displaying
Warning methods
System Reference Gr
lamp Warning
Multi-Use Tester
display
Common rail 13E
Exhaust gas recirculation O O 17
Starter continuous energizing preventing function 54
1.2 Types of diagnosis codes

(1) Present diagnosis code
• Fault developed in the vehicle after the starter switch is set to ON is indicated by corresponding diagnosis code.
• The fault warning is displayed at the same time.
(2) Past diagnosis code

• Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec-
tronic control unit.
• With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re-
pair against present diagnosis codes, the present diagnosis code is stored as past diagnosis codes in the memory
of the electronic control unit.
• The warning is not displayed because the indicated fault is not present one.
2. Access and Clearing of Stored Diagnosis Code

2.1 Using Multi-Use Tester
(1) Connecting Multi-Use Tester
Special tools
Mark Tool name and shape Part No. Application
FMS-E12-3 or
higher (Multi- Data transmission between V.C.I. and
PC
Use Tester-III PC
version)
Data transmission between electronic

V.C.I. MH062927
control unit and PC
00-28
00
Multi-Use Tester test

harness E
MH063659
A: For inspection and
A: MH063661
drive recorder Power supply to V.C.I. and communi-
B: MH063663
B: For drive recorder cation with electronic control unit
C: MH063665
C: Drive recorder har-
D: MH063666
ness
D: Cigar plug harness
Multi-Use Tester test

Multi-Use Tester test harness A and B
harness D MH062951
extension
(used for extension)
Communication between V.C.I. and

USB cable MH063668
PC
(1.1) System inspection

• Move the starter switch to the LOCK position.
• Connect installed PC, , -A and as illustrat-
ed.
• Connect the Multi-Use Tester connector on the vehicle with the
connector of -A.
00-29
DIAGNOSIS CODES
(1.2) Inspection using the drive recorder function
• Move the starter switch to the LOCK position.
• Connect installed PC, , -A, -B and as
illustrated.
• Connect the cigarette lighter plug of -C with the cigarette
lighter socket.
• Connect the Multi-Use Tester connector with the connector of
-B.
(1.3) To extend the cable

• Use to extend the cable if -A is not long enough such
as when using Multi-Use Tester outside the vehicle.
(2) Access of diagnosis code

• Set the starter switch to ON.
• Operate the Multi-Use Tester for a display of necessary diagnosis code stored in the memory of the electronic
control unit and identify the location of the fault.
(3) Clearing of diagnosis code

• Set the starter switch to ON (the engine not to be started).
• Operate the Multi-Use Tester to delete all the diagnosis codes stored in the memory of the electronic control unit.
00-30
00
2.2 Use of Warning Display for Diagnosis Code
(1) Engine control
• Using the diagnosis and memory clear switches, display diagnosis codes.
CAUTION
• Opening the memory clear switch followed by its reconnection will erase the stored diagnosis codes from
the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure de-
scribed below before handling diagnosis codes.
(1.1) Reading diagnosis codes

• To read a diagnosis code, observe how may times the warning
flashes and how long each illumination lasts.
• The duration of illumination differs between the first and second
digits.
• Second digit: 1.2 sec.
• First digit: 0.4 sec.
• A diagnosis code consists of the flashing of second digit and the
flashing of first digit in that order. If a diagnosis code has “0” in
the second digit, only the first digit will be displayed.
• The diagnosis code 01 will be displayed if the system is normal.
• The same diagnosis code will be displayed 3 times in a row be-
fore moving to the display of the next code.
• After the last diagnosis code is displayed, the first code will be
displayed again 3 times in a row and then the subsequent
codes. This will be repeated.
00-31
DIAGNOSIS CODES
(1.2) Present diagnosis codes
• Turn the starter switch ON.
• Open the diagnosis switch.
• Present diagnosis codes will be displayed by flashing of the
warning.
• When the diagnosis switch is connected, electronic control unit
will stop (terminate) displaying diagnosis codes.
(1.3) Present and past diagnosis codes

• Turn the starter switch to the ON position.
• Open the diagnosis switch.
• Present diagnosis codes will be displayed by flashing of the
warning.
• Open the memory clear switch.
• Present and past diagnosis codes will be displayed by flashing
of the warning.
• Turn the starter switch to the OFF position and connect the
memory clear switch and diagnosis switch to terminate the diag-
nosis code displaying mode.
(1.4) Erasing diagnosis codes

• Turn the starter switch to the ON position (do not start the en-
gine).
• Open the memory clear switch and reconnect it; all diagnosis
codes stored in electronic control unit memory will be erased.
To cancel diagnosis code erasure after opening the memory
clear switch, turn the starter switch to the OFF position and then
reconnect the memory clear switch.
00-32
00
M E M O
00-33
1. Tightening Torques
• Tightening torques are roughly classified into the following two categories:
Availability of
How to determine tightening
Tightening torque Definition torque specifica-
torque
tions in text
Locate a bolt or nut correspond-
Standard tightening Tightening torque determined according to thread
None ing to actual part in the following
torque size and material of bolts and nuts
standard tightening torque table.
Tightening torque of bolts and nuts other than those
Specified tightening Tightening torque is shown in
defined in “Standard tightening torque”, or that of Provided
torque the text.
bolts and nuts not identified in the following tables
• Fasteners used in a location denoted by “wet” should always be tightened in a wet condition (lubricated with en-
gine oil or grease). Any other fasteners than those so specified should be tightened in a dry condition.
2. Table of Standard Tightening Torque

• Threads and bearing surfaces shall be dry (tightened in a dry condition).
• If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the
bolt.
• Automotive screws refer to coarse screw thread with nominal diameter of 3 to 8 mm or fine screw thread with
nominal diameter of 10 mm or larger.
(1) Hexagon head bolts and stud bolts (Unit: N·m {kgf·m})
Strength
4T 7T 8T
(stud) (stud) (stud)

Automotive Coarse screw Automotive Coarse screw Automotive Coarse screw
screw thread thread screw thread thread screw thread thread
2 to 3 4 to 6 5 to 7
M5 – – –
{0.2 to 0.3} {0.4 to 0.6} {0.5 to 0.7}
4 to 6 7 to 10 8 to 12
M6 – – –
{0.4 to 0.6} {0.7 to 1.0} {0.8 to 1.2}
9 to 13 16 to 24 19 to 28
M8 – – –
{0.9 to 1.3} {1.6 to 2.4} {1.9 to 2.9}
18 to 27 17 to 25 34 to 50 32 to 48 45 to 60 37 to 55
M10
{1.8 to 2.8} {1.7 to 2.5} {3.5 to 5.1} {3.3 to 4.9} {4.6 to 6.1} {3.8 to 5.6}
34 to 50 31 to 45 70 to 90 65 to 85 80 to 105 75 to 95
M12
{3.5 to 5.1} {3.2 to 4.6} {7.1 to 9.2} {6.6 to 8.7} {8.2 to 11} {7.6 to 9.7}
Nominal
60 to 80 55 to 75 110 to 150 100 to 140 130 to 170 120 to 160
diameter M14
{6.1 to 8.2} {5.6 to 7.6} {11 to 15} {10 to 14} {13 to 17} {12 to 16}
mm
90 to 120 90 to 110 170 to 220 160 to 210 200 to 260 190 to 240
M16
{9.2 to 12} {9 to 11} {17 to 22} {16 to 21} {20 to 27} {19 to 24}
130 to 170 120 to 150 250 to 330 220 to 290 290 to 380 250 to 340
M18
{13 to 17} {12 to 15} {25 to 34} {22 to 30} {30 to 39} {25 to 35}
180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
M20
{18 to 24} {17 to 22} {35 to 47} {32 to 42} {41 to 54} {37 to 49}
250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M22
{25 to 34} {23 to 31} {47 to 63} {43 to 57} {55 to 73} {50 to 66}
320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
M24
{33 to 44} {30 to 39} {61 to 83} {55 to 73} {71 to 96} {63 to 85}
00-34
00
Strength
8.8 (Nut 4T) 8.8 (Nut 6T)
Automotive screw thread

18 to 27 45 to 60
M10
{1.8 to 2.8} {4.6 to 6.1}
Nominal
34 to 50 80 to 105
diameter M12
{3.5. to 5.1} {8.2 to 11}
mm
60 to 80 130 to 170
M14
{6.1 to 8.2} {13 to 17}
(2) Hexagon flange bolts (Unit: N·m {kgf·m})

Strength
4T 7T 8T

4 to 6 8 to 12 10 to 14
M6 – – –
{0.4 to 0.6} {0.8 to 1.2} {1.0 to 1.4}
10 to 15 19 to 28 22 to 33
Nominal M8 – – –
{1.0 to 1.5} {1.9 to 2.9} {2.2 to 3.4}
diameter
mm 21 to 31 20 to 29 45 to 55 37 to 54 50 to 65 50 to 60
M10
{2.1 to 3.2} {2.0 to 3.0} {4.6 to 5.6} {3.8 to 5.5} {5.1 to 6.6} {5.1 to 6.1}
38 to 56 35 to 51 80 to 105 70 to 95 90 to 120 85 to 110
M12
{3.9 to 5.7} {3.6 to 5.2} {8.2 to 11} {7.1 to 9.7} {9.2 to 12} {8.7 to 11}
Strength
8.8 (Nut 4T) 8.8
Automotive screw thread

21 to 31 50 to 65
Nominal M10
{2.1 to 3.2} {5.1 to 6.6}
diameter
mm 38 to 56 90 to 120
M12
{3.9 to 5.7} {9.2 to 12}
00-35
(3) Hexagon nuts (Unit: N·m {kgf·m})
Strength
4T 6T (Bolt 7T) 6T (Bolt 8T)

2 to 3 4 to 6 5 to 7
M5 – – –
{0.2 to 0.3} {0.4 to 0.6} {0.5 to 0.7}
4 to 6 7 to 10 8 to 12
M6 – – –
{0.4 to 0.6} {0.7 to 1.0} {0.8 to 1.2}
9 to 13 16 to 24 19 to 28
M8 – – –
{0.9 to 1.3} {1.6 to 2.4} {1.9 to 2.9}
18 to 27 17 to 25 34 to 50 32 to 48 45 to 60 37 to 55
M10
{1.8 to 2.8} {1.7 to 2.5} {3.5 to 5.1} {3.3 to 4.9} {4.6 to 6.1} {3.8 to 5.6}
34 to 50 31 to 45 70 to 90 65 to 85 80 to 105 75 to 95
M12
{3.5 to 5.1} {3.2 to 4.6} {7.1 to 9.2} {6.6 to 8.7} {8.2 to 11} {7.6 to 9.7}
Nominal
60 to 80 55 to 75 110 to 150 100 to 140 130 to 170 120 to 160
diameter M14
{6.1 to 8.2} {5.6 to 7.6} {11 to 15} {10 to 14} {13 to 17} {12 to 16}
mm
90 to 120 90 to 110 170 to 220 160 to 210 200 to 260 190 to 240
M16
{9.2 to 12} {9 to 11} {17 to 22} {16 to 21} {20 to 27} {19 to 24}
130 to 170 120 to 150 250 to 330 220 to 290 290 to 380 250 to 340
M18
{13 to 17} {12 to 15} {25 to 34} {22 to 30} {30 to 39} {25 to 35}
180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
M20
{18 to 24} {17 to 22} {35 to 47} {32 to 42} {41 to 54} {37 to 49}
250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M22
{25 to 34} {23 to 31} {47 to 63} {43 to 57} {55 to 73} {50 to 66}
320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
M24
{33 to 44} {30 to 39} {61 to 83} {55 to 73} {71 to 96} {63 to 85}
(4) Hexagon flange nuts (Unit: N·m {kgf·m})

Strength
4T
Automotive Coarse screw

screw thread thread
4 to 6
M6 –
{0.4 to 0.6}
10 to 15
Nominal M8 –
{1.0 to 1.5}
diameter
mm 21 to 31 20 to 29
M10
{2.1 to 3.2} {2.0 to 3.0}
38 to 56 35 to 51
M12
{3.9 to 5.7} {3.6 to 5.2}
(5) Tightening torques of general flare nuts (Unit: N·m {kgf·m})

Pipe diameter mm φ4.76 φ6.35 φ8 φ10 φ12 φ15
Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10}
00-36
00
(6) Tightening torques of nylon tubes for general air piping (DIN) (Unit: N·m {kgf·m})
Nominal diameter
6×1 10 × 1.25 12 × 1.5 15 × 1.5
× wall thickness mm
+6 +0.6 +10 +1.0 +10 +1.0 +5 +0.5
Tightening torque 20 0 {2.0 0 } 34 0 {3.5 0 } 49 0 {5.0 0 } 54 0 {5.5 0 }
(7) Tightening torques of nylon tubes for general air piping (SAE) (Unit: N·m {kgf·m})
Nominal diameter in. 1/4 3/8 1/2 5/8
+4 +0.4 +5 +0.5 +5 +0.5 +5 +0.5
Tightening torque 13 0 {1.3 0 } 29 0 {3.0 0 } 49 0 {5.0 0 } 64 0 {6.5 0 }
00-37
GROUP 21 CLUTCH
SPECIFICATIONS............................................................................... 21-2
STRUCTURE AND OPERATION

1. Clutch Control .............................................................................. 21-3
2. Clutch Booster and Clutch Master Cylinder .................................. 21-4
3. Clutch Proper and Direct Power Cylinder ..................................... 21-8
TROUBLESHOOTING .......................................................................21-11
ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Brake Fluid Level ........................................................................ 21-12
2. Replacement of Brake Fluid (Clutch System) .............................. 21-12
3. Air Bleeding of Brake Fluid (Clutch System) ............................... 21-15
4. Inspection of Clutch Booster ...................................................... 21-17
5. Inspection of Clutch Disc Wear Limit .......................................... 21-17
6. Inspection and Adjustment of Clutch Pedal ................................ 21-18
CLUTCH PEDAL............................................................................... 21-20
CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER ............. 21-22
CLUTCH HOSE................................................................................. 21-24
CLUTCH PROPER............................................................................ 21-26
CLUTCH CONTROL ......................................................................... 21-30
21-1
SPECIFICATIONS
Item Specifications
Clutch model C5W33
Drive type Strap drive
Clutch disc type Dry, single plate type
Pressure plate type Diaphragm spring type
Control system Fluid and vacuum pressure type
Clutch master cylinder manufacturer NISSIN KOGYO
Clutch booster Bosch
Direct power cylinder manufacturer NISSIN KOGYO
21-2
STRUCTURE AND OPERATION 21
1. Clutch Control
• Fluid and vacuum pressure is used to control the clutch operation.

• When the clutch pedal is depressed, the boosted force by the booster is then applied to the clutch master cylinder.
This pressurizes the brake fluid inside the clutch master cylinder, pushing the direct power cylinder and disengag-
ing the clutch.
21-3
2. Clutch Booster and Clutch Master Cylinder
2.1 Clutch booster
• The clutch booster magnifies the stepping force applied onto the clutch pedal (therefore reduces the operator’s
pedal effort) through the utilization of pressure difference between the vacuum it generates and the atmospheric
pressure.
21-4
21
(1) When clutch pedal is depressed
• With the clutch pedal released and no
stepping force applied to the clutch
pedal, the operating rod and the valve
plunger are held to the left by the force
of the valve return spring. The atmo-
spheric pressure valve remains closed
while the vacuum valve remains open.
• The vacuum pump creates vacuum in
chamber A. As the atmospheric pres-
sure valve is closed, no outside air
flows into chamber B. Instead, vacu-
um in chamber A flows through the air
passage and into chamber B. Cham-
bers A and B are both filled with vacu-
um, and there is no pressure
difference between the chambers. No
boosting occurs.
• As the clutch pedal is depressed, the

stepping force acts on the operating
rod. This seats the poppet onto the
seat part of the power piston, closing
the vacuum valve and cutting off vacu-
um supply into chamber B. As the
clutch pedal is depressed further, the
valve plunger separates from the pop-
pet. This opens the atmospheric pres-
sure valve, allowing outside air into
chamber B. There is now a pressure
difference between chambers A and
B.
• The stepping force, boosted as a re-
sult of the pressure difference be-
tween chambers A and B, overcomes
the force of the power piston return
spring, pushing the diaphragm and the
push rod to operate the clutch master
cylinder.
21-5
(2) When clutch pedal is released
• With the clutch pedal depressed,
chamber A is filled with vacuum gener-
ated by the vacuum pump while cham-
ber B is open to the atmosphere.
When the clutch pedal is released, the
stepping force no longer acts on the
operating rod. This causes the valve
plunger to seat on the poppet, closing
the atmospheric pressure valve and
cutting off air flow into chamber B.
• In further progression, the poppet sep-

arates from the seat part of the power
piston. This opens the vacuum valve,
allowing vacuum from the vacuum
pump to flow into chamber B. As there
is now no pressure difference between
chambers A and B, the power piston
return spring pushes back the dia-
phragm along with the push rod to
their original positions.
21-6
21
2.2 Clutch master cylinder
(1) When clutch pedal is depressed

• The push rod of the clutch booster is depressed and the valve
seal closes the connection port to the brake fluid tank. At the
same time, the piston moves in the arrow direction and pressur-
izes the brake fluid in the cylinder.
• This pressurized brake fluid is transmitted to the direct power
cylinder.
(2) When clutch pedal is released

• The piston is pushed back to the illustrated direction by the com-
bined force of oil pressure from the direct power cylinder and the
spring force of the return spring.
• This opens up the port that has been blocked by the valve seal,
connecting the cylinder to the brake fluid tank. This allows the oil
pressure to completely drain to the tank.
21-7
3. Clutch Proper and Direct Power Cylinder
• Clutch engagement and disengagement are controlled by the brake fluid pressure from the clutch master cylinder
acting on the piston of the direct power cylinder, and are achieved by the operation of the piston and the release
bearing.
21-8
21
3.1 When clutch pedal is released
or engaging the clutch
• There is no fluid pressure acting on
the direct power cylinder. The piston
and release bearing remain in their
home positions.
• The force of the diaphragm spring acts
on the pressure plate, which in turn
keeps the clutch disc pressed against
the flywheel.
• Pressed against the flywheel, the
clutch disc rotates together with the
flywheel and transmits the engine
power to the transmission drive pinion.
3.2 When clutch pedal is de-

pressed or disengaging the
clutch
• Fluid pressure from the clutch master
cylinder moves the piston in the direct
power cylinder.
• As it moves, the piston pushes the re-
lease bearing, which in turn pushes
the diaphragm spring.
• The diaphragm spring pivots around
the pivot ring. This movement, via the
strap plate, causes the pressure plate
to retract from the flywheel. As a re-
sult, the clutch disc separates from the
flywheel, cutting off the transmission of
engine power to the transmission.
21-9
3.3 When clutch disc wear limit
• As the clutch disc approaches to its
wear limit, the release bearing is
pushed by the inner edge of the dia-
phragm spring in the direction of the
arrow shown in the illustration.
• The wear limit will be reached when
the flanged section of the release
bearing comes in contact with the
stepped section of the rod.
21-10
TROUBLESHOOTING 21
Symptoms
Clutch makes noise on disengagement
Clutch pedal requires too much effort

Clutch makes noise on engagement
Clutch does not engage smoothly
Clutch disengaged but drags
Judder when vehicle starting

Reference Gr
Clutch slips
Possible causes
Diaphragm spring heights uneven O O O O
Diaphragm spring fatigued O O
Clutch cover Pressure plate warped or faulty O O O O
Loose rivets O O O
Strap plate bent O O O O
Disc deformed O O O
Disc rivets loose O O
Disc torsion spring fatigued or damaged O
Spline worn O O O
Clutch disc
Spline rusted O O O
Facing worn O
Facing surface hardened O O O
Facing oily or greasy O O
Pedal free play insufficient O O
Pedal free play excessive O O
Clutch pedal
Pedal stroke insufficient O
Pedal sliding part faulty O O O
Spring fatigued O
Brake fluid passage port clogged O O O
Clutch booster
Vacuum pressure reduced O
Malfunction O
Piston and pressure cup sliding movement
O O O O
faulty
Clutch master cylinder
Spring fatigued O
Brake fluid passage port clogged O O O O
Piston and piston cup sliding movement
O O O O
faulty
Direct power cylinder
Brake fluid passage port clogged O O O O
Release bearing faulty O O O
Transmission drive pinion spline worn O O Gr22
Engine idling speed too low O O Gr13
Engine mounting fatigued O
Flywheel warped, deformed or worn forming steps O O O O Gr11
Flywheel pilot bearing faulty O
Air mixed in clutch hydraulic system O
Clutch hydraulic system leaking O
21-11
1. Brake Fluid Level
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Between “MAX”
Brake fluid (SAE J1703 or FMVSS
– Brake fluid tank and “MIN” of fluid
No. 116 DOT3)
tank
• Check that brake fluid level in the brake fluid tank is between
“MAX” and “MIN”.
• If the fluid level is lower than “MIN”, replenish the brake fluid.
2. Replacement of Brake Fluid (Clutch System)

• Clutch fluid (brake fluid) is shared by the clutch and brake systems, and is divided in the brake fluid tank into the
two systems. This section describes the replacement of the clutch fluid (brake fluid) for the clutch system. In order
to completely replace the clutch fluid (brake fluid), the brake fluid in the brake system should also be replaced.
(See Gr35.)
Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Bleeder screw 6.8 to 8.8 {0.7 to 0.9} –

– Brake fluid tank As required
No. 116 DOT3)
CAUTION
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork.
• If brake fluid is spilled onto the paintwork, immediately wipe it off.
• Be sure to use new brake fluid (SAE J1703 or FMVSS No. 116 DOT3). Do not mix it with brake fluid of dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter the original properties of brake fluid, causing the boiling point to drop as well as the clutch rubber
parts to swell. Faulty operation of the clutch will result.
• Ensure that no foreign matter or water enter into the brake fluid when refilling it, as they will cause faulty
clutch operation.
• Use a mug exclusively kept for the specified brake fluid. This ensures that no brake fluid of different prop-
erties or mineral oil enter into the system.
21-12
21
2.1 Work before replacement
• Start the engine and keep it running at idle until finishing the re-
placement to ensure that vacuum booster functions properly.
• Install one end of a vinyl pipe onto the bleeder screw. Place the
loose end into a container.
21-13
2.2 Replacement of brake fluid
• Replace the brake fluid in the following sequence.
CAUTION
• Replacement of old brake fluid with new brake fluid in the
clutch fluid line can be recognized by a change in color of
the brake fluid being discharged through the vinyl pipe.
Loosen the bleeder screw.
Depress and release the clutch pedal repetitively until

brake fluid is no longer discharged.
Fill brake fluid up to the “MAX” level on the brake fluid

tank.
Tighten the bleeder screw.
Cycle the clutch pedal several times, then depress and

hold the pedal.
Loosen the bleeder screw to discharge the brake fluid.
Air in brake fluid No air in brake fluid
Tighten the bleeder screw.
Release the clutch pedal and wait for at least

one second.
Add brake fluid up to the “MAX” level on the

tank.
Tighten the bleeder screw to the specified torque.
Release the clutch pedal.
Add brake fluid up to the “MAX” level on the tank.
Finish
21-14
21
3. Air Bleeding of Brake Fluid (Clutch System)
• Clutch fluid (brake fluid) is shared by the clutch and brake systems, and is divided in the brake fluid tank into the
two systems. This section describes the air bleeding procedures for the clutch system. For air bleeding proce-
dures for the brake system (See Gr35.)

– Bleeder screw 6.8 to 8.8 {0.7 to 0.9} –

No. 116 DOT3)
CAUTION
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork.
• If brake fluid is spilled onto the paintwork, immediately wipe it off.
• Be sure to use new brake fluid (SAE J1703 or FMVSS No. 116 DOT3). Do not mix it with brake fluid of dif-
ferent properties or mineral oil (gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will al-
ter the original properties of brake fluid, causing the boiling point to drop as well as the clutch rubber
parts to swell. Faulty operation of the clutch will result.
clutch operation.
3.1 Work before air bleeding

• Start the engine and keep it running at idle until finishing the air
bleeding to ensure that vacuum booster functions properly.
• Install one end of a vinyl pipe onto the bleeder screw. Place the
21-15
3.2 Air bleeding of brake fluid
• Bleed the air in the following sequence.
Fill brake fluid up to the “MAX” level on the brake fluid

tank.
Cycle the clutch pedal several times, then depress and

hold the pedal.
Loosen the bleeder screw to discharge the brake fluid.
Tighten the bleeder

screw.
Release the clutch

pedal and wait for at
least one second.
Tighten the bleeder screw to the specified torque.
Release the clutch pedal.
Add brake fluid up to the “MAX” level on the tank.
Finish
21-16
21
4. Inspection of Clutch Booster
4.1 Operation
• Depress the clutch pedal several times. Make negative pressure
be zero.
• Start the engine and keep it running at idle with depressing the
pedal slightly.
A little while later, check the pedal sinks slightly.
• If the pedal doesn’t sink, replace the clutch booster.
4.2 Air leakage

• Hang a thread onto the valve body.
• Check it the thread is mightily drawn to the valve body when the
pedal is depressed.
• Check it the thread is not drawn to the valve body when the ped-
al is released.
• When the thread is drawn, air leaks from the poppet of the clutch
booster. So replace the clutch booster.
5. Inspection of Clutch Disc Wear Limit

• Remove the grommet from the clutch housing. Check the posi-
tion of the release bearing flange relative to the rod on the direct
power cylinder.
• If the flange has reached to the clutch disc wear limit position
shown on the rod (see the drawing), replace the clutch disc.
21-17
6. Inspection and Adjustment of Clutch Pedal
• Perform inspection and adjustment of clutch pedal after finishing air bleeding in clutch system.
Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
– Clutch pedal installed height 256 ± 3.0 – Adjust
– Clutch pedal play 0.1 to 7 9 Replace
– Clearance between clutch switch and clutch pedal 0.5 to 1.5 – Adjust

– Lock nut (for retention of operating rod) 21.6 ± 2.9 {2.2 ± 0.3} –
6.1 Clutch pedal installed height

[Inspection]
• With the engine stopped and the clutch pedal released, measure
the height between the center of the pedal pad and the center of
the clutch booster and clutch master cylinder.
• If the measurement is out of the standard value, adjust by turn-
ing the clutch booster operating rod.
[Adjustment]
• Loosen the lock nut of the clutch booster operating rod and turn
the rod to adjust the installed height of the clutch pedal.
• Retighten the lock nut to the specified torque.
• After tightening the lock nut, inspect the clutch pedal play and
the clearance between the clutch switch and clutch pedal.
6.2 Clutch pedal play

• Measure the clutch pedal play with the engine stopped.
• If the measurement exceeds the limit, replace the clutch pedal.
6.3 Clearance between clutch switch and clutch pedal

• Measure the clearance from the end of the clutch switch threads
to the pedal stopper (with the clutch switch pressed in). If the
measurement is out of the standard value, adjust the clearance.
• After adjustment, tighten the lock nut securely.
CAUTION
• Do not contact the clutch switch threads with the pedal
stopper as it can be a cause of clutch slippage.
21-18
21
M E M O
21-19
CLUTCH PEDAL
Disassembly sequence
1 Fluid hose 8 Collar
2 Pipe 9 Bushing
3 Vacuum hose 10 Bushing
4 Clevis pin 11 Pedal pad
5 Clutch booster and clutch master cylinder 12 Clutch pedal
(See later section.) 13 Clutch pedal support
6 Clutch switch
7 Return spring : Non-reusable parts
Assembly sequence
Follow the disassembly sequence in reverse.
• Perform inspection and adjustment of clutch pedal after installation. (See “ON-VEHICLE INSPECTION AND AD-
JUSTMENT”.)

Nut (clutch booster mounting) 9 to 14 {0.9 to 1.4} –
Lock nut (for retention of clutch booster operating rod) 21.6 ± 2.9 {2.2 ± 0.3} –
Nut (clutch switch mounting) 18.6 to 27.5 {1.9 to 2.8} –
Bolt (clutch pedal mounting) 16.7 to 25.5 {1.7 to 2.6} –
21-20
21
Clevis pin Chassis grease
As required
Inner surface of collar [NLGI No. 1 (Li soap)]
21-21
CLUTCH BOOSTER AND CLUTCH MASTER CYLINDER
1 Piston
2 Clip
3 Packing
4 Union collar
5 Cylinder body
6 Clutch booster
: Non-reusable parts
• Do not attempt to disassemble the

clutch booster because it is of a unit
construction.
Assembly sequence
Follow the disassembly sequence in re-
verse.
Repair kit: Clutch master cylinder kit

Clearance between push rod of clutch booster and pis-
– 0 to 0.75 – Adjust
ton of clutch master cylinder
1, 5 Clearance between piston and cylinder body 0.02 to 0.1 0.2 Replace

Nut (clutch master cylinder mounting) 8.8 to 14 {0.9 to 1.4} –

Piston cup surface in friction against cylinder body Rubber grease 0.2 to 0.3 g
Cylinder body inner surface Rust preventive oil As required
Push rod end and sealed portion of clutch booster Silicone grease As required
Removal procedure
Removal: Piston
• Close the opening A and cover with a cloth the cylinder bore end
from which the piston is to be removed.
• Apply compressed air to the cylinder while slowly increasing its
pressure from 0 kPa {0 kgf/cm2} to force out the piston.
WARNING
• Do not apply high-pressure compressed air suddenly. Oth-
erwise, the piston will fly out with full force.
21-22
21
Installation: Clutch master cylinder and clutch booster
• Measure the indicated dimensions A and B on the clutch master
cylinder.
• Using the following equation, obtain the amount of projection C

of the push rod that enables the clearance between the clutch
master cylinder’s piston and the clutch booster’s push rod to fall
within the standard value.
C = A – B – standard value
• Adjust the adjuster of the push rod to the dimension C that is the
amount of projection of the push rod obtained in the above.
• After the adjustment, apply grease to the push rod end and
sealed portion of clutch booster.
Work after installation

Adjustment: Operating rod
• To facilitate height adjustment during installation of the clutch
pedal, pre-adjust the operating rod length to the reference value
indicated in the illustration.
21-23
CLUTCH HOSE
Removal sequence
1 Eyebolt
2 Clutch hose
*a: Connector
*b:: Clutch housing
Non-reusable parts
Installation sequence
Follow the removal sequence in reverse.
• After the installation, bleed the clutch

system. (See “ON-VEHICLE INSPEC-
TION AND ADJUSTMENT”.)

Eyebolt 20 to 25 {2.0 to 2.5} –
Special tools (Unit: mm)

Cap nut
Prevention of brake fluid leakage
A B ME538216
when removing brake hose
16 M12 × 1.25
Removal procedure
Removal: Clutch hose
• Place a container under the connected part of the clutch hose
and loosen the eyebolt while holding the connector.
CAUTION
• Be sure to hold the connector when loosening the eyebolt.
Otherwise, the connection between the connector and the
clutch direct power cylinder may loosen.
21-24
21
• Release the clutch hose together with the eyebolt and the gas-
kets from the connector, quickly fit to the eyebolt, and tight-
en it so that the brake fluid would not leak from this end. The
fluid leak from the connector is ignorable, so just receive it by the
container.
CAUTION
• Loosening the eyebolt causes the brake fluid to leak. Work
quickly.
• After disconnecting the clutch hose, temporarily install an M12 ×

1.25 mm bolt in the connector to prevent foreign matter and
grease from entering it.
CAUTION
• Installing the clutch hose with the connected part stained
with foreign matter or grease may cause a brake fluid leak
or incomplete clutch disengagement.
Installation procedure
Installation: Clutch hose
• Install the clutch hose by following the removal procedure in re-
verse. (See “ Removal: Clutch hose”.)
• After the installation, check that the clutch hose does not contact
with other parts around it.
CAUTION
• When installing the clutch hose, be sure not to apply ten-
sion to or twist it.
21-25
CLUTCH PROPER
Removal sequence
1 Clutch cover
2 Clutch disc
*a: Flywheel
: Locating pin
CAUTION
• To prevent clutch slippage, keep
the surfaces of the clutch cover,
clutch disc and flywheel free from
oil and grease.

Pressure plate flatness 0 to 0.05 –
1 Replace
Diaphragm spring finger height unevenness 0 to 1.0 –
Depth from facing surface to rivet 1.8 to 2.4 0.2
Play in revolving direction in splines 0.05 to 0.23 0.5
2 Clutch disc Replace
Vertical runout 0 to 1.0 1.5
Lateral runout 0 to 0.8 1.5

Entire surface of splines Molybdenum disulfide grease 0.8 to 1.1 g
Fill in the grease grooves of splines [NLGI No. 2 (Li soap)] 3.2 to 4.2 g
21-26
21
Clutch alignment arbor

MH061387 Holding clutch disc
A B C
φ28.94 φ20 120
Sleeve
Checking diaphragm spring for in-
A B MH061425
stalled height
φ45 φ28.94
Clutch master plate

Checking diaphragm spring for in-
MH062291
A B C D stalled height
φ325 φ32 9.2 “5”
Removal procedure
Removal: Clutch cover
• Insert into the flywheel pilot bearing. While supporting the
clutch disc with , remove the clutch cover.
Inspection procedure
Inspection: Clutch cover
(1) Pressure plate flatness
• Place a straight edge across the friction surface of the pressure
plate. Using a feeler gauge, measure the clearance between the
gauge and the surface in several locations selected randomly.
• Obtain the flatness of the pressure plate by subtracting the
smallest clearance measured from the greatest clearance mea-
sured.
• If the flatness does not conform to the standard value, replace
the clutch cover.
21-27
CLUTCH PROPER
(2) Inspection of diaphragm spring
• Inspect the diaphragm spring for play.
• If the spring has play, the clutch cover needs to be replaced.
(3) Inspection of installed height

• Using , install (in place of the clutch disc) and the
clutch cover.
• Install and check for unevenness in height of the fingers
using a feeler gauge.
• If the unevenness does not conform the standard value, replace
the clutch cover.
Inspection: Clutch disc

(1) Depth from facing surface to rivet
• Measure depth from the clutch disc facing surface to the rivet.
• If the measured value is equal to or less than the limit, replace
the clutch disc.
(2) Play in revolving direction in splines

• Reshape a feeler gauge such that it can be inserted into the
drive pinion splines. Then, using the gauge, measure the splines
for play in revolving direction.
• If the measured value is equal to or exceeds the limit, replace
the clutch disc.
Installation: Clutch disc
• Insert into the flywheel pilot bearing to support the clutch
disc.
• Install the clutch cover by tightening the bolts diagonally and
gradually.
21-28
21
M E M O
21-29
CLUTCH CONTROL
Removal sequence
1 Connector 6 Oil seal
2 Grommet 7 Dust plug
3 Bleeder cap 8 Bracket
4 Bleeder screw
5 Direct power cylinder
(See later section.)
*a:: Clutch housing
Non-reusable parts
CAUTION
• When handling the direct power cylinder, be careful not to smear it with mineral oil such as engine oil and
transmission oil. The smeared cylinder can cause brake fluid leakage.
21-30
21
Connector 40 {4.1} –
Nut (bleeder hose mounting) 51 to 60 {5.0 to 5.9} –
Bolt (direct power cylinder mounting) 44.5 {4.5} –
Bleeder screw 6.8 to 8.8 {0.7 to 0.9} –
Nut (bracket mounting) 38 to 54 {3.9 to 5.5} –

Direct power cylinder mating face with clutch housing ThreeBond 1215 As required
Wheel bearing grease
Oil seal lips As required
[NLGI No. 2 (Li soap)]

Oil seal installer

Protecting oil seal during direct power
A MH063322
cylinder installation
φ36.5
Oil seal installer
A MH062714 Oil seal installation

φ89
Installation: Oil seal
• Apply grease onto the oil seal lips. Then, install the oil seal onto
the direct power cylinder making sure that the seal faces as
shown in the drawing.
Installation: Direct power cylinder

• After cleaning the sealant application surfaces, apply sealant as
required.
• Install onto the drive pinion to protect the oil seal previously
installed onto the direct power cylinder.
21-31
CLUTCH CONTROL
Direct Power Cylinder
1 Snap ring 10 Outer cup
2 Release bearing 11 Piston
3 Oil seal 12 Bleeder
4 Rear spring stopper 13 Rod
5 Front spring stopper 14 Cylinder body A
6 Boots 15 O-ring
7 Spring 16 Cylinder body B
8 Front inner cup
9 Rear inner cup : Non-reusable parts
CAUTION
• Remove the bleeder only when cylinder body A is being replaced. Because removing the bleeder may
cause the thread deformation of the cylinder body A. Therefore you must replace the cylinder body A
when removing the bleeder once. Reusing the body causes oil leak.
Assembly sequence
CAUTION
• Install the piston correctly: It needs to be faced as shown in the drawing, and the cups should not be dis-
lodged. An incorrectly installed piston causes brake fluid leakage and clutch drag.
21-32
21
Bolt (cylinder bodies A, B and rod mounting) 6.8 to 8.8 {0.7 to 0.9} –
Bleeder hose 15.7 to 17.6 {1.6 to 1.8} –

Front inner cup sliding face with cylinder body B Rubber grease 0.1 to 0.2 g
Cylinder body A sliding face
Rust preventive oil As required
Cylinder body B sliding face
Removal procedure
Removal: Piston
• With the bleeder hose fitting hole or opening of cylinder body A
blocked, feed compressed air gradually starting from 0 kPa {0
kgf/cm2} to remove the piston.
WARNING
• Do not apply compressed air suddenly at high pressure, or
the piston will fly out with full force.
Removal: Cylinder body A

• Install left-hand screws (M8 × 1.25 mm) evenly into the jacking
holes on cylinder body A and remove the body.
21-33
CLUTCH CONTROL
Installation: Front inner cup, rear inner cup and outer cup
• Install the front inner cup, rear inner cup, and outer cup onto the
piston, facing them in the illustrated directions.
CAUTION
• Install the front inner cup, rear inner cup, and outer cup cor-
rectly, facing them in the illustrated directions. Incorrectly
installed cups cause brake fluid leakage and clutch drag.
• Do not apply grease onto the rear inner cup or the outer
cup. Otherwise, brake fluid will leak.
• Apply only a thin coat of grease to the front inner cup.
Greasing it too much can cause brake fluid leakage.
Installation: Front spring stopper

• Install the front spring stopper onto cylinder body A such that its
cutout aligns with the rod on the body and that it faces in the il-
lustrated direction.
Installation: Release bearing

• Install the release bearing onto cylinder body B such that its
flange aligns with the rod on cylinder body A and that it faces in
the illustrated direction.
21-34
GROUP 22 MANUAL TRANSMISSION
SPECIFICATIONS.................................. 22-2 TRANSMISSION CONTROL................ 22-60
STRUCTURE AND OPERATION BEARING PULLER AND

1. Transmission ................................... 22-3 INSTALLER .......................................... 22-71
2. Synchromesh Mechanism ............... 22-4
3. Interlock Mechanism........................ 22-6
4. Speedometer Gear Bushing ............. 22-6
TROUBLESHOOTING ........................... 22-7
ON-VEHICLE INSPECTION AND

ADJUSTMENT
1. Inspection of Transmission Oil
Leakage ........................................... 22-8
2. Inspection of Looseness in
Transmission Mounting Bolts .......... 22-8
3. Inspection of Play and Looseness
in Companion Flange ....................... 22-9
4. Inspection and Replacement of
Transmission Oil............................ 22-10
REMOVAL AND INSTALLATION OF

TRANSMISSION .................................. 22-12
GEAR SHIFTER UPPER...................... 22-16
EXTENSION HOUSING AND

PARKING BRAKE................................ 22-22
REVERSE IDLER GEAR ..................... 22-28
6TH GEAR............................................ 22-32
TRANSMISSION BODY....................... 22-38
DRIVE PINION ..................................... 22-48
MAINSHAFT......................................... 22-50
COUNTERSHAFT ................................ 22-58
22-1
SPECIFICATIONS
Item Specifications
Transmission model M036S6 (5.175/0.669)
1st 5.175
2nd 2.913
3rd 1.682
Gear ratio 4th 1.000
5th 0.793
6th 0.669
Rev 5.175
Gear oil API GL-3, GL-4
Classification
Engine oil API CC
GL-3
General 80
GL-4
Transmission Viscosity (applica-
oil Warm GL-3 90
tion/SAE viscosi-
ty number) Tropical GL-4 90
Long period
CC 30 or 40
of high-speed
Quantity dm3 {L} Approx. 4.4 {4.4}
Mass kg Approx. 100
Mode of control Floor shift remote control
• Transmission oil depends on the driving conditions.
22-2
1. Transmission
• The transmission changes revolution and torque generated by the engine into those that match the vehicle’s pow-
er requirement (driving force). The power requirement (driving force) is increased or decreased by making a se-
lection from several sets of engaged gears.
• The transmission uses an interlock mechanism to avoid double engagement.
22-3
2. Synchromesh Mechanism
• The synchromesh mechanism, when a shift change is made, synchronizes the rotation speed of the mainshaft,
drive pinion and synchronizer hub that rotates integrally with the mainshaft with that of the gear to be shifted.
Synchromesh type Gears of application
Single cone type Reverse, 1st, 4th, 5th, 6th
Triple cone type 2nd, 3rd
2.1 Single cone type

The following descriptions are for 4th gear of 4th and 5th synchronizer.
• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the syn-
chronizer hub has a spline that engages the synchronizer sleeve and three grooves.
• Shifting plungers are inserted into these grooves. When the gear shift is in neutral, the shifting plunger engage
grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting
plunger springs.
• Synchronizer rings are inserted into the respective taper cone of each gear.
• The outer splines of the synchronizer rings engage the synchronizer sleeve. On the synchronizer hub are three
grooves in which protrusions of the synchronizer rings are inserted. These grooves are wider than the width of the
protrusions of the synchronizer rings.
• Synchronizer rings rotate relative to the synchronizer sleeve by the amount of play (width difference).
• When the gear shift is in neutral (Figure A), moving the shift fork in the direction of the arrow as illustrated, moves
the synchronizer sleeve slightly to the gear. At the same time, the shifting plunger, the central protrusion of which
engages the synchronizer sleeve, moves to the gear and presses the synchronizer ring against the taper cone of
the gear (Figure B).
• The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchro-
nous operation.
• The rotation speed of the synchronizer hub becomes gradually closer to that of the gear due to the synchronous
operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to move smoothly to
engage the synchronizer hub and gear, completing the shift change (Figure C).
22-4
22
2.2 Triple cone type
The following descriptions are for 3rd gear of 2nd and 3rd synchronizer.
• The synchromesh structure and operation of the triple cone type are basically the same as for the single cone
type. The synchronizer ring is divided into three parts (synchronizer inner ring, synchronizer center cone and syn-
chronizer outer ring) and the center cone (both the inside and outside surfaces are tapered) and the inner ring
(both the inside and outside surfaces are tapered) are sandwiched between the outer ring and the taper cone of
each gear to shorten the time required for synchronization with cone clutches at three locations.
• Six protrusions on the outside of the synchronizer center cone fit into corresponding gear holes. As in the taper
cone of the single cone type, the center cone and the gear are installed as if integrated.
• The inside of the synchronizer hub engages the spline of the mainshaft and rotates with it. The outside of the syn-
chronizer hub has a spline that engages the synchronizer sleeve and three grooves.
• Shifting plungers are inserted into these keyways. When the gear shift is in neutral, the shifting plungers engage
grooves in the synchronizer sleeve and are pressed against the inside of the synchronizer sleeve by shifting
plunger springs.
• The synchronizer outer ring and synchronizer inner ring are inserted into synchronizer center cones, respectively.
• The outer spline of the synchronizer outer ring engages the synchronizer sleeve. On the synchronizer hub are
three grooves in which protrusions of the synchronizer outer ring are inserted. These grooves are wider than the
width of the protrusions of the synchronizer outer ring.
• The synchronizer outer ring rotates relative to the synchronizer sleeve by the amount of play.
• When the gear shift is in neutral (Figure A), moving the shift fork in the direction of the arrow as illustrated, moves
the synchronizer sleeve slightly to the gear. At the same time, the shifting plunger, the central protrusion of which
engages the synchronizer sleeve, moves to the gear and presses the synchronizer outer ring and the center cone
against the taper cone of the synchronizer center cone and the synchronizer inner ring, respectively and in addi-
tion, presses the inner ring against the gear (Figure B).
• The taper cones of synchronizer rings, which act as cone clutches, generate friction torque and perform synchro-
nous operation.
• The rotation speed of the synchronizer hub becomes gradually closer to that of the gear due to the synchronous
operation, and eventually they rotate at the same speed. This allows the synchronizer sleeve to move smoothly to
engage the synchronizer hub and gear, completing the shift change (Figure C).
22-5
3. Interlock Mechanism
• The interlock mechanism prevents double engagement of gears.

• When the 2nd and 3rd shift rail is shifted, the finger of the gear shift sliding lever engages with the 2nd and 3rd
gear shift jaw, and the rail on the bottom surface of the interlock plate locks the other gear shift jaws.
4. Speedometer Gear Bushing

• The speedometer gear bushing is eccentric, and displacing the
installed position allows it to correspond to the different number
of teeth of the speedometer gear.
• The numbers marked on the front at four locations show the
range of the number of teeth of the corresponding speedometer
gear.
“15-17”: Number of teeth 15 to 17
• An identification mark showing the number of teeth is marked on
the speedometer gear.
Identification
A B C D L E F G
mark
Number of
15 16 17 18 19 20 21 22
teeth
Gear ratio 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4
22-6
TROUBLESHOOTING 22
Symptoms
Gears slip out of engagement
Noise when engine is idling
Noise when changing gear

Gears hard to engage
Noise when cruising

Reference Gr
Possible causes
Mainshaft rear lock nut loose O O
Mainshaft thrust washer worn O O
Mainshaft bearing worn or damaged O O
Synchronizer ring and synchronizer sleeve spline worn O
Synchronizer ring and gears taper cone area worn O
Mainshaft pilot bearing worn or damaged O O
Transmission Drive pinion bearing worn or damaged O
body faulty Countershaft bearing worn or damaged O
Needle bearings of gears worn or damaged O O
Mainshaft and countershaft gears worn or damaged O
Mainshaft and countershaft gears backlash excessive O
Spline of gears worn O
Gears damaged O
Transmission oil insufficient O
Clutch disengagement faulty O O Gr21
Clutch faulty
Clutch pedal play faulty O
Contacting surface of synchronizer
Single cone type O O
ring and gear taper cone worn
Contacting surface of synchronizer in-
ner and outer rings and center cone O O
Triple cone type worn
Synchronizer Contacting surface of synchronizer in-
O O
faulty ner ring and gear taper cone worn
Synchronizer ring spline chamfer worn O
Shifting key worn O
Shifting key spring deteriorated or damaged O
Synchronizer sleeve worn or damaged O O
Control rod joint play O O
Control rod joint lubricated in insufficiently O
Control rod length adjusted incorrectly O
Control rod bent O
Control mecha- Bushings worn O O
nisms faulty Steel ball and groove of shift rail worn O
Poppet spring of shift rail fatigued or damaged O
Shift rail sliding movement faulty O
Shift fork jaws worn O
Shift fork bent O
22-7
1. Inspection of Transmission Oil Leakage
1.1 Inspection of oil leakage at each part of transmis-
sion body
• Check the oil leakage at each part of transmission body in visu-
al. If the oil leakage is found, replace the defective part.
1.2 Inspection of oil leakage around transmission

mounting part
• Check there is not oil stain on flywheel housing, clutch housing
and transmission mounting part caused by oil leakage from en-
gine.
• If there is the oil stain, remove the transmission and clean the
mounting surface of clutch housing and flywheel housing using
brake cleaner etc. after repairing oil leakage part. Because the
oil stain may loosen the transmission mounting bolts and nuts.
(See “REMOVAL AND INSTALLATION OF TRANSMISSION”.)
2. Inspection of Looseness in Transmission Mounting Bolts

M10 47.1 {4.8}
– Bolt (transmission mounting) –
M12 82.4 {8.4}
• Check the transmission mounting bolts for looseness.

• Retighten any loose bolt to the specified torque.
22-8
22
3. Inspection of Play and Looseness in Companion Flange
• Check the propeller shaft mounting bolts for looseness. (See
Gr25.)
• Move the parking brake drum in axial and vertical directions to
check for excessive play between the companion flange and
mainshaft.
• If excessive play is detected, remove the propeller shaft, then
check the lock nut for looseness and the splines on companion
flange and mainshaft for abnormalities. If any part is found de-
fective, replace the part. (See “EXTENSION HOUSING AND
PARKING BRAKE”.)
22-9
4. Inspection and Replacement of Transmission Oil
WARNING
• Temperature of transmission oil is high immediately after driving. Perform work when oil is cold.

Inspection plug
– 68.6 ± 14.7 {7.0 ± 1.5} Sealant
Drain plug

Thread area of inspection plug
– ThreeBond 1105 As required
Thread area of drain plug
Gear oil
General: API GL-3 SAE80
Warm region: API GL-3 SAE90
Approx. 4.4 dm3
– Transmission case Tropical region: API GL-4 SAE90
{4.4 L}
Engine oil
Vehicle operated continuously at high
speed: API CC SAE30 or SAE40
• Grease depends on the driving conditions.
[Inspection]
(1) Inspection of oil quantity
• Remove the inspection plug, and check that oil is filled up to the
neck.
• If oil is not sufficient, fill oil from the inspection plug hole up to the
neck.
• After filling, apply sealant to the inspection plug and tighten it to
the specified torque.
(2) Inspection of oil quality and inclusions

• When draining transmission oil, check for oil quality, metal chips
and metal powder.
• If an abnormally large amount of metal chips and metal powder
is found, disassemble the transmission assembly for service, as
abnormalities may be caused inside.
[Replacement]
• Remove the drain plug to drain transmission oil. Drainage can
be made quickly with the inspection plug removed.
• After draining transmission oil, apply sealant to the drain plug
and tighten it to the specified torque. Magnet type drain plugs
should be cleaned before installation.
• Fill transmission oil in the specified quantity from the inspection
plug hole.
• After filling, wait for 1 minute or more to check that oil is filled up
to the neck of the inspection plug hole by inserting a finger to the
inspection plug hole. If oil is not sufficient, replenish it.
• After completing work, apply sealant to the inspection plug and
tighten it to the specified torque.
22-10
22
M E M O
22-11
REMOVAL AND INSTALLATION OF TRANSMISSION
Removal sequence
1 Engine speed sensor
2 O-ring
3 Propeller shaft (See Gr25.)
4 Parking brake cable (See Gr36.)
5 Transmission
6 U-bracket
7 Insulator
8 Transmission mounting bracket

Nut (transmission mounting) 130 to 180 {13 to 18} –
M10 47.1 {4.8}
Bolt (transmission mounting) –
M12 82.4 {8.4}
Nut (U-bracket mounting) 50 to 65 {5.5 to 6.5} –
Bolt (engine speed sensor mounting) 8 {0.82} –

Molybdenum disulfide grease
Drive pinion spline As required
Mating surface of clutch housing and engine ThreeBond 1215 As required
22-12
22
Removal procedure
Removal: Transmission
• Support the transmission on the transmission jack.
• Ensure that the harnesses, piping and other relevant parts have
been disconnected.
• Remove transmission mounting bolts.
• Insert a screwdriver into the three removal grooves and remove

the transmission from the engine.
• Move the transmission backward until the spline of the drive pin-
ion is detached from the clutch.
CAUTION
• Make sure that you pull the transmission out in a straight
line. If you seesaw the transmission violently, you will dam-
age the spline that connects the drive pinion and the clutch.
Installation: Insulator
• Install the insulator on the transmission mounting bracket in the
illustrated direction.
Installation: Transmission
• Check the spline of the drive pinion for rust.
• If rust is found, remove it using a wire brush.
• Rub grease evenly onto the clutch disc sliding surface of the
drive pinion using your hand.
CAUTION
• Make sure that you apply only the necessary amount of
grease because too much grease can drip and cause clutch
slip.
22-13
REMOVAL AND INSTALLATION OF TRANSMISSION
[Applying sealant]
• Apply sealant to the clutch housing side of the transmission
while observing the following cautions and then engage the
transmission with the engine.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes oil leak.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.
• The applied sealant covers the bleeding hole of the
clutch housing and engine parts.
<Case of using nozzle gun>

• Clean the mating surfaces of each part.
• Apply sealant on the width center of the mating surfaces so that
the diameter of the applied sealant is the same as the diameter
of the nozzle.
<Case of using spatula, etc.>

• Apply sealant evenly on the entire mating surfaces.
[Installation]
• After applying the sealant, install the transmission before the
sealant dries. Be sure not to allow the sealant to be displaced.
• Do not start the engine within one hour after installing the trans-
mission.
• When loosening or removing transmission mounting bolts, be
sure to reapply the sealant.
• Support the transmission on the transmission jack, and insert

the transmission into the pilot bearing of the flywheel paying at-
tention to the drive pinion spline.
• Tighten transmission mounting bolts to the specified torque.
Installation: Engine speed sensor

• If metal dust is adhered to the sensor portion of the engine
speed sensor, wipe it off with a soft shop towel and install the
sensor in the clutch housing.
22-14
22
M E M O
22-15
GEAR SHIFTER UPPER
Removal sequence
1 Gear shifter upper
2 Poppet spring plate
3 Poppet spring <Except 4th and
5th>
4 Poppet spring <4th and 5th>
5 Steel ball
6 Backup lamp switch
7 Torque limit switch
8 Stopper plate
9 Interlock plate
*a: Transmission case

: Locating pin

103.8 ± 10.4 N 72.7 N Re- Pink
3 Poppet spring installed load (installed length 19.2)
{11 ± 1.1 kgf} {7.4 kgf} place paint
124.6 ± 12.5 N 87.2 N Re- Red
4 Poppet spring installed load (installed length 19.1)
{13 ± 1.3 kgf} {8.9 kgf} place paint

Bolt (gear shifter upper mounting)
Bolt (poppet spring plate mounting) 23.5 {2.4} –
Bolt (stopper plate mounting)
Backup lamp switch 29.4 to 39.2 {3 to 4} Sealant
Torque limit switch 49 ± 2.9 {5 ± 0.3} Sealant

Mating surface of gear shifter upper and transmission
case ThreeBond 1194 As required
Thread area of torque limit switch
Mating surface of poppet spring plate and transmission
ThreeBond 1215 or Loctite 5999 As required
case
Thread area of backup lamp switch ThreeBond 1215 As required
22-16
22
Installation: Gear shifter upper
[Applying sealant]
• Apply sealant to the transmission case side while observing the
following cautions and then engage the gear shifter upper with
the transmission.
CAUTION

of the nozzle.

[Installation]
• After applying the sealant, install the gear shifter upper before
the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the gear
shifter upper.
• When loosening or removing gear shifter upper mounting bolts,
be sure to reapply the sealant.
22-17
GEAR SHIFTER UPPER
Gear Shifter Upper
1 Air breather 9 Spring retainer 17 Oil seal
2 Neutral switch 10 Gear shift sliding lever 18 Bushing
3 Spring pin 11 Spring retainer 19 Oil seal
4 Torsion shaft 12 Return spring 20 Selector lever case
5 Steel ball 13 Lock pin
6 Poppet spring 14 Gear selector lever : Non-reusable parts
7 Return spring 15 Washer
8 Return spring 16 Gear selector lever
NOTE
• Do not remove bushing except for replacement.
Assembly sequence
22-18
22
Poppet spring installed load 20 ± 1 N 14 N
6 Replace
(installed length 14) {2.08 ± 0.1 kgf} {1.5 kgf}
Return spring installed load 31 ± 1.6 N 22N
7 Replace
(installed length 16.7) {3.2 ± 0.16 kgf} {2.2 kgf}
Return spring installed load 38.1 ± 1.9 N 27 N
8 Replace
(installed length 16.7) {3.9 ± 0.2 kgf} {2.7 kgf}
Return spring installed load 80.5 ± 4.0 N 56 N
12 Replace
(installed length 27) {8.2 ± 0.4 kgf} {5.7 kgf}

Neutral switch 49 ± 2.9 {5 ± 0.3} Sealant
Nut (lock pin mounting) 6.9 {0.7} –

Neutral switch of torsion shaft and steel ball mounting
groove
Sliding area of washer Wheel bearing grease As required
Lip area of oil seal [NLGI No. 2 (Li soap)]
Sliding area of bushing inner surface and gear selector
lever shaft
Thread area of neutral switch
Contact surface of bushing outer surface and selector le- ThreeBond 1194 As required
ver case

Spring pin puller
A MH062445
M12 × 1.25
Removal of spring pin
Reverse shaft puller
A 03726-82000
M12 × 1.25
22-19
GEAR SHIFTER UPPER
Removal procedure
Removal: Spring pin
• Tap the spring pin using an M4 tap.
• Insert spring pin puller with an M4 screw of appropriate
length into the spring pin, and remove the spring pin using
reverse shaft puller.
Removal: Bushing
• Remove the bushing using a screwdriver.
CAUTION
• Be careful not to damage the selector lever case.
22-20
22
Installation: Bushing
• Clean the bushing and bushing mounting surface of the selector
lever case.
• Apply grease to the inner surface of the bushing and sealant to
its outer surface.
NOTE
• Do not allow sealant to adhere to the inner surface of the
bushing.
• Mount the bushing by evenly tapping it using a round bar of out-

er diameter of approximately 15 mm.
Installation: Gear selector lever

• Install the gear selector lever while turning so that the oil seal is
not damaged in the lip.
Installation: Torsion shaft

• Install the torsion shaft so that the angle the punch mark “ ” at
the tip of the torsion shaft forms with the gear shift sliding lever is
as illustrated.
22-21
EXTENSION HOUSING AND PARKING BRAKE
1 Drain plug 9 L-joint 18 Speedometer worm
2 O-ring 10 Spring pin 19 Bearing
3 Dust plug 11 Speedometer gear 20 Bearing retainer
4 Parking brake drum 12 O-ring 21 Distance pipe
(See Gr36.) 13 Oil seal
5 Companion flange 14 Speedometer gear bushing : Locating pin
6 Reamer bolt 15 Lever set bolt : Non-reusable parts
7 Parking brake (See Gr36.) 16 Oil seal
8 Vehicle speed sensor 17 Extension housing
Assembly sequence

5 Runout at socket portion of companion flange 0 to 0.15 0.5 Replace
Clearance between speedometer gear and speedome-
11, 14 0.04 to 0.09 0.15 Replace
ter gear bushing
22-22
22
Lock nut 245 to 343 {25 to 35} –
Reamer bolt 52 to 66.7 {5.3 to 6.8} –
Vehicle speed sensor 14.7 to 29.4 {1.5 to 3.0} –
L-joint 34 to 39 {3.5 to 4.0} –
Bolt (speedometer gear bushing mounting) 23.5 {2.4} –
Bolt (extension housing mounting) 44.5 {4.5} –
Lever set bolt 160 {16.3} Sealant
Drain plug 68.6 ± 14.7 {7.0 ± 1.5} Sealant

O-ring Wheel bearing grease
As required
Lip area of oil seal [NLGI No. 2 (Li soap)]
Sliding surface of speedometer gear and speedometer Molybdenum disulfide grease
As required
gear bushing [NLGI No. 2 (Li soap)]
Mating surface of extension housing and transmission
ThreeBond 1215 As required
case
Thread area of drain plug ThreeBond 1105 As required
Thread area of lever set bolt Loctite 271 As required

Flange puller
A B C MH061848 Removal of companion flange

φ95 φ100 φ90
Oil seal installer
A B C MH062691 Installation of oil seal

φ64 φ50 17
Work before removal

Alignment marks: Speedometer gear bushing
• The installed direction of the speedometer gear bushing is deter-
mined by the number of the speedometer gear teeth.
• Make alignment marks to prevent misassembly.
22-23
Removal procedure
Removal: Runout at socket portion of companion flange
• After removing the parking brake drum, measure the runout at
the socket portion of the companion flange.
• If the measured value exceeds the limit, replace the companion
flange.
Removal: Companion flange
Inspection: Clearance between speedometer gear and
speedometer gear bushing
• If the clearance exceeds the limit, replace the speedometer gear
bushing.
• Install the oil seal in the extension housing in the illustrated di-
rection.
• After installation, apply grease to the lip area of the oil seal.
22-24
22
Installation: Extension housing
[Applying sealant]
• Apply sealant while observing the following cautions and then
engage the extension housing with the transmission.
CAUTION

of the nozzle.

[Installation]
• After applying the sealant, install the extension housing before
placed.
• Do not start the engine within one hour after installing the exten-
sion housing.
• When loosening or removing extension housing mounting bolts,
Installation: Lever set bolt

• Apply sealant to the thread areas of the lever set bolts to install
them onto the extension housing holes and reverse lever hole.

• Apply grease to the lip area of the oil seal.
• Install the oil seal evenly in the illustrated direction using a round
bar with an outer diameter of approximately 14 mm.
22-25
Installation: Spring pin
• Install the spring pin in the illustrated direction to prevent the
speedometer gear from slipping off.
Installation: Speedometer gear bushing

• When replacing the speedometer gear bushing, align the align-
ment mark of the old part with that of the rear cover to install.
22-26
22
M E M O
22-27
REVERSE IDLER GEAR
1 Power take-off cover 5 Side washer
2 Reverse idler gear shaft
3 Side washer
*a: Transmission case
4 Reverse idler gear : Non-reusable parts
Assembly sequence

Play of reverse idler gear in diameter direction 0.045 to 0.107 0.4
– Replace
End play of reverse idler gear 0.22 to 0.68 1.0

Bolt (power take-off cover mounting) 44.5 {4.54} –

Mating surface of power take-off cover and transmission
Loctite 5999 As required
case
22-28
22
Reverse shaft puller
A 03726-82000 Removal of reverse idler gear shaft

M12 × 1.25
Removal procedure
Removal: Power take-off cover
• Insert a scraper from the lower right or lower left of the power
take-off cover to remove the power take-off cover.
CAUTION
• Beware that prying the scraper halfway could deform the
power take-off cover or damage the transmission case.
Inspection: Reverse idler gear

• After the power take-off cover or the transmission power take-off
is removed, perform the following check. If the measurement ex-
ceeds the limit, replace defective parts.
• Check the play again after assembly and make sure it does not
exceed the limit.
(1) Play in diameter direction
(2) End play

• Measure the end play using the feeler gauge.
Removal: Reverse idler gear shaft
22-29
REVERSE IDLER GEAR
Installation: Power take-off cover
[Applying sealant]
• Apply sealant to the transmission case side while observing the
following cautions and then engage the power take-off cover
with the transmission.
CAUTION

• Apply sealant on the width center of the mating surface so that
of the nozzle.

[Installation]
• After applying the sealant, install the power take-off cover before
placed.
• Do not start the engine within one hour after installing the power
take-off cover.
• When loosening or removing power take-off cover mounting
bolts, be sure to reapply the sealant.
22-30
22
M E M O
22-31
6TH GEAR
1 Spring pin 8 Shifting plunger 15 Snap ring
2 6th shift rail jaw B 9 Shifting plunger spring 16 Countershaft rear bearing
3 6th reverse lever 10 Synchronizer hub 17 Mainshaft 6th gear
4 Gear shift fork piece 11 Countershaft 6th gear
5 Shifting key retainer 12 Needle bearing
*a: Countershaft
6 Synchronizer ring 13 Countershaft 6th gear sleeve : Non-reusable parts
7 Synchronizer sleeve 14 Thrust washer
Assembly sequence
22-32
22
End play of countershaft 6th gear 0.25 to 0.35 0.7 Replace
–
Play of countershaft 6th gear in diameter direction 0.08 to 0.14 0.2 Replace
Clearance between 6th gear shift fork piece and syn-
4, 7 0.3 to 0.6 1.0 Replace
chronizer sleeve
Clearance between protrusion of synchronizer ring and
6, 10 3.0 to 3.3 4.0 Replace
synchronizer hub groove
Clearance between synchronizer ring and countershaft
6, 11 1.23 to 1.47 0.5 Replace
6th gear

Lock nut 295 to 392 {30 to 40} –

Bearing puller and in-

staller
Removal of countershaft 6th gear
A B MH062697 sleeve, thrust washer and counter-
shaft rear bearing
φ68 78.5

staller
Installation of countershaft rear bear-
A B ing
φ80 φ42
MH062696
staller
Installation of countershaft 6th gear
A B C sleeve
φ80 φ56 φ45.5
Work before removal

Inspection: End play of countershaft 6th gear
• Measure the end play using feeler gauge.
• If the measurement exceeds the limit, replace defective parts.
22-33
6TH GEAR
Inspection: Play of countershaft 6th gear in diameter direc-
tion
Alignment marks: Synchronizer hub and countershaft 6th

gear
• Put alignment marks on the synchronizer sleeve and counter-
shaft 6th gear, each at one location before disassembly.
• Put alignment marks on the synchronizer ring and synchronizer
hub, each at one location alignment with the alignment mark put
on the synchronizer sleeve before disassembly.
Removal procedure
Removal: Countershaft 6th gear sleeve, thrust washer and
countershaft rear bearing
• Remove the countershaft rear bearing together with the sleeve
and washer.
Inspection: Clearance between gear shift fork piece and
synchronizer sleeve of mainshaft
22-34
22
Inspection: Clearance between synchronizer ring and syn-
chronizer hub
• If the clearance exceeds the limit, replace defective parts.
Inspection: Clearance between synchronizer ring and coun-

tershaft 6th gear
• When measuring the clearance, press the synchronizer ring
evenly against the gear and measure all around the circumfer-
ence.
• If the measurement is less than the limit, replace the ring and the
gear.
Installation: Countershaft rear bearing
• Install the countershaft rear bearing on the countershaft in the il-
Installation: Countershaft 6th gear sleeve
Installation: Synchronizer sleeve and synchronizer hub

• When replacing the synchronizer sleeve or synchronizer hub
with a new one, align the three keyways of the synchronizer hub
with three locations of the stub gear tooth of the synchronizer
sleeve to install.
22-35
6TH GEAR
Installation: Gear shift fork piece
• Install the gear shift fork piece on the reverse lever as shown in
the illustration after checking that its shaft diameter is appropri-
ate.
CAUTION
• Never fail to check the shaft diameter of the gear shift fork
piece. Installation of any gear shift fork piece with a smaller
diameter shaft is possible but not permitted.
Installation: 6th reverse lever

• Place the synchronizer sleeve in neutral position before install-
ing the 6th reverse lever.

• Install the spring pin in the illustrated direction (the spring pin
notch to be positioned forward or rearward of the vehicle). When
installing the spring pin, leave 0 to 0.5 mm outside from the
transmission shift rail.
• Drive the spring pin carefully not to impose too much load on the
transmission shift rail.
22-36
22
M E M O
22-37
TRANSMISSION BODY
1 Inspection plug 10 Shift rail and shift fork (See later section.)
2 Drain plug 11 Countershaft (See later section.)
3 Direct power cylinder (See Gr21.) 12 Drive pinion (See later section.)
4 Lever set bolt 13 Mainshaft (See later section.)
5 Rear bearing retainer 14 Clutch housing
6 Snap ring
7 Mainshaft rear bearing : Locating pin
8 Transmission case : Non-reusable parts
9 Bearing retainer
NOTE
• After removing direct power cylinder, perform work with the transmission body laid vertically on its clutch
housing side.
• If the countershaft, drive pinion and mainshaft are not disassembled, the shift rail and shift fork can be
disassembled on its own while mounted on the clutch housing.
22-38
22
Assembly sequence

Bolt (direct power cylinder mounting)
Bolt (bearing retainer mounting) 44.5 {4.5} –
Bolt (rear bearing retainer mounting)
Lever set bolt 160 {16.3} Sealant
Bolt (transmission case mounting) 54 {5.5} –
Inspection plug
68.6 ± 14.7 {7.0 ± 1.5} Sealant
Drain plug

Clutch housing mounting surface of direct power cylinder
Transmission case mounting surface of clutch housing
Thread area of lever set bolt Loctite 271 As required
Thread area of inspection plug
Thread area of drain plug
22-39
TRANSMISSION BODY
Snap ring expander MH061268 Removal and installation of snap ring

staller
A B
Removal of mainshaft rear bearing
φ96.8 40
MH062697
staller
A B Installation of mainshaft rear bearing
φ94 φ48
Eyebolt
A MH062340 Lifting of transmission case

M10 × 1.5
Steel lifting band

A
MH063410
251
Removal and installation of counter-

shaft, mainshaft and drive pinion
Eye nut
A MH063308
M24 × 1.5
Synchromesh guard
A B
For preventing synchromesh from
98 30.9 MH062889
sticking when mainshaft is driven
22-40
22
Removal procedure
Removal: Mainshaft rear bearing
Removal: Transmission case

• Install on the transmission case and make preparations for
lifting it up with a crane.
• After removing the bolts, lift up the transmission case while hit-
ting the rear end portions (arrow indicating) of the countershaft
and mainshaft and the rear rib portions (arrow indicating) of the
clutch housing with a plastic hammer to remove the transmis-
sion case.
CAUTION
• Be sure to hit the ribs as illustrated because hitting other
areas may break the clutch housing.
• Secure the countershaft and the 2nd gear area of the mainshaft
with for safety. Be sure to tighten enough to prevent it
from coming undone, but not excessively.
22-41
TRANSMISSION BODY
Removal: Shift rail and shift fork, countershaft, drive pinion
and mainshaft
• Leave the countershaft and mainshaft secured with .
• Install on the mainshaft and make preparations for lifting it
up with a crane.
• Secure the shift rail and shift fork with a rubber band to prevent it
from coming undone from the mainshaft.
• Put a piece of wood on the clutch housing and lift it up while hit-
ting it with a plastic hammer to remove.
• When lifting up, be sure to support the drive pinion with your
hand to prevent it from falling.
Installation: Shift rail and shift fork, countershaft, drive pin-
ion and mainshaft
• When driving in the drive pinion, mainshaft and countershaft, in-
stall to prevent the drive pinion and synchronizer of the
mainshaft from sticking.
• Place the synchronizer sleeve of mainshaft in neutral position
before installing the shift rail and shift fork on the mainshaft.
• Be sure to remove all the special tools used.
Installation: Transmission case

[Applying sealant]
• Apply sealant to the clutch housing side of the transmission
while observing the following cautions and then engage the
transmission case with the clutch housing.
CAUTION

• Apply sealant on the width center of the mating surface so that
of the nozzle.

22-42
22
[Installation]
• After applying the sealant, install the transmission case before
placed.
• Do not start the engine within one hour after installing the trans-
mission case.
• When loosening or removing transmission case mounting bolts,
Installation: Mainshaft rear bearing

• Install the mainshaft rear bearing on the transmission case in the
illustrated direction.
Installation: Lever set bolt

• Apply sealant to the thread areas of the lever set bolts to install
them onto the transmission case holes and reverse lever hole.
22-43
TRANSMISSION BODY
Shift Rail and Shift Fork
1 Spring pin 10 Gear shift fork piece 19 4th and 5th shift jaw B
2 6th shift jaw 11 Spring pin 20 4th and 5th shift rail
3 6th shift rail 12 Spring pin 21 4th and 5th reverse lever
4 Spring pin 13 2nd and 3rd shift jaw 22 Gear shift fork piece
5 Spring pin 14 2nd and 3rd shift fork
6
7
1st and reverse shift jaw B
1st and reverse shift jaw A
15
16
2nd and 3rd shift rail
Spring pin
*a: Mainshaft (Synchronizer
sleeve)
8 1st and reverse shift rail 17 Spring pin : Non-reusable parts
9 1st and reverse lever 18 4th and 5th shift jaw A
Assembly sequence
22-44
22
3, 8, 15, Correct or
Bend of shift rail 0 to 0.04 0.05
20 replace
10, 22, Clearance between gear shift fork piece and synchro-
0.3 to 0.6 1.0 Replace
*a nizer sleeve
14 Tilt of 2nd and 3rd gear shift fork claw 0 to 0.1 0.2 Replace
Clearance between 2nd and 3rd gear shift fork and syn-
*
14, a
chronizer sleeve of mainshaft
0.3 to 0.6 1.0 Replace
Inspection: Bend of gear shift rail
• Measure the extent of bending at the middle of each of gear shift
rail.
• While rotating the gear shift rail by one revolution, read how
much the dial gauge needle will move. A half of the reading ob-
served represents the bend, if any, of the shaft.
• If the measurement exceeds the limit, replace the gear shift rail.
Inspection: Clearance between gear shift fork piece and

synchronizer sleeve of mainshaft
Inspection: Tilt of 2nd and 3rd gear shift fork claw

• Measure the tilt (difference between A and A´) of claw A-A´
against the 2nd and 3rd gear shift rail hole of 2nd and 3rd gear
shift fork with pressing the rail to V-block and standing it vertical-
ly.
• If the measurement exceeds the limit, replace the 2nd and 3rd
gear shift fork.
Inspection: Clearance between 2nd and 3rd gear shift fork

and synchronizer sleeve of mainshaft
• If the measurement exceeds the limit, replace defective part.
22-45
TRANSMISSION BODY
Installation: Gear shift fork piece
• Install the gear shift fork piece on the reverse lever as shown in
the illustration after checking that its shaft diameter is appropri-
ate.
Shaft portion diameter (mm)
1st & Rev 10
4th & 5th 15
CAUTION
• Never fail to check the shaft diameter of the gear shift fork
piece. Installation of any gear shift fork piece with a smaller
diameter shaft is possible but not permitted.
Installation: 1st and reverse lever, 4th and 5th reverse lever
• Place the synchronizer sleeve of mainshaft in neutral position
before installing the reverse lever on the mainshaft.

• Install the spring pin in the illustrated direction (the spring pin
notch to be positioned forward or rearward of the vehicle). When
installing the spring pin, leave 0 to 0.5 mm outside from each
gear shift rail or each gear shift jaw.
• Drive the spring pin carefully so as not to impose too much load
on each gear shift rail and each gear shift jaw.
22-46
22
M E M O
22-47
DRIVE PINION
1 Snap ring
2 Drive pinion bearing
3 Drive pinion
Assembly sequence
verse.


staller
A B
Removal of drive pinion bearing
φ92.5 62.5
MH062697

staller
A B Installation of drive pinion bearing
φ94 φ48
22-48
22
Removal procedure
Removal: Drive pinion bearing
Installation: Drive pinion bearing
• Install the drive pinion bearing, facing the grooved side in the il-
22-49
MAINSHAFT
1 1st gear thrust washer 13 Needle bearing
2 1st gear 14 Snap ring
3 Needle bearing 15 3rd gear thrust washer
4 Snap ring 16 3rd gear
5 1st and reverse synchronizer (See later section.) 17 Needle bearing
6 Reverse gear 18 Snap ring
7 Needle bearing 19 2nd and 3rd synchronizer (See later section.)
8 Snap ring 20 2nd gear
9 Pilot bearing 21 Needle bearing
10 Snap ring 22 Mainshaft
11 4th and 5th synchronizer (See later section.)
12 5th gear
*a: Drive pinion
Assembly sequence
22-50
22
1st gear 0.15 to 0.46 0.7
2nd gear 0.15 to 0.61 0.8
– End play 3rd gear 0.15 to 0.46 0.7 Replace
5th gear 0.2 to 0.56 0.8
Reverse gear 0.15 to 0.46 0.7
1st gear 0.02 to 0.05 0.12
2nd gear 0.02 to 0.05 0.12
Play in the diameter
– 3rd gear 0.02 to 0.06 0.12 Replace
direction
5th gear 0.05 to 0.09 0.2
Reverse gear 0.04 to 0.07 0.12
1st gear and synchronizer ring of
1.23 to 1.47 0.5 Replace
1st and reverse synchronizer
Reverse gear and synchronizer
ring of 1st and reverse synchro- 1.23 to 1.47 0.5 Replace
nizer
Clearance 5th gear and synchronizer ring of
1.23 to 1.47 0.5 Replace
– between gear and 4th and 5th synchronizer
synchronizer ring Drive pinion and synchronizer ring
1.23 to 1.47 0.5 Replace
of 4th and 5th synchronizer
3rd gear and synchronizer ring of
0.96 to 1.54 0.5 Replace
2nd and 3rd synchronizer
2nd gear and synchronizer ring of
0.96 to 1.54 0.5 Replace
2nd and 3rd synchronizer
9 Play of pilot bearing in the diameter direction 0.04 to 0.08 0.12 Replace
Special tools
Work before removal

Inspection: End play of gears
• Measure the end play using feeler gauge.
22-51
MAINSHAFT
Inspection: Play in diameter direction of each gears
Alignment marks: Each gear and each synchronizer

• Put alignment marks on the each gear and the synchronizer
sleeve of the each synchronizer so that the combination of their
mating surfaces can be maintained when reassembled.
Inspection: Clearance between gear and synchronizer ring
of synchronizer
<Triple cone type>
• When measuring the clearance, press the ring and the center
cone evenly against the gear and measure all around the cir-
cumference.
• If the measurement is less than the limit, replace the ring and
gear or the drive pinion.
<Single cone type>

• When measuring the clearance, press the ring evenly against
the gear and measure all around the circumference.
• If the measurement is less than the limit, replace the ring and the
gear.
Inspection: Play in diameter direction of pilot bearing

• Carry out the measurement with installing the drive pinion, pilot
bearing and mainshaft and holding the mainshaft as illustrated.
• Measure the play with moving the gear of drive pinion in diame-
ter direction.
• If the measurement exceeds the limit, replace the pilot bearing.
22-52
22
M E M O
22-53
MAINSHAFT
2nd and 3rd Synchronizer
1 Synchronizer inner ring
2 Synchronizer center cone
3 Synchronizer outer ring
4 Synchronizer sleeve
5 Shifting plunger
6 Shifting plunger spring
7 Synchronizer hub
Assembly sequence
verse.

Clearance between synchronizer outer ring protrusion
3, 7 3.0 to 3.3 4.0 Replace
and synchronizer hub groove
Work before removal

Alignment marks
• Put alignment marks on the synchronizer inner ring, center
cone, outer ring and hub, each at one location, aligning with the
alignment mark put on the synchronizer sleeve before disas-
sembly.
Inspection: Clearance between synchronizer outer ring pro-
trusion and synchronizer hub groove
22-54
22
sleeve to install.
22-55
MAINSHAFT
1st and Reverse, 4th and 5th Synchronizer
1 Synchronizer ring
2 Synchronizer sleeve
3 Shifting plunger
4 Shifting plunger spring
5 Synchronizer hub
Assembly sequence
verse.

Clearance between synchronizer ring protrusion and
1, 5 3.0 to 3.3 4.0 Replace
synchronizer hub groove
Work before removal

Alignment marks
• Put alignment marks on the synchronizer ring and synchronizer
hub, each at one location alignment with the alignment mark put
on the synchronizer sleeve before disassembly.
Inspection: Clearance between synchronizer ring protru-
sion and synchronizer hub groove
22-56
22
sleeve to install.
22-57
COUNTERSHAFT
1 Snap ring
2 Countershaft front bearing
3 Countershaft gear
Assembly sequence
verse.


staller
A B
Removal of countershaft front bearing
φ72 49.5
MH062696
staller
Installation of countershaft front bear-
A B ing
φ80 φ42
22-58
22
Removal procedure
Removal: Countershaft front bearing
Installation: Countershaft front bearing
• Install the countershaft front bearing on the countershaft in the il-
22-59
TRANSMISSION CONTROL
Removal sequence
1 Gear shift lever cover 13 Lever (See later section.) 24 No. 2 select lever
2 Gear shift lever knob 14 Select rod No. 3 (See later section.)
3 Gear shift lever boot 15 Spacer 25 No. 3 select lever
4 Bracket 16 Bushing (See later section.)
5 Ball joint 17 Select rod No. 4 26 Cross shaft bushing
6 Grommet 18 Spacer 27 Cross shaft boot
7 Gear shift lever 19 Bushing 28 Cross shaft
(See later section.) 20 Shift rod No. 3 29 Cross shaft bracket
8 Hose 21 Spacer
9 Select rod No. 1 22 Bushing
*a: Torsion shaft
10 Shift rod No. 1 23 No. 2 shift lever
*b: Gear select lever
11 Shift rod No. 2 (See later section.) : Non-reusable parts
12 Select rod No. 2
22-60
22

Nut (ball joint mounting)
Nut (select rod No. 2 mounting) 34 to 44 {3.5 to 4.5} –
Nut (shift rod No. 2 mounting)
Nut (select rod No. 1 mounting)
Nut (select rod No. 2 mounting) 39 to 50 {4.0 to 5.1} –
Nut (select rod No. 4 mounting)
Bolt (cross shaft mounting) 15 to 20 {1.5 to 2.0} –
Nut (cross shaft bracket mounting) 19 to 28 {1.9 to 2.9} –
Nut (No. 2 shift lever mounting)
Nut (No. 2 select lever mounting)
45 to 55 {4.5 to 5.5} –
Nut (No. 3 select lever mounting)
Nut (cross shaft bracket mounting)
Lock nut on ball joint
Lock nut on shift rod No. 1
Lock nut on shift rod No. 2 16 to 24 {1.6 to 2.4} –
Lock nut on select rod No. 1
Lock nut on shift rod No. 3
18 to 27 {1.8 to 2.8} –

Sliding area of select rod No. 3 and bushing
Sliding area of select rod No. 4 and bushing
Wheel bearing grease As required
Sliding area of shift rod No. 3 and bushing
[NLGI No. 2 Li soap]
Inner and outer periphery of cross shaft bushing
Filling in cross shaft boot 0.05 g
Installation: Cross shaft
• Insert the cross shaft so that the punch mark “ ” of the torsion
shaft on the transmission is positioned at the center of the slit of
the cross shaft.
22-61
Installation: Shift rod No. 1 and No. 2 and select rod No. 1
and No. 2
• Install each shift rod and select rod with the dimension shown in
the drawing.
• Position the ball joints on both ends so that their relative installa-
tion angle become as shown in the table below.
Shift rod No. 1 180° ± 2°
Shift rod No. 2 0° ± 2°
Select rod No. 1 90° ± 2°
Select rod No. 2 180° ± 2°
Installation: Shift rod No. 3 and select rod No. 4

• Adjust the length of the shift rod and select rod to the values
shown in the drawing by turning turnbuckles. When adjusting,
the thread lengths remaining at both ends of each turnbuckle
(A1 and A2, or B1 and B2) should be almost equal.
• Install the ball joint to the select rod No. 4 with the dimension
shown in the drawing and with the relative angle against the con-
necting bolt at the other end of the select rod to be 90° ± 3°.
22-62
22
Inspection: Gear shift lever
[Inspection]
• With the gearshift lever in the neutral position, check that the dis-
tances specified below meet the standard values in the following
table.
Fore-and-aft direction C : Distance from instrument panel
Right-and-left direction D: Distance from the center of the
steering wheel:
To the 4th-5th line on the gear shift le-
ver knob
Fore-and-aft direction C (mm) Right-and-left direction D (mm)

207 366
• If the measurement deviates from the standard value, adjust.
[Adjustment]
• With the torsion shaft of transmission and gear select lever in
their neutral positions, adjust the shift rod No. 3 and select rod
No. 4 using the turnbuckles on the transmission side so that
neutral position of gear shift lever is as specified below.
Adjustment Gear shift lever Shift rod No. 3

of longitudi-
Tilt forward Shorten the rod
nal direction
C Tilt backward Lengthen the rod
Adjustment Gear shift lever Select rod No. 4

of trans-
Tilt rightward Lengthen the rod
verse direc-
tion D Tilt leftward Shorten the rod
• Amount of threaded portion remainder of rod at each end should
be the same.
• Make sure to operate the gear shift lever that it shifts smoothly
and selects each position.
22-63
Gear Shift Lever
1 Shift lever
2 Spacer
3 Wave washer
4 Collar
5 Bushing
6 Spacer
7 Return spring
8 Collar
9 Bushing
10 Cross sleeve
11 Plate
Assembly sequence
verse.

Nut (shift lever mounting)
17 to 26 {1.7 to 2.7} –
Nut (cross sleeve mounting)

Multipurpose grease
Outer periphery of collar As required
[NLGI No. 2 Li soap]
Installation: Cross sleeve
• Assemble the cross sleeve and plate and tighten the nut to the
specified value. Measure the clearance between the cross
sleeve and plate. If the measurement is out of the dimension
shown in the drawing, adjust by spacer.
• After installation, make sure that the shift lever operates smooth-
ly without hesitation.
Spacer thickness: 0.3 mm and 0.5 mm (2 types)
22-64
22
Installation: Shift lever
• Temporarily assemble the shift lever and cross sleeve with no
wave washers and tighten the nut to the specified torque. Mea-
sure the clearance between the shift lever and cross sleeve. Se-
lect an appropriate spacer to make the clearance to the
dimension shown in the drawing. Reassemble the shift lever and
cross sleeve with the selected spacer and two wave washers in-
stalled.
22-65
Lever
1 Return spring
2 Lever bracket A
3 Lever bracket B
4 Bushing
5 Dust boot
6 Cover
7 Lock pin
8 Lever
9 Spacer
10 Bushing
11 No. 1 lever B
12 No. 1 lever A
Assembly sequence
verse.

Nut (lock pin mounting) 10 to 15 {1.0 to 1.5} –

Filling in cross shaft boot
Inner periphery of No. 1 lever B Multipurpose grease
As required
Outer periphery of No. 1 lever A [NLGI No. 2 Li soap]
Inner surface of bushing
22-66
22
Installation: Lever
• While applying a force of 98 N {10 kgf} on the lever around No. 1
lever A as shown in the drawing, align the lever and the groove
on No. 1 lever A. Then insert the lock pin with its tapered side to-
ward the shaft and tighten it with a nut.
• With the nut tightened to the specified torque, check that the
clearance between No. 1 lever A and No. 1 lever B meets the di-
mension shown in the drawing. If the measurement is out of the
specified value, adjust using spacer.
• After installation, check that the lever, No. 1 lever B and No. 1 le-
ver A moves smoothly without hesitation.
Installation: Cover and dust boot

• Press the covers fully into the grooves of the lever brackets.
• Pack grease at section A shown in the drawing.
22-67
No. 2 Shift Lever
1 Bushing
2 No. 2 shift lever
3 Spacer
4 No. 2 shift lever bracket
Assembly sequence
verse.

Nut (No. 2 shift lever mounting) 27 to 34 {2.8 to 3.5} –

Inner periphery of bushing Multipurpose grease
As required
Outer periphery of No. 2 shift lever bracket shaft [NLGI No. 2 Li soap]
Installation: Spacer
• Assemble the No. 2 shift lever and No. 2 shift bracket and tight-
en the nut to the specified value. Measure the clearance be-
tween the No. 2 shift lever and No. 2 shift bracket. If the
measurement is out of the dimension shown in the drawing, ad-
just by spacer.
• After installation, make sure that the No. 2 shift lever operates
smoothly without hesitation.
22-68
22
No. 2 Select Lever
1 Bushing
2 No. 2 select lever
3 Spacer
4 No. 2 select lever bracket
Assembly sequence
verse.

Nut (No. 2 select lever mounting) 27 to 34 {2.8 to 3.5} –

As required
Outer periphery of No. 2 select lever bracket shaft [NLGI No. 2 Li soap]
• Assemble the No. 2 select lever and No. 2 select lever bracket
and tighten the nut to the specified value. Measure the clear-
ance between the No. 2 select lever and No. 2 select lever
bracket. If the measurement is out of the dimension shown in the
drawing, adjust by spacer.
• After installation, make sure that the No. 2 select lever operates
22-69
No. 3 Select Lever
1 Bushing
2 No. 3 select lever
3 Spacer
4 No. 3 select lever bracket
Assembly sequence
verse.

Nut (No. 3 select lever mounting) 27 to 34 {2.8 to 3.5} –

As required
Outer periphery of No. 3 select lever bracket shaft [NLGI No. 2 Li soap]
• Assemble the No. 3 select lever and No. 3 select lever bracket
and tighten the nut to the specified value. Measure the clear-
ance between the No. 3 select lever and No. 3 select lever
bracket. If the measurement is out of the dimension shown in the
drawing, adjust by spacer.
• After installation, make sure that the No. 3 select lever operates
22-70
BEARING PULLER AND INSTALLER 22
• Bearing pullers and installers are special tools used for removing and installing the bearings listed in the table be-
low and used in this group.
• For each puller (for removing) and each installer (for installing), use the components of the bearing pullers and in-
stallers in combination.
Application
Countershaft front bearing
Countershaft rear bearing

Mainshaft rear bearing
Drive pinion bearing
6th gear sleeve

Component
Bearing
puller and Component Part No. Puller Installer Puller Installer Puller Installer Puller Installer Installer
installer
Adapter MH062590 O
03726-
Plug O O O
81017
Bolt MH062700 O
Body MH062701 O O O O
Protector MH061306 O
Counter-
shaft 03726-
MH062696
bearing 81012
claw
Bearing
MH062707 O
claw
Mainshaft
bearing MH061305
claw
Bearing
MH062706
claw
Bearing
MH062589 O
claw
03726-
Plug O O
81017
Bolt MH062700 O O O
Body MH062702 O O O O O
MH062697
Protector ME624229 O O O
Mainshaft
bearing ME624226 O
claw
Bearing
MH062636 O
claw
22-71
GROUP 25 PROPELLER SHAFT
SPECIFICATIONS............................................................................... 25-2

1. Configuration of Propeller Shaft Connection ................................ 25-3
2. Propeller Shaft .............................................................................. 25-3
TROUBLESHOOTING ........................................................................ 25-5

1. Inspection of Propeller Shaft Joint Fasteners for Looseness ........ 25-6
2. Inspection of Play in Spline Connection of Slip Yoke Joint ........... 25-6
3. Inspection of Play in Universal Joints ........................................... 25-6
4. Inspection of Play in Center Bearing............................................. 25-6
REMOVAL AND INSTALLATION OF PROPELLER SHAFT ............. 25-8
PROPELLER SHAFT........................................................................ 25-10
25-1
SPECIFICATIONS
Item Specifications
<Without center bearing> P3 (straight type, swage type)
Propeller shaft Model
<With center bearing> P3
25-2
1. Configuration of Propeller Shaft Connection
2. Propeller Shaft
25-3
• There are two types of propeller shaft: the straight type (stan-
dard) and swage type.
• Relative positions of the transmission and rear axle vary de-

pending upon the unevenness of the road surface and the vibra-
tion and load shifts that occur during vehicle operation.
The universal joint and the slip yoke joint allow for this variation
in transmission-to-rear axle relative position.
25-4
TROUBLESHOOTING 25
Symptoms Propeller shaft vi- Abnormal noise
brates from propeller shaft
Abnormal noise at acceleration from
Abnormal noise at normal running

Vibration at high speed
Vibration at low speed
zero or at coasting
Possible causes
Wrong combination of flange yoke directions O
Insufficient grease O
Slip yoke joint
Excessive play at spline O O
Excessive clearance in axial direction of spider shaft O O
Universal joint Insufficient needle bearing greasing O
Worn out needle bearing O O O
Insufficient grease O
Seizure, wear or improper rotation O O
Center bearing
Deteriorated or deformed cushion rubber O
Loose hanger mounting bolt O
Loose mounting bolts O O
Propeller shaft Bent O
Dynamic balance improper O
Transmission in high speed gear O
25-5
1. Inspection of Propeller Shaft Joint Fasteners for Looseness
• Check the bolts and nuts of the following components for loose-
ness.
• Flange yokes
• Front propeller shaft hanger
• Tighten loose fasteners, if any, to the specified torques. (See
“REMOVAL AND INSTALLATION OF PROPELLER SHAFT”.)
2. Inspection of Play in Spline Connection of Slip Yoke Joint

• Move the propeller shaft in rotational, vertical and lateral direc-
tions to check for play in the spline connection.
• If large play is detected in any direction, remove the propeller
shaft from the vehicle to inspect the propeller shaft itself. (See
“PROPELLER SHAFT”.)
CAUTION
• This inspection must be performed before greasing the slip
yoke joint. Grease on part surfaces may prevent detection
of play.
3. Inspection of Play in Universal Joints

• Holding both flanges of each universal joint by hand, move it in
rotational, vertical and lateral directions to check for play.
• If large play is detected in any direction, disassemble and in-
spect the universal joint. Replace any defective components.
(See “PROPELLER SHAFT”.)
CAUTION
• This inspection must be performed before greasing the uni-
versal joint. Grease on part surfaces may prevent detection
of play.
4. Inspection of Play in Center Bearing

• Holding the propeller shaft sections on both sides of the center
bearing by hand, move it in vertical and lateral directions to
check for play. Also check the cushion rubber for damage and
deterioration by aging.
• If large play is detected in any direction or the cushion rubber is
damaged or deteriorated, replace the center bearing and/or
cushion rubber.
CAUTION
• This inspection must be performed before greasing the cen-
ter bearing. Grease on part surfaces may prevent detection
of play.
25-6
25
M E M O
25-7
REMOVAL AND INSTALLATION OF PROPELLER SHAFT
Removal sequence
1 Propeller shaft <Without center bearing> (See later section.)
2 Propeller shaft <With center bearing> (See later section.)
3 Rubber bushing
4 Spacer
CAUTION
• Securely chock the wheels so that the vehicle does not move.
• Do not remove the chocks until the entire operation is completed.
25-8
25
Nut (propeller shaft mounting) 100 to 120 {10 to 12} –
Nut (propeller shaft hanger mounting) 73 to 92 {7.4 to 9.4} –
Nut (propeller shaft hanger mounting) 47 to 65 {4.8 to 6.6} –

Supply through grease nipple of propeller shaft As required
Work before removal

Alignment marks: Propeller shaft
• Be sure to make alignment marks before removal.
Installation: Propeller shaft

• Assemble the front and rear propeller shaft sections with the re-
sidual imbalance marks on them in positions opposite to each
other as shown in the drawing.

Lubrication: Grease nipple
• Fill grease through grease nipple until clean grease overflows
from the hole in dust plug of slip yoke joint.
25-9
PROPELLER SHAFT
<Without Center Bearing>
1 Snap ring 6 Grease nipple 11 Shield packing
2 Needle bearing 7 Spider 12 Propeller shaft
3 Flange yoke 8 Grease nipple
4 Snap ring 9 Slip yoke joint : Non-reusable parts
5 Needle bearing 10 Retainer packing
Assembly sequence
Follow the disassembly sequence in reverse, excepting:
12→10→11→9
Repair kit: Universal joint spider kit

• Be sure to reinstall removed parts at their original positions.
• Correct dynamic balance after replacement of parts. (See “REMOVAL AND INSTALLATION OF PROPELLER
SHAFT”.)
• Fill grease through the grease nipple of the slip yoke joint after mounting the propeller shaft to the vehicle. (See
“REMOVAL AND INSTALLATION OF PROPELLER SHAFT”.)

– Axial clearance of spider 0 to 0.06 – Adjust
10 g max./3000 rpm
– Permissible amount of imbalance of propeller shaft (periphery of pipe portion – Adjust
of shaft)
–0.033 to 0.008
2, 3 Clearance between needle bearing and flange yoke 0.1 Replace
“–” means interference.
2, 5, 7 Play between needle bearing and spider 0.01 to 0.06 0.1 Replace
Clearance between needle bearing and slip yoke joint –0.033 to 0.008
5, 9, 12 0.1 Replace
or propeller shaft “–” means interference.
Play in rotating direction between slip yoke joint and
0.01 to 0.09 0.3 Replace
propeller shaft spline
9, 12
Play in diametric direction between slip yoke joint and
0.02 to 0.16 0.3 Replace
propeller shaft spline
Correct or
12 Bend of propeller shaft 0 to 0.3 0.4
replace
25-10
25
Supply through grease nipple Wheel bearing grease
As required
Shield packing lips [NLGI No. 2 (Li soap)]

Universal joint tool

set
A: Yoke assembly MB999024
B: Push rod A: MB999025 Removal and installation of needle
C: Guide B: MB999026 bearing
C: MB999010
D E F
φ29 φ29 φ27.7
Work before removal

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

combination)
Identifica- Identifica-
Thickness Combination Thickness
tion color tion color
1.49 mm None 1.49 mm None
1.52 mm Black 1.52 mm Black
1.55 mm Blue 1.55 mm Blue
1.58 mm Yellow 1.58 mm Yellow
1.61 mm Purple 1.61 mm Purple
Alignment mark: Propeller shaft

• To prevent assembly of wrong parts, make alignment marks on
flange yoke, slip yoke joint and propeller shaft.
25-11
PROPELLER SHAFT
Removal procedure
Removal: Needle bearing
• Fit -C into -A from outside.
• Applying -B to the spider, operate -A to force out the
spider and remove the needle bearing.
Inspection: Clearance between needle bearing and spider
• If the measurement exceeds the limit, replace the spider and
bearings with the universal joint spider kit.
Inspection: Play between slip yoke joint and propeller shaft

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

• Before checking the pipe for bend, be sure to peel off the paint
from the measurement position and the portion supported by the
V-block using the paint remover.
• Measure bend of propeller shaft at the center of its pipe portion.
• To measure the bend of propeller shaft, turn it fully once and
read the dial gauge indication. The bend is one half of the indi-
cated value.
• If the measurement exceeds the limit, correct the bend with a
press or replace the propeller shaft.
• Check the propeller shaft for cracks in the welded area after cor-
recting the bend using a press. If cracking is found, replace the
shaft.
CAUTION
• When peeling off the paint, use care not to damage the pipe.
25-12
25
Installation: Retainer packing
• Hold retainer packing against slip yoke joint and caulk tabs (at
eight places).
Installation: Spider
• Fit the grease nipple to the spider facing it in the illustrated direc-
tion.
• Orient the transmission and axle side grease nipples in the

same direction.
Installation: Needle bearing

• Fit -C into -A from inside.
• Operating -A, install needle bearing into place.

• Fill grease through the grease nipple until clean grease over-
flows from all of the four oil seals of spider.
• If grease does not overflow from all of the four oil seals or rust,
water and dirt come out with grease, replace the spider and
bearings with the spider kit.
25-13
PROPELLER SHAFT
Inspection: Propeller shaft
[Inspection]
• Measure the amount of imbalance (dynamic imbalance) of com-
pleted propeller shaft assembly on a balancing machine.
• If measured value exceeds the standard value, make adjust-
ment as follows.
[Adjustment]
• Attach appropriate balance pieces at the illustrated points so
that the amount of imbalance comes within the specified stan-
dard value.
• Maximum balance piece allowance for one point is 100 g.
• Use a combination that keeps the number of balance pieces to a
minimum.
Available balance pieces

Mass
2g
4g
6g
8g
10 g
12 g
16 g
24 g
• After balancing the propeller shaft, mark the residual imbalance

point (heavy spot) on the transmission side of the propeller shaft
as shown in the drawing.
25-14
25
M E M O
25-15
PROPELLER SHAFT
<With Center Bearing>
1 Snap ring 7 Spider 13 Center bearing
2 Needle bearing 8 Disc spring 14 Propeller shaft
3 Flange yoke 9 Companion flange
4 Snap ring 10 Holder : Non-reusable parts
5 Needle bearing 11 Hanger
6 Grease nipple 12 Cushion rubber
Assembly sequence
Repair kit: Universal joint spider kit
• Be sure to reinstall removed parts at their original positions.

• Correct dynamic balance after replacement of parts. (See “REMOVAL AND INSTALLATION ON PROPELLER
SHAFT”.)

– Axial clearance of spider 0 to 0.06 – Adjust
5 g max./3000 rpm
– Permissible amount of imbalance of propeller shaft (periphery of pipe portion – Adjust
of shaft)
–0.033 to 0.008
2, 3 Clearance between needle bearing and flange yoke 0.1 Replace
2, 5, 7 Play between needle bearing and spider 0.01 to 0.06 0.1 Replace
–0.033 to 0.008
5, 14 Clearance between needle bearing and propeller shaft 0.1 Replace
Correct or
14 Bend of propeller shaft 0 to 0.3 0.4
replace

Nut (companion flange mounting) 290 to 390 {30 to 40} –
25-16
25
Supply through grease nipple As required
70 to 100% of
Fill space in center bearing housing Heat-resisting grease space capacity
[NLGI No. 3] (20 to 29 g)
Center bearing seal lips As required

Universal joint tool

set
A: Yoke assembly MB999024
B: Push rod A: MB999025 Removal and installation of needle
C: Guide B: MB999026 bearing
C: MB999010
D E F
φ29 φ29 φ27.7
Work before removal

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

combination).
Identifica- Identifica-
Thickness Combination Thickness
tion color tion color
1.58 mm Yellow 1.58 mm Yellow
1.61 mm Purple 1.61 mm Purple
Alignment mark: Propeller shaft

• To prevent assembly of wrong parts, make alignment marks on
flange yoke, companion flange and propeller shaft.
25-17
PROPELLER SHAFT
Removal procedure
Removal: Needle bearing
• Fit -C into -A from outside.
• Applying -B to the spider, operate -A to force out the
spider and remove the needle bearing.
Inspection: Clearance between needle bearing and spider
• If the measurement exceeds the limit, replace the spider and
bearings with the universal joint spider kit.
Inspection: Center bearing

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

• Before checking the pipe for bend, be sure to peel off the paint
from the measurement position and the portion supported by the
V-block using the paint remover.
• Measure bend of propeller shaft at the center of its pipe portion.
• To measure the bend of propeller shaft, turn it fully once and
read the dial gauge indicator. The bend is one half of the indicat-
ed value.
• If the measurement exceeds the limit, correct the bend with a
press or replace the propeller shaft.
• Check the propeller shaft for cracks in the welded area after cor-
recting the bend using a press. If cracking is found, replace the
shaft.
CAUTION
• When peeling off the paint, use care not to damage the pipe.
25-18
25
Installation: Grease nipple
• Fit the grease nipple to the spider facing in the illustrated direc-
tion.
Installation: Needle bearing

• Fit -C into -A from inside.
• Operating -A, install the needle bearing into place.

• Fill grease through the grease nipple until grease overflows from
all of the four oil seals of spider.
• If grease does not overflow from all of the four oil seals or rust,
water and dirt come out with grease, replace the spider and
bearings with the spider kit.
Inspection: Propeller shaft

[Inspection]
• Use a balancing machine to measure the amount of imbalance
(dynamic imbalance) with the propeller shaft positioned as
shown in the illustration.
• If measured value exceeds the standard value, make adjust-
ment as follows.
[Adjustment]
• Attach appropriate balance pieces at the illustrated points so
that the amount of imbalance comes within the specified stan-
dard value.
• Maximum balance piece allowance for one point is 100 g.
• Use a combination that keeps the number of balance pieces to a
minimum.
25-19
PROPELLER SHAFT
Available balance pieces
Mass
2g
4g
6g
8g
10 g
12 g
16 g
24 g
• After balancing the propeller shaft, mark the residual imbalance

point (heavy spot) on both transmission side and differential side
of the propeller shaft as shown in the drawing. The mark on the
companion flange must be in line with the mark on the differen-
tial side of the propeller shaft.
25-20
GROUP 26 FRONT AXLE
SPECIFICATIONS............................................................................... 26-2

1. Wheel Hub and Rotor .................................................................... 26-3
2. Wheel Hub and Brake Drum .......................................................... 26-3
3. Knuckle and Kingpin, Front Axle .................................................. 26-4

1. Inspection and Adjustment of Wheel Alignment ........................... 26-6
2. Inspection and Adjustment of Steering Angle ............................. 26-10
3. Inspection of Side Slip .................................................................26-11
4. Inspection of Tie Rod End Ball Joint ............................................26-11
5. Inspection of Wheel Bearing for Play .......................................... 26-12
6. Inspection of Knuckle Joint for Play ........................................... 26-12
WHEEL HUB AND ROTOR .............................................................. 26-14
WHEEL HUB AND BRAKE DRUM................................................... 26-22
KNUCKLE AND KINGPIN, FRONT AXLE ....................................... 26-30
TIE ROD ............................................................................................ 26-38
26-1
SPECIFICATIONS
Item Specifications
Model F020B
Front axle
Type Reverse Elliot, “I” beam
Kingpin outer diameter × length mm 28 × 180
Tread (dimension notified to the
1655
authorities) mm
Approx. 140 <Drum brake type>
Mass kg
Approx. 145 <Disc brake type>
26-2
1. Wheel Hub and Rotor
• The brake pad wear indicator is installed in both the right and left wheels.
2. Wheel Hub and Brake Drum
26-3
3. Knuckle and Kingpin, Front Axle
26-4
TROUBLESHOOTING 26
Symptoms
Uneven wear or early wear of front tires

Unable to turn the steering wheel
Steering wheel pulls to one side
Continuous noise while cruising
Intermittent noise while cruising
Steering wheel return poor

Steering wheel feels stiff
Reference Gr
Steering wheel shakes

Possible causes
Wheel alignment misaligned O O O O
Steering angle adjustment faulty O
Wheel hub bearing seized, worn or defec-
O O
tive rotation
Wheel hub bearing broken O
Kingpin worn O
Clearance between kingpin and kingpin
O O
bushing excessive
Greasing to kingpin insufficient O
Kingpin thrust bearing seized, worn or de-
O
Wheel hub, knuckle and fective rotation
kingpin, front axle Vertical clearance between knuckle and
O
front axle excessive
Knuckle arm and tie rod arm tightening nuts
O
loose
Ball stud tightening nut of tie rod end loose O
Tie rod end ball stud worn O
Tie rod bent O
Knuckle bent O
Front axle bent O
Various parts of front axle tightened exces-
O
sively
U-bolt nut of front suspension loose O
Front suspension Gr33
One of front springs worn-out or broken O
Tire inflation pressure uneven O O
Tire inflation pressure too little O
Inflation pressures uneven for right and left
O
tires
Tire Gr31
Size and type of right and left tires different O O
Outer diameters of right and left tires re-
O
markably different
Handling of tires inadequate O
26-5
1. Inspection and Adjustment of Wheel Alignment
Because the value of wheel alignment is related to the side slip amount, both wheel alignment and the side slip
amount must conform to the standard values.
Perform the following before carrying out inspection and adjustment of wheel alignment.
• Park the unloaded vehicle on a level surface.
• Check that the tire sizes are appropriate.
• If the wear conditions of the right and left tires are remarkably different, replace them.
• Adjust the tire pressure to the specified value.
• If the vehicle is tilted due to faulty suspension, repair it.
• Adjust the front axle to eliminate the following conditions.
• Play at or loose kingpin
• Loose front wheel hub
• Loose securing bolts for the tie rod arm, knuckle arm and tie rod
• Bent knuckle and front axle
• Adjust the play of the steering wheel.
• For wheel alignment, which is related to the side slip amount, both wheel alignment and the side slip amount must
conform to the standard values.

Toe-in 0 to 6 – Adjust
Camber 1°00’ ± 1°00’ – Replace
–
Caster 1°15’ ± 0°45’ – Replace
Kingpin inclination angle 8° ± 10’ – Replace

– Clamp nut (tie rod end clamp fastening) 25 ± 5 {2.5 ± 0.5} –
– Alignment gauge adapter 113 ± 15 {11.5 ± 1.5} –

Hubcap wrench
A B MB999108 Removal of hubcap

0.5 78°
Alignment gauge
adapter
Measurement of camber, caster and
MH063428
kingpin inclination angle
A B C D
φ80 M24 × 1.5 φ45 69
26-6
26
1.1 Inspection and adjustment of toe-in
[Inspection]
• Direct the front wheels straight ahead.
• Put a mark at the front center of each front tire.
• Align the needle tips of the toe-in gauge with the marks on the
tires to measure distance A between the marks.
• Push the vehicle to roll the tires 180 degrees.

• Measure distance B between the marks that have moved to the
rear of the vehicle.
• If toe-in (difference between A and B) deviates from the stan-
dard value, adjustment is needed.
[Adjustment]
• Loosen the clamp nuts on the right and left.
• Turn the tie rod with a pipe wrench to adjust the toe-in.
C: Toe-out direction
D: Toe-in direction
• After the adjustment, tighten the clamp nut to the specified
torque.
• Hold down the tie rod end toward the front of the vehicle with the
front wheels directed straight ahead so that both the right and
left tie rod ends are in contact with the ball studs. In this state,
adjust so that the specified toe-in is achieved and tighten the
clamp nut to secure the tie rod.
26-7
1.2 Inspection of camber
• Remove the hubcap with .
• Remove the lock nut.

CAUTION
• Do not apply the vehicle weight to the hub bearing with the
lock nut loosened.
• Wipe off grease from the knuckle end, attach and tighten
the knuckle to the specified torque.
• Attach the camber/caster/kingpin gauge.
• Place the level with its bubble staying in the middle.

• Read the center of a bubble in the camber scale to obtain the
camber. Measure at both front tires.
• If the measured value deviates from the standard value, check
the kingpin and kingpin bushing for wear, the wheel bearing for
looseness, and the knuckle and front axle for distortion. Replace
defective parts.
1.3 Inspection of caster and kingpin inclination angle

• Prepare a platform of the same height as the turning radius
gauges and place it under the rear wheels so that the vehicle
may be placed level.
• Apply chocks to the rear wheels.
• Keep the turning radius gauges locked.
• Jack up the vehicle and align the centers of the ground contact
areas of the right and left front wheels with the centers of the
corresponding turntables.
• Unlock the turning radius gauges and set the scale to 0 degrees.
• In the same manner as “1.2 Inspection of camber”, attach the
camber/caster/kingpin gauge and adjust the level so that the
bubble staying in the middle.
26-8
26
• Depress the brake pedal. With brake applied to the front wheels,
turn the steering wheel slowly, to the right when inspecting the
right wheel and left when inspecting the left wheel, until the scale
of the turning radius gauge moves from 0 to 20 degrees.
NOTE
• If brake is not applied, the wheel may turn slightly, resulting
in an inaccurate measurement.
• With the wheel turned 20 degrees, turn the adjuster to set the
center of the bubbles in the caster scale and kingpin scale to 0
degrees.
NOTE
• There are two kingpin scales, right and left. Be sure to use
the right kingpin scale to inspect the right front wheel and
left to inspect the left front wheel.
• Slowly turn the steering wheel in reverse until the turning radius
gauge indicates 20 degrees of the reverse direction.
• Read the centers of the bubbles in the caster scale and kingpin
scale in this condition to obtain the caster and kingpin inclination
angles.
the kingpin and kingpin bushing for wear, the wheel bearing for
looseness, and the knuckle and front axle for distortion. Replace
defective parts.
• After the inspection, install the lock nut and measure the starting
torque of the wheel hub bearing. (See later section.)
the wheel bearing and adjust the starting torque. (See later sec-
tion.)
• Fill the lock nut mounting potion of the wheel hub with the speci-
fied amount of grease with the grease pump nozzle so that the
outer bearing surface is covered with the grease. Then, install a
new hubcap. (See later section.)
26-9
2. Inspection and Adjustment of Steering Angle
• Perform steering angle inspection and adjustment only after inspection and adjustment of wheel alignment have
been completed.
Service standards
Inside (outside steering angle is only 0°
– Steering angle 47° (35°) – Adjust
for reference) –2°

– Lock nut (tightening of knuckle stopper bolt) 46.5 ± 7 {4.75 ± 0.75} –
• Prepare the turning radius gauge and a platform under the vehi-
cle in the same manner as “1.3 Inspection of caster and kingpin
inclination angle”.
• With the turning radius gauge set to 0 degrees, fully turn the
steering wheel right or left, and read the scale of the turning radi-
us gauge to obtain the steering angle.
• If the measured value deviates from the standard value, adjust
the steering angle with the knuckle stopper bolt and tighten the
lock nut to the specified torque.
26-10
26
3. Inspection of Side Slip
• Perform side slip inspection only after inspection and adjustment of wheel alignment have been completed.
• Because the value of the side slip amount is related to wheel alignment, both the side slip amount and wheel
alignment must conform to the standard values.

– Side slip amount (per meter) 3 or less – Adjust

• Move over the side slip tester as slowly as possible to inspect
side slip.
NOTE
• Pay attention to the following items when moving over the
side slip tester.
• Move the vehicle straight ahead. Do not turn the steering
wheel.
• Do not apply brake.
• Keep the speed constant.
• If the measured value deviates from the standard value, inspect

and adjust wheel alignment.
4. Inspection of Tie Rod End Ball Joint

4.1 Play
• Hold the tie rod section of the tie rod with the vehicle kept sta-
tionary, and move it in the back-and-forth, up-and-down and
right-and-left directions to check for play at ball joints of the tie
rod end.
NOTE
• Be sure to check for play at ball joints of both right and left
sides of the tie rod.
• If feeling play with your hand, replace the tie rod end of the tie
rod.
4.2 Dust cover

• Check that there are no wear, cracks or damage. Their abnor-
malities can cause water to enter the ball joint, resulting in pre-
mature wear.
• If wear, crack, or damage is present, inspect traces of water en-
try and occurrence of rust in the ball joint. If any abnormality is
found, replace the tie rod end. If no abnormality is found, replace
the dust cover and reapply grease.
26-11
5. Inspection of Wheel Bearing for Play
• Jack up the vehicle.
• Try to move the top and bottom of the front tire by hands in the il-
lustrated directions to inspect the wheel bearing for play.
• If play is found with the feel of hands, repeat the inspection pro-
cedure while having the brake pedal depressed by another per-
sonnel. When the play is removed by operating the brake pedal,
the symptom indicates that there is play in the wheel bearing.
Then inspect the turning torque of the wheel bearing and adjust
it as required. (See “WHEEL HUB AND ROTOR” and “WHEEL
HUB AND BRAKE DRUM”.)
• If the turning torque of the wheel bearing cannot be adjusted
correctly or the play still remains after the adjustment, replace
the wheel bearing with a new one. (See “WHEEL HUB AND RO-
TOR” and “WHEEL HUB AND BRAKE DRUM”.)
6. Inspection of Knuckle Joint for Play

• Jack up the vehicle.
• Try to move the top and bottom of the front tire by hands in the il-
lustrated directions to inspect the knuckle joint for play.
sonnel. If there is any play, it may be caused by the play in the
knuckle joint. Check each part and replace a defective part. (See
“KNUCKLE AND KING PIN, FRONT AXLE”.)
26-12
26
M E M O
26-13
WHEEL HUB AND ROTOR
1 Brake pipe 12 Inner bearing outer race
2 Brake hose 13 Outer bearing outer race
3 Eyebolt 14 Disc rotor (See Gr35.)
4 Brake hose 15 Hub bolt
5 Front disc brake (See Gr35.) 16 Wheel hub
6 Hubcap 17 Bracket
7 Lock nut 18 Adapter
8 Lock washer 19 Dust shield
9 Outer bearing inner race 20 Spacer
10 Oil seal
11 Inner bearing inner race : Non-reusable parts
• Plug the brake hoses that have been removed to prevent the ingress of dust and other contaminants.
Assembly sequence
CAUTION
• Make sure that the disc rotor surface and the pad surface of the front disc brake are free from grease to
avoid malfunction of brakes.
• Make sure that the brake hose is not twisted when installing it.
• After assembly, check the drag torque of the disc brake. (See Gr35.)
• After assembly, bleed air in the brake system. (See Gr35.)
26-14
26
Service standards
1 to 3.5 N·m
Starting torque of wheel hub bearing {0.1 to 3.5 kgf·m}
– – Adjust or replace
(tangential force at hub bolt with oil seal installed) (tangential force: 9.6 to
33.6 N {1 to 3.4 kgf})

Brake hose 14 to 17 {1.4 to 1.7} –
Eyebolt 22 ± 2 {2.25 ± 0.25} –
Bolt (installation of front disc brake) 152 ± 25 {15.5 ± 2.5} –
Primary tightening 113 ± 15 {11.5 ± 1.5} –
Lock nut Secondary tightening after fully loos- Back-off angle
59 {6}
ened 45° (1/8 turn)
Bolt (installation of wheel hub and disc rotor) 85.8 ± 12 {8.75 ± 1.25} –
Bolt (installation of adapter) 118 ± 20 {12 ± 2} –
Bolt (installation of bracket) 12.3 ± 2.5 {1.25 ± 0.25} –

Outside of wheel hub 65 ± 10 g*
Inside of wheel hub 210 ± 20 g*
Between rollers of outer bearing inner race and inner [NLGI No. 2 (Li soap)]
bearing inner race As required
Lip area of oil seal
*: For each wheel hub

Hubcap wrench

0.5 78°
Oil seal installer

Installation of oil seal (to be used in
A B MB999097
combination)
φ84 φ70
Bearing installer
A B C MB999069
combination)
φ94.5 φ60 φ92.5
26-15
WHEEL HUB AND ROTOR
Bearing installer
A B MB999100
φ70 φ57
Installation of inner bearing outer race

and outer bearing outer race (to be
used in combination)
Bearing installer
A B C MB999099
φ88.5 φ51 φ71
Removal procedure
Removal: Brake hose
• When removing the brake hose, remove it from the frame side
first, and then from the wheel brake side.
Removal: Hubcap
Removal: Inner bearing outer race

• Through the notches (three locations) in the wheel hub, tap the
inner bearing outer race evenly to remove it.
26-16
26
Removal: Outer bearing outer race
outer bearing outer race evenly to remove it.
Inspection: Outer bearing inner race
• Clean the bearing to remove the grease before inspecting the
outer bearing inner race.
• Replace the outer bearing inner race if it has cracks or other
damage, or defective rotation.
• The inner race and outer race should be replaced as a set.
Inspection: Inner bearing inner race

• Follow the same procedure as for the inspection of inner bearing
inner race.
(See “ Inspection: Outer bearing inner race”.)
Inspection: Wheel hub

• Check the disc wheel mounting surface of the wheel hub visually
and by hand. If there is any damage or crack, replace the wheel
hub.
• Check that there is not rust, dust, paint or foreign matter on the
disc wheel mounting surface to prevent the wheel nut from loos-
ening.
• If any abnormality is found, remove it with sandpaper.
(2) Wear in disc wheel mounting part of wheel hub

• Clean the wheel mounting surface of the wheel hub before in-
spection.
• Place a straightedge on the hub being in contact with the two
hub bolts on the disc wheel mounting surface.
CAUTION
• The straightedge must not run on the hub bolt.
• Use feeler gauges to measure the amount of wear at the disc

wheel mounting part. Measure at the disc wheel mounting part
of every hub bolt.
• If the amount of wear at any point exceeds the following stan-
dard value, check the wheel hub for cracks.
Wear standard value: 0.8 mm
26-17
WHEEL HUB AND ROTOR
(3) Crack check
• Check that there is no crack on the entire rounded corner on the
root of the flange on the brake drum side of the wheel hub by a
magnetic inspection or liquid penetrant testing.
• If a crack is found on the wheel hub bolt, replace it.
• If there is a crack or stepped wear on the wheel hub mounting

surface of the wheel, replace it. (See Gr31.)
Installation: Outer bearing outer race
Installation: Inner bearing outer race
Installation: Packing grease in inner bearing inner race

• Insert the grease pump nozzle into the space between the roll-
ers of the inner bearing inner race to pack grease sufficiently.
26-18
26
• Apply grease to the lip area of the oil seal and install it in the
wheel hub in the illustrated direction while aligning the end sur-
faces of the oil seal and wheel hub.
Installation: Packing grease in outer bearing inner race

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

CAUTION
• Unless this packing procedure is performed, seizure of the
wheel hub bearing may result.
• For a grease amount, pack the specified amount using a
measuring cup.
• As shown in the illustration, fill the hub body with grease in such
a manner that grease covers the outer races of the outer bearing
and inner bearing. Make sure that the grease reaches the outer
bearing and inner bearing.
Installation: Wheel hub and rotor

• Slowly install the wheel hub and rotor assembly so as not to
damage the oil seal.
26-19
WHEEL HUB AND ROTOR
Adjustment: Starting torque of wheel hub bearing
CAUTION
• Unless this procedure is performed, seizure of the wheel
hub bearing may result.
[Adjustment]
• Tighten the lock nut to the specified torque (primary tightening)
while turning the wheel hub and rotor. Then, fully loosen the lock
nut.
• See the movement of the outer bearing and inner bearing by
turning the wheel hub and rotor several times, and then tighten
the lock nut to the specified torque (secondary tightening).
• Loosen the lock nut approximately 45 degrees (1/8 turn) and se-
cure it with the split pin. If the pin cannot be inserted due to the
position of the pin hole, loosen the lock nut until the position of
the hole becomes appropriate. Make sure that there is no play in
the axial direction.
[Inspection]
• Perform the following inspections after installing the lock nut.
• Measure the tangential force at hub bolt with a spring scale.
• If the tangential force is within the specified value, the starting
torque conforms to the standard value.
If the measured value is within the specified value, install the
split pin in either of the ways shown in the illustration.
• If the measured value deviates from the specified value, the ad-
justment of the lock nut may be inadequate. Perform adjustment
again.
• If the abnormality still remains, replace the outer and inner bear-
ings.
Installation: Packing grease outside of wheel hub

CAUTION
measuring cup.
• After installing lock nut, fill the outside of the outer bearing with
the specified amount of grease using a grease pump nozzle so
as to make a grease wall.
CAUTION
• Do not pile grease in the hubcap. Otherwise, grease may
not reach the outer bearing, causing poor lubrication of the
bearing.
26-20
26
Installation: Brake hose
• To install the brake hose, follow the removal procedure in re-
verse. (See “ Removal: Brake hose”.)
• After installing, make sure that the brake hose does not interfere
in the peripheral parts.
CAUTION
• Make sure that the brake hose is not twisted when you in-
stall it.
26-21
WHEEL HUB AND BRAKE DRUM
1 Brake pipe 10 Outer bearing outer race
2 Brake hose 11 Brake drum (See Gr35.)
3 Hubcap 12 Hub bolt
4 Lock nut 13 Wheel hub
5 Lock washer 14 Front drum brake (See Gr35.)
6 Outer bearing inner race 15 Spacer
7 Oil seal
9 Inner bearing outer race
• Plug the brake hoses that have been removed to prevent the ingress of dust and other contaminants.
Assembly sequence
CAUTION
• Make sure that the brake lining surface of the front drum brake and inner surface of the brake drum are
free from grease to avoid malfunction of brakes.
• Make sure that the brake hose is not twisted when installing it.
• After assembly, adjust the brake shoe clearance. (See Gr35.)

26-22
26
Service standards
1.5 N·m
Starting torque of wheel hub bearing (tangential force at {0.15 kgf·m} or less
hub bolt with oil seal installed) (tangential force: 14 N
{1.4 kgf} or less)

Brake hose 13 to 17 {1.3 to 1.7} –
Primary tightening 113 ± 15 {11.5 ± 1.5} –
Lock nut Secondary tightening after fully loos- Back-off angle
59 {6}
ened 45° (1/8 turn)
Nut (installation of brake drum and wheel hub) 343 ± 39 {35 ± 4} –
Nut (installation of front drum brake) 118 ± 20 {12 ± 2} –

Outside of wheel hub 65 ± 10 g
Inside of wheel hub 395 ± 40 g
Between rollers of outer bearing inner race and inner [NLGI No. 2 (Li soap)]
bearing inner race As required
: For each wheel hub

Hubcap wrench

0.5 78°
Oil seal installer
A B MB999097
φ84 φ70

combination)
Bearing installer
A B C MB999069
φ94.5 φ60 φ92.5
26-23
Bearing installer
A B MB999100
φ70 φ57
Installation of inner bearing outer race

and outer bearing outer race (to be
used in combination)
Bearing installer
A B C MB999099
φ88.5 φ51 φ71
Removal procedure
Removal: Brake hose
• When removing the brake hose, remove it from the frame side
first, and then from the wheel brake side.
Removal: Hubcap
Removal: Wheel hub and brake drum

• If the wheel hub and brake drum cannot be removed due to
stepped wear, remove them as follows.
• Remove the plug and insert a wire of 2 mm in diameter in the
hole and raise the adjusting lever of the wheel cylinder.
• Turn the adjuster through the adjusting hole in a direction the re-
verse of the arrow stamped on the backing plate to extend the
clearance between the brake drum and the brake shoe.
CAUTION
• Correct or replace the brake drum if it is found to be defec-
tive.
26-24
26
inner bearing outer race evenly to remove it.

outer bearing outer race evenly to remove it.
• Clean the bearing to remove the grease before inspecting the
outer bearing inner race.
• Replace the outer bearing inner race if it has cracks or other
damage, or defective rotation.
• The inner race and outer race should be replaced as a set.

• Follow the same procedure as for the inspection of outer bearing
inner race.
26-25
• Check the disc wheel mounting surface of the wheel hub visually
and by hand. If there is any damage or crack, replace the wheel
hub.
• Check that there is not rust, dust, paint or foreign matter on the
disc wheel mounting surface to prevent the wheel nut from loos-
ening.

spection.
• Place a straightedge on the hub being in contact with the two
hub bolts on the disc wheel mounting surface.
CAUTION
• The straightedge must not run on the hub bolt.
• Use feeler gauges to measure the amount of wear at the disc

wheel mounting part. Measure at the disc wheel mounting part
of every hub bolt.
dard value, check the wheel hub for cracks.
(3) Crack check

• Check that there is no crack on the entire rounded corner on the
root of the flange on the brake drum side of the wheel hub by a
magnetic inspection or liquid penetrant testing.
• If a crack is found on the wheel hub bolt, replace it.
• If there is crack or stepped wear on the wheel hub mounting sur-

face of the wheel disc, replace it. (See Gr31.)
Installation: Hub bolt
• Screw the nut into the hub bolt until just before they become
flush.
• Drive the hub bolt into the wheel hub by hitting the end face of
the nut.
26-26
26
• Assemble the brake drum and wheel hub with the hub bolt. After
tightening the nut to the specified torque, caulk it with a punch.

• Insert the grease pump nozzle into the space between the roll-
ers of the inner bearing inner race to pack grease sufficiently.

• Apply grease to the lip area of the oil seal and install it in the
wheel hub in the illustrated direction while aligning the end sur-
faces of the oil seal and wheel hub.
26-27
• Follow the same procedure as for the inner bearing inner race.
race”.)
Installation: Packing grease inside of wheel hub

CAUTION
measuring cup.
• As shown in the illustration, fill the hub body with grease in such
a manner that grease covers the outer races of the outer bearing
and inner bearing. Make sure that the grease reaches the outer
Installation: Wheel hub and brake drum

• Slowly install the wheel hub and brake drum so as not to cause
damage to the oil seal.
• Position the wheel hub and brake drum only 20 mm before the
backing plate, and hereafter slowly tighten the lock nut to install
the wheel hub and brake drum.
CAUTION
• Be careful that installing the wheel hub and brake drum
without leaving a clearance with the backing plate may
damage the wheel speed sensor.
Adjustment: Starting torque of wheel hub bearing

CAUTION
• Unless this adjustment procedure is performed, seizure of
the wheel hub bearing can be caused.
[Adjustment]
while turning the wheel hub and brake drum. Then, fully loosen
the lock nut.
• See the movement of the outer bearing and inner bearing by
turning the wheel hub and brake drum several times, and then
tighten the lock nut to the specified torque (secondary tighten-
ing).
• Loosen the lock nut approximately 45 degrees (1/8 turn) and se-
cure it with the split pin. If the pin cannot be inserted due to the
position of the pin hole, loosen the lock nut until the position of
the hole becomes appropriate. Make sure that there is no play in
the axial direction.
26-28
26
[Inspection]
• Perform the following inspections after installing the lock nut.
• Measure the tangential force at hub bolt with a spring scale.
torque conforms to the standard value.
If the measured value is within the specified value, install the
split pin in either of the ways shown in the illustration.
• If the measured value deviates from the specified value, the ad-
justment of the lock nut may be inadequate. Perform adjustment
again.
• If the abnormality still remains, replace the outer and inner bear-
ings.
Installation: Packing grease outside of wheel hub

CAUTION
measuring cup.
• After installing lock nut, fill the outside of the outer bearing with
the specified amount of grease using a grease pump nozzle so
as to make a grease wall.
CAUTION
• Do not pile grease in the hubcap. Otherwise, grease may
not reach the outer bearing, causing poor lubrication of the
bearing.
Installation: Brake hose

• To install the brake hose, follow the removal procedure in re-
verse. (See “ Removal: Brake hose”.)
• After installing, make sure that the brake hose does not interfere
in the peripheral parts.
CAUTION
• Make sure that the brake hose is not twisted when you in-
stall it.
26-29
KNUCKLE AND KINGPIN, FRONT AXLE
1 Tie rod (See later section.) 10 Grease nipple 19 U-bolt
2 Key 11 Plug 20 Stud bolt
3 Knuckle arm 12 Dust seal 21 Front axle
4 Key 13 Bushing
5 Tie rod arm 14 Knuckle stopper bolt
*b:
a: Drag link (See Gr37.)
6 Dust plug 15 Lock nut
* Shock absorber
7
8
Dust cap
Lock pin
16
17
Knuckle
Thrust bearing
*c:: Stabilizer
Non-reusable parts
9 Kingpin 18 Kingpin shim
CAUTION
• When removing the tie rod, take care not to damage the dust cover. It may cause ingress of water in the
ball joint, resulting in its premature wear.
Assembly sequence
Repair kit: Kingpin kit
• After assembly, check and adjust toe-in. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
26-30
26
9 Outer diameter of kingpin 27.947 to 27.980 27.9 Replace
9, 13 Clearance between kingpin and bushing 0.020 to 0.086 0.15 Replace
9, 21 Clearance between kingpin and front axle 0.02 to 0.074 0.1 Replace
Inner diameter of bushing (after having been pressed
13 28.000 to 28.033 – Replace
into knuckle)
16, 21 Vertical clearance between knuckle and front axle 0.02 to 0.10 0.20 Adjust
Longitudinal bend – 2
21 Front axle Vertical bend – 2 Replace
Kingpin inclination angle 8° ± 10’ –

Nut (installation of tie rod) 93 ± 25 {9.5 ± 2.5} –
Nut (installation of knuckle arm)
345 ± 49 {35 ± 5} –
Nut (installation of tie rod arm)
Nut (installation of lock pin) 33 ± 5 {3.4 ± 0.5} –
Lock nut (tightening of knuckle stopper bolt) 46.5 ± 7 {4.75 ± 0.75} –
Nut (installation of U-bolt) 103 to 118 {10.5 to 12.0} Wet
Thread-locking
Installation 88 {9} or more
Stud bolt compound
Removal 137 {14} or more –

As required when
Knuckle arm and tie rod arm threads
parts are reused
Hole in front axle for kingpin insertion [NLGI No. 2 (Li soap)]
As required
Nut thread
Lip area of dust seal
Inside surface of bushing
As required
Top face of thrust bearing
Chassis grease
Both side of kingpin shim
Until grease
starts overflow-
Fill from grease nipple
ing from dust
plug
Stud threads of stud bolt Loctite 271 As required
26-31
Kingpin puller
A: Pipe MB999013
B: Bolt A: MB999014
C: Cap B: MB999015 Removal of kingpin
D: Nut C: MB999016
D: MB999017
E
φ47
Bushing installer
A: Bushing installer A MB999066

Removal and installation of kingpin
B: Bushing installer B A: MB999067
bushing
B: MB999068
C D E F G
φ25 φ30 φ28 φ25 φ32.8
Removal procedure
Removal: Lock pin
• Remove the nut, spring washer and washer.
• Screw the nut into the lock pin again until just before they be-
come flush. Then, lightly tap the nut to loosen the lock pin.
• Remove the nut, apply a pin punch to the lock pin and lightly tap
it to remove the lock pin.
Removal: Kingpin
• Screw -B into the kingpin threads to remove the kingpin.
26-32
26
Inspection: Outer diameter of kingpin
• Measure at a total of four levels of the kingpin: two levels for the
axle fitting portion and the other two levels for the upper and low-
er knuckle fitting portions.
• If the measured value is under the limit, replace the kingpin.
Inspection: Clearance between kingpin and bushing

• Measure the inner diameter of the upper and lower bushings
with a cylinder gauge and obtain the clearance by deducting the
outer diameter of the kingpin from the inner diameter of the
bushing. If the clearance exceeds the limit, replace the bushing.
Replacement of bushing
[Removal]
• Remove the bushing and the dust seal at the same time using
.
[Installation]
• Install the bushing using so that a step height between the
bushing and the knuckle is within 1 mm.
• The oil hole of the bushing must not deviate from the screw hole
of the knuckle more than 5 mm.
26-33
• Apply grease to the dust seal lip before installing it in the knuck-
le. Be sure to face the dust seal as shown in the illustration.
Inspection: Thrust bearing

• Check the thrust bearing for integrity including proper rotation.
Replace the bearing if it has cracks or other damage, or rotation
faulty.
Inspection: Front axle

(1) Bend of front axle in the longitudinal direction and vertical
direction
• Put a piece of thread through the kingpin holes on the front axle
and hang weights at both ends.
• Use a square to measure bend in the longitudinal and vertical di-
rections.
• If the measured value exceeds the limit, replace the front axle.
(2) Kingpin inclination angle

• Set the kingpin on the front axle as illustrated to measure the an-
gle.
• If the measured value deviates from the standard value, replace
the front axle.
26-34
26
(3) Clearance between kingpin and front axle
• Measure the inner diameter of the axle’s hole for kingpin inser-
tion with a cylinder gauge and obtain the clearance by deducting
the outer diameter of the kingpin from it. If the clearance ex-
ceeds the limit, replace the axle or the kingpin.
Installation: Stud bolt
• Apply Loctite to the front axle mounting threads of the stud bolt.
• Install the stud bolt with the dimension in the illustration.
Installation: Plug
• After installing the plug, caulk the knuckle at three evenly spaced
points of the plug circumference avoiding the previously caulked
points.
Installation: Knuckle
• After temporarily assembling the thrust bearing, knuckle and
kingpin into the front axle, move the knuckle a few times to
smooth its operation.
• Measure the clearance between the front axle top face and the
knuckle bottom.
• If the measured value exceeds the limit, adjust with a kingpin

shim. Choose the kingpin shim that can minimize the clearance
within the standard value.
Thickness of kingpin shims available
0.15, 0.40, 0.50, 0.60, 0.70 mm (five thickness)
• After assembly, make sure that the knuckle moves smoothly.
26-35
Installation: Lock pin
• Install the lock pin so that the taper part of the lock pin is aligned
with the notch of the kingpin.
Installation: Tie rod arm and knuckle

(1) When one or both the tie rod arm and knuckle need reas-
sembly, making use of existing parts
• Polish the entire tapered surfaces of the tie rod arm and knuckle
evenly by means of sand paper #120 or higher until sand paper
score is visible on polished surfaces. (This does not apply to
new replacement parts.)
• Clean the tapered surfaces and thread areas of the tie rod arm
and knuckle.
NOTE
• Use acetone, cleaning fluid for color check, or equivalent as
solvent.
• Apply grease to the thread area of the tie rod arm and install it.
CAUTION
• When installing the tie rod arm, make sure that tapered sur-
faces of the tie rod arm and knuckle are free from grease.
• Tighten the nut to the specified torque. Be sure to align pin holes
in the course of tightening and insert the split pin as illustrated.
(2) When both the tie rod arm and knuckle for assembling are
new parts
• Clean tapered surfaces and thread areas of the tie rod arm and
knuckle.
• Apply grease to the thread area of the tie rod arm and install it.
CAUTION
• When installing the tie rod arm, make sure that tapered sur-
faces of the tie rod arm and knuckle are free from grease.
26-36
26
Installation: Knuckle arm and knuckle
(1) When one or both the knuckle arm and knuckle need reas-
sembly, making use of existing parts
• Polish the entire tapered surfaces of the knuckle arm and knuck-
le evenly by means of sand paper #120 or higher until sand pa-
per score is visible on polished surfaces. (This does not apply to
new replacement parts.)
• Clean the tapered surfaces and thread areas of the knuckle arm
and knuckle.
NOTE
• Use acetone, cleaning fluid for color check, or equivalent as
solvent.
• Apply grease to the thread area of the knuckle arm and install it.
CAUTION
• When installing the knuckle arm, make sure that tapered
surfaces of the knuckle arm and knuckle are free from
grease.
(2) When both the knuckle arm and knuckle for assembling
are new parts
• Clean tapered surfaces and thread areas of the knuckle arm and
knuckle.
• Apply grease to the thread area of the knuckle arm and install it.
CAUTION
• When installing the knuckle arm, make sure that tapered
surfaces of the knuckle arm and knuckle are free from
grease.
Installation: Tie rod

• Install the tie rod with its identification marking, which is applied
to the left thread tie rod end side of the rod, coming to the left
side of the vehicle.
Identification marking: Blue
26-37
TIE ROD
1 Tie rod end
2 Tie rod
Assembly sequence
verse.

Play
0 to 0.15 –
(± 980 N {± 10 kgf} loaded)
1 Ball joint of tie rod end Replace
1.0 to 5.9 N·m
Rotation torque –
{0.1 to 0.6 kgf·m}
Correct or
2 Bend of tie rod – 1
replace

Nut (tightening of tie rod end) 25 ± 5 {2.5 ± 0.5} –

Lip area of dust cover of tie rod end As required
Inspection: Tie rod end
(1) Play
• Fix the tie rod end with a vise.
CAUTION
• Take care not to damage the dust cover when fixing it with a
vise.
• The position of the ball joint with applying no load is adjusted to

standard position.
• Measure each play of the ball joint with applying the specified
push and pull load from the standard position.
• Total each play and if the total deviates from standard value, re-
place the tie rod end.
26-38
26
(2) Rotation torque of ball joint
• Install the tie rod mounting nut in the tie rod end.
• Install the socket, adapter and torque wrench and measure the
rotation torque.
the tie rod end.
(3) Dust cover

• Check the dust cover for wear, cracks and other damage. They
may cause ingress of water in the ball joint, resulting in its pre-
mature wear.
• If wear, cracks or damage is found, check the ball joint for trace
of water entry and rust. If there is any abnormality, replace the
tie rod end. If no abnormality is occurring, replace the dust cover
and grease.
Inspection: Bend of tie rod

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

tie rod.
Installation: Tie rod end
• Screw in the tie rod end so that the difference of dimension A be-
tween the tie rod end and the clamp is within 1.5 mm between
right and left.
A: Approximately 74 mm
CAUTION
• Ensure that the difference of the amount of screwing in the
tie rod end between right and left is within one turn.
• Secure the tie rod ends so that the illustrated axis B-B on
the right is parallel to that on the left.
26-39
GROUP 27 REAR AXLE
SPECIFICATIONS............................................................................... 27-2

1. Wheel Hub and Brake Drum .......................................................... 27-3
2. Reduction and Differential ............................................................ 27-4

1. Inspection and Replacement of Differential Oil ............................. 27-8
2. Inspection of Wheel Bearing for Play ............................................ 27-9
WHEEL HUB AND BRAKE DRUM................................................... 27-10
AXLE HOUSING ............................................................................... 27-20
REDUCTION AND DIFFERENTIAL.................................................. 27-24
27-1
SPECIFICATIONS
Item Specifications
Model R033B
Rear axle
Type Axle pipe type, full floating
Model D033H
Reduction Type Single-reduction hypoid gear
Gear ratio 4.875
Differential Tooth shape Straight bevel gear
Gear oil:
Normal: Maximum air temperature during operation below 40°C
API GL-5
Grade SAE90
Gear oil Hot area: Maximum air temperature during operation above 40°C
*API GL-5
*SAE140
Quantity
4.5 {4.5}
dm3 {L}
Mass kg 190 to 220 (approx.)
* Use this oil when a vehicle is used under heavily-loaded, severe conditions such as continuous driving on uphill
grades. However, the air temperature must be above 10°C.
27-2
1. Wheel Hub and Brake Drum
27-3
2. Reduction and Differential
27-4
27
M E M O
27-5
TROUBLESHOOTING
Symptoms Power transmission in-
sufficient
Oil leakage from differential carrier and axle housing

Propeller shaft turns but vehicle does not move
Oil leakage from companion flange assembly
Noise when starting and changing gears
Reference Gr

Oil leakage from the axle shaft

Tires drag while cornering
Noise while cornering
Possible causes
Wheel hub bearing seized, worn or rotation
O
faulty
Wheel hub bearing broken O
Axle shaft mounting bolts loose O O
Axle shaft broken O
Wheel hub, axle shaft, Axle shaft slips out of spline of side gear O
axle housing Axle shaft to spline of side gear backlash
O
excessive
Oil seal faulty O
Axle housing bent O
Inspection plug and drain plug loose O
Vent plug clogged O O
Gear oil excessive O
Gear oil insufficient O O
Oil seal faulty O
Sealant faulty O
Reduction and differential assembly mount-
O O
ing nuts and bolts loose
Differential carrier cracked or damaged O
Bearing cap mounting bolts loose O
Side bearing seized, worn or rotation faulty O O
Reduction and differential
Side bearing broken O
Side bearing preload adjusted incorrectly O
Reduction pinion or reduction gear broken O O O O
Reduction pinion or reduction gear worn O O
Reduction pinion or reduction gear dam-
O
aged
Reduction gear backlash excessive O
Reduction gear backlash or tooth contact
O
adjusted incorrectly
27-6
27
Symptoms Power transmission in-
sufficient
Oil leakage from differential carrier and axle housing

Propeller shaft turns but vehicle does not move
Oil leakage from companion flange assembly
Noise when starting and changing gears
Reference Gr

Oil leakage from the axle shaft

Tires drag while cornering
Noise while cornering
Possible causes
Starting torque of pinion bearing faulty O O
Lock nut loose O O
Front and rear bearings seized O
Front and rear bearings worn O
Front and rear bearings broken O
Pinion pilot bearing worn O
Pinion pilot bearing seized or broken O
Reduction and differential Pinion shaft and pinion spider broken O
Reduction gear and differential case mount-
O O
ing bolt and nut loose
Side gear backlash excessive O
Side gear or differential pinion broken O O O O
Side gear or differential pinion seized O O
Side gear or differential pinion worn O O
Side gear washer worn or damaged O O O
27-7
1. Inspection and Replacement of Differential Oil
WARNING
• The oil temperature is high immediately after the vehicle has stopped, so take care not to scald yourself.

Inspection plug
– 98 to 120 {10 to 12} –
Drain plug

Normal: Maximum air tempera-
ture during operation
below 40°C
API GL-5
SAE90
– Axle housing 2.7 dm3 {2.7 L}
Hot areas: Maximum air tempera-
ture during operation
above 40°C
*API GL-5
*SAE140
* Use this oil under heavily-loaded, severe conditions such as continuous driving on uphill grades. However, the
air temperature must be above 10°C.
[Inspection]
(1) Checking for oil leaks
• Check the differential casing for oil leaks by visually observing or
by hand.
• If any oil leak is found, replace defective parts.
(2) Inspection of oil quantity

• Remove the inspection plug, and check that oil is filled up to the
neck.
• If oil is not sufficient, fill oil from the inspection plug hole up to the
neck.
(3) Inspection of oil quality and inclusions

• When draining differential oil, check for oil quality, metal chips
and metal powder.
• If an abnormally large amount of metal chips and metal powder
is found, disassemble the assembly for service, as abnormalities
may be caused inside.
[Replacement]
• Remove the drain plug to drain differential oil. Drainage can be
made quickly with the inspection plug removed.
• As the drain plug (magnet type) is a magnet, clean it before in-
stallation.
• Fill the specified quantity of differential oil from the inspection
plug hole.
• After filling, check that oil is filled up to the neck. If oil is not suffi-
cient, replenish it.
27-8
27
2. Inspection of Wheel Bearing for Play
• Jack up the vehicle and try to move the top and bottom of the
front tire by hands in the illustrated directions to inspect the
wheel bearing for play.
sonnel. When the play is removed by operating the brake pedal,
the symptom indicates that there is play in the wheel bearing,
not in the suspension or other related parts. Then inspect the
starting torque of the wheel bearing and adjust it as required.
(See “WHEEL HUB AND BRAKE DRUM”.)
• If the starting torque of the wheel bearing cannot be adjusted
correctly or the play still remains after the adjustment, replace
the wheel bearing with a new one. (See “WHEEL HUB AND
BRAKE DRUM”.)
27-9
1 Brake pipe 10 Outer bearing outer race
2 Axle shaft 11 Brake drum (See Gr35.)
3 Outer oil seal 12 Hub bolt
4 Lock washer 13 Wheel hub
5 Lock nut 14 Rear drum brake (See Gr35.)
6 Outer bearing inner race
7 Oil seal : Locating pin
9 Inner bearing outer race
• Plug the brake pipe that has been removed to prevent the ingress of dust and other contaminants.
Assembly sequence
CAUTION
• Make sure that the brake lining surface of the rear drum brake and the inner surface of the brake drum are
free from grease to avoid malfunction of brakes.
• After assembly, adjust brake shoe clearance. (See Gr35.)

27-10
27
2.0 to 3.9 N·m
Starting torque of wheel hub bearing (tangential force at {0.2 to 0.4 kgf·m}
hub bolt position with oil seal assembled) (tangential force: 17.6 to
34.4 N {1.8 to 3.5 kgf})
Bend at center 0 to 1 2
2 Axle shaft Replace
Lateral runout at flange face 0 to 0.03 0.05

Brake pipe 12.7 to 16.7 {1.3 to 1.7} –
Bolt (axle shaft mounting) 98 to 120 {10 to 12} –
Bolt (lock plate mounting) 4.9 ± 1 {0.5 ± 0.1} –
Primary tightening 98 to 130 {10 to 13}
Lock nut Secondary tightening after –
30 to 40 {3 to 4}
complete tightening
Nut (brake drum and wheel hub mounting) 340 ± 40 {35 ± 4} –
Bolt (rear drum brake mounting) 98 to 140 {10 to 14} –

Lip area of outer oil seal
Thread area of lock nut
Pack space between rollers of outer bearing inner race Wheel bearing grease As required
and inner bearing inner race [NLGI No. 2 (Li soap)]
Pack interior of wheel hub 370 ± 37 g
: For a wheel
27-11
Lock nut adjust tool
A B
MB999150 Removal and installation of lock nut
70 12.7
Hub puller MB999070

A: Hub puller body A: MH064134
B: Attachment (MB999071) Removal of wheel hub and brake
C: Bolt B: MH064136 drum
(MB999073)
D E C: MH064135
φ50 165 (MB999072)
Oil seal installer
A B MB999097
φ84 φ70
Installation of inner and outer bearing

outer races (to be used in combina-
tion)
Bearing installer
A B C MB999098
φ109 φ99 φ77
Oil seal installer
A B MH061752 Installation of oil seal

φ130 φ100
Removal procedure
Removal: Axle shaft
• Screw two axle shaft mounting bolts evenly into the axle shaft
removal screw holes to remove the axle shaft.
27-12
27
Removal: Outer oil seal
• To remove the outer oil seal, pull protrusions on the outer periph-
ery of the outer oil seal evenly around the whole circumference
with pliers.
Removal: Lock nut
Removal: Wheel hub and brake drum

• If the brake drum has stepped wear and the wear prevents the
wheel hub and brake drum assembly from being removed, the
removal can still be effected by taking the following procedure.
• Insert a wire of approx. φ2 mm into the hole from which the plug
has been removed, and lift up the adjust lever of the wheel cylin-
der.
• Turn the adjuster from the adjust hole in the opposite direction to
the arrow on the backing plate to increase the clearance be-
tween the brake drum and the brake shoe. Then, remove the
wheel hub and brake drum assembly.
CAUTION
• Correct or replace the brake drum if any fault is found.
• Install using axle shaft mounting bolts to remove the wheel

hub and brake drum assembly.
27-13
• Drive out the inner bearing outer race by tapping evenly at three
or four notches in the wheel hub.

• Drive out the outer bearing outer race by tapping it evenly at
three or four notches in the wheel hub.
Inspection: Axle shaft
• Perform the following inspection. If the measurement exceeds
the limit, replace the axle shaft.
(1) Bend at shaft center
• Give the axle shaft one complete turn and read the dial gauge at
this time. The bend is one half of the reading.
(2) Lateral runout at flange face

• Inspect the outer bearing inner race after cleaning the bearing to
remove grease completely.
• If any damage, wear, or poor rotating condition is evident in the
inner race, replace it with a new one.
• The inner race and the outer race should be replaced as a set.
27-14
27
• Check the disc wheel mounting surface of the wheel hub by
watching and touching. If there is damage or crack on it, replace
the wheel hub.
• Make sure that there is not rust, dust, paint or foreign body on
the disc wheel mounting surface of the wheel hub to prevent the
wheel nut to loosen.

spection.
• Place a straightedge on the hub so as to contact to the two hub
bolts on the disc wheel mounting surface.
CAUTION
• Make sure that the straightedge does not run onto the hub
bolt.
• Using feeler gauges to measure the amount of wear at the outer

periphery of the wheel hub. Measure the amount of wear in the
area of every hub bolt.
dard value, inspect the crack check of wheel hub.
(3) Crack check

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

• Inspect the inner bearing inner race in the same manner as for
the outer bearing inner race.
27-15
Installation: Hub bolt
• Screw the nut into the hub bolt and stop just before it becomes
flush.
• Drive the hub bolt into the wheel hub vertically by hitting the end
face of the nut.
• Assemble the brake drum and wheel hub with the hub bolt. After
tightening the nut to the specified torque, crimp it with a punch.

• Insert the grease pump nozzle into the space between rollers of
the inner bearing inner race to pack grease sufficiently.
27-16
27
• Apply grease to the lip area of oil seal and install the oil seal in
the wheel hub so that the oil seal faces in the illustrated direction
and the end surface of oil seal is flush with the end surface of
wheel hub.

• Follow the same procedure as for packing the inner bearing in-
ner race with grease.
race”.)
Installation: Packing grease in wheel hub

CAUTION
wheel hub bearing may be caused.
• Apply the specific amount of grease measured by measure-
ment cup or etc.
• As shown in the drawing, fill grease inside of the hub body in

such a manner that grease covers the outer bearing and inner
bearing outer races. Make sure that grease reaches the outer
Installation: Wheel hub and brake drum

• Slowly install the wheel hub and brake drum so as not to cause
damage to the oil seal.
• Mount the wheel hub and brake drum without jiggling until back-
ing plate extends 20 mm from the edge of the brake drum. Then,
tighten the lock nut slowly.
27-17
Installation: Starting torque of wheel hub bearing
CAUTION
• Unless this adjustment procedure is performed, seizure of
the wheel hub bearing can be caused.
[Adjustment]
while turning the wheel hub and brake drum, and then loosen it
completely.
• Smooth operation of the outer bearing and inner bearing by turn-
ing the wheel hub and brake drum several times, and then tight-
en the lock nut to the specified torque (secondary tightening).
• Insert the flat area of the lock washer, aligning it with the notch of
the axle housing, and mount two bolts diagonally to the lock nut.
• If the lock nut does not align with a screw hole of the lock wash-
er, align by loosening the lock nut. Make sure that there is no
play in the axial direction.
[Inspection]
• After installing the lock plate, carry out the following inspections.
• Make sure that there is no drag in the brake lining and brake
drum.
• If any abnormality is found, adjust the brake shoe clearance.
• Measure the tangential force at the hub bolt position using a
spring balance.
torque conforms to the standard value. If the measured value
deviates from the specified value, repeat adjustment because
the adjustment of the lock nut may be insufficient.
• If the result is found to be abnormal, replace the outer and inner
bearings.
Installation: Axle shaft

• Align the pin hole of the locating pin with that of the axle shaft to
install the axle shaft.
NOTE
• (A pin hole is not necessarily located at the position of a
protrusion on the axle shaft flange face.) The second hole
from a removal screw hole clockwise is a pin hole.
27-18
27
M E M O
27-19
AXLE HOUSING
Removal sequence
1 Inspection plug 9 Connector
2 Drain plug 10 Axle housing
3 Reduction and differential (See later sections.)
4 Brake pipe
*b:
a: Propeller shaft
5 Brake hose
* Shock absorber
6
7
Vent plug
U-bolt
*c:: Leaf spring
Non-reusable parts
8 Brake pipe
CAUTION
• Plug the brake hose and the brake pipe to prevent entry of dust and dirt after they have been removed.
• Be careful not to damage the brake hose, brake pipe and sensor harness when removing and installing
the axle housing.
• When removing the axle housing, the suspension parts around the axle housing must be removed. (See Gr34.)

0 to 4.9 kPa
6 Valve opening pressure of vent plug – Replace
{0 to 0.05 kfg/cm2}
Runout at outer bearing portion 0 to 0.5 1
10 Axle housing Difference between before and af- Replace
0 to 1 5
ter rotation at center
27-20
27
Inspection plug
98 to 120 {10 to 12} –
Drain plug
Nut (propeller shaft mounting) 100 to 120 {10 to 12} M12
Nut (reduction and differential mounting) 69 to 93 {7 to 9.5} –
Bolt (reduction and differential mounting) 83 to 108 {8.5 to 11} Sealant
Brake hose 14 to 17 {1.4 to 1.7} –
Nut (U-bolt mounting) 127.5 to 166.7 {13 to 17} Wet

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

Differential carrier
base
Removal and installation of reduction
MB999102
A and differential
φ28
Work before removal

Inspection: Play of companion flange
• If there is play in the forward, backward, vertical, lateral or rotat-
ing direction, replace all of the following parts.
• Front bearing and rear bearing
• Pinion spacer
• Reduction gear set <Reduction pinion and reduction gear>
• Companion flange
Removal procedure
Removal: Reduction and differential
• Remove the saucer of the garage jack and place on it.
Fabricate the pin as illustrated, insert and fix it with the bolts that
were used to fix the saucer.
• Screw two bolts (M12 × 1.25 mm) evenly into the reduction and
differential removal screw holes to remove the reduction and dif-
ferential.
27-21
AXLE HOUSING
Inspection: Axle housing
• Horizontally support the inner bearing fittings at both ends of the
housing spindle of the axle housing.
• Perform the following inspection. If the measured value exceeds
the limit, replace the axle housing.
(1) Runout at outer bearing portion
• Apply a dial gauge to the outer bearing fitting and turn it 360 de-
grees to measure runout.
(2) Difference between before and after rotation at center

• For measurement of A1 and A2, place the axle housing at right
angles using a square and measure A1. Then, turn it 180 de-
grees and measure A2.
Installation: Reduction and differential
• Clean the seal surface of each part.
• Apply sealant to the reduction and differential mounting surface
of the axle housing evenly and without breaks. Apply sealant in
a straight line direction for illustrated position A and along the
outer periphery for notches of illustrated position B.
27-22
27
M E M O
27-23
REDUCTION AND DIFFERENTIAL
1 Lock plate 6 Differential (See later sections.)
2 Side bearing nut 7 Pinion (See later sections.)
3 Bearing cap 8 Shim
4 Side bearing outer race 9 Differential carrier
5 Side bearing inner race
CAUTION
• Be sure to replace the bearing cap, differential carrier and bolts as a differential carrier set.
• Be sure to replace the differential reduction gear and reduction pinion as a reduction gear set.
• Keep side bearings that have been removed separated from each other and ensure that during installation each
one is correctly placed.
• Record the number and thickness of shims to use them as reference at assembly.
Assembly sequence

2.0 to 2.9 N·m
4, 5 Starting torque of side bearing – Adjust
{0.2 to 0.3 kgf·m}
6 Wobble at back face of reduction gear 0 to 0.1 – Replace
6, 7 Backlash between reduction gear and reduction pinion 0.20 to 0.28 0.5 Adjust or replace
27-24
27
Bolt (lock plate mounting) 20 to 26 {2.0 to 2.7} –
Bolt (bearing cap mounting) 200 {20.5} –
Bolt (pinion mounting) 67 to 90 {6.8 to 9.2} –

Pinion pilot bearing mounting surface of differential carri-
er

Differential working
base assembly
H J K L
11 20 40 φ11
Workbench for reduction and differen-
tial
Component Part No. MB999034
Flange stopper to be used for remov-
Attachment – al and installation of companion
A RA F G – flange
R158 30° φ13 MH064132 (MB999040)
B Holder MH064130 (MB999036)
C Holder MH064131 (MB999037)
D Working base MH064129 (MB999035)
E Flange stopper MH064137 (MB999096)
Adapter
Removal of side bearing inner race
A B MB999076 (to be used in combination with com-
mercial bearing puller)
φ45 φ59
Bearing installer
A B MH061748 Installation of side bearing inner race

φ80 φ70
Bearing retainer guide

pin
Installation of pinion (two pieces are
MH061745
used)
A B C D
85 18 12 M12 × 1.25
27-25
Work before removal
Preparatory work: Installation of differential working base
assembly
• Install the reduction and differential on .
Alignment marks: Bearing cap and differential carrier

• Put alignment marks on the bearing cap and differential carrier
for correct identification of right and left parts.
Removal procedure
Removal: Side bearing inner race
Removal: Pinion
• Screw two bolts evenly into the pinion removal screw holes to re-
move the pinion.
27-26
27
Selection: Shim
• Calculate shim thickness by using the following formula based
on the machining error data stamped on pinion assembly and
differential carrier.
• Formula: Shim thickness = 0.5 – a + b + 0.2
a: 1/100 of numeral stamped on outer periphery of flange of dif-
ferential carrier flange
b: Numeral stamped on top of pinion
• Select the shim(s) based on the calculated shim thickness.
Thickness of shims available: 0.1 and 0.2 mm (2 types)
Installation: Pinion
• Apply sealant to the pilot bearing mounting surface of the differ-
ential carrier.
• Aligning the embossed alignment mark on the bearing retainer

of the pinion assembly with that on the differential carrier, mount
the pinion assembly.
CAUTION
• Leave for 30 minutes to 2 hours after installation to let the
sealant harden.
• Wait at least three hours or, if feasible, 24 hours before run-
ning the vehicle to let the sealant harden.
Inspection: Starting torque of pinion bearing

• The starting torque of the pinion in single unit should be the
standard value.
• After installing the pinion, measure the starting torque of the pin-
ion bearing.
• Record the measured starting torque for reference when the
starting torque of the side bearing is calculated.
27-27
Installation: Side bearing inner race

Adjustment: Backlash between reduction gear and reduc-
tion pinion
• Adjust backlash with the side bearing nut, taking care not to al-
low the side bearing starting torque to change.
CAUTION
• When one side bearing nut is loosened, be sure to tighten
the other one by the same amount to prevent the side bear-
ing starting torque from changing.
Inspection: Wobble at back face of reduction gear

• Measure wobble at the illustrated position of the reduction gear.
the reduction gear and reduction pinion of the differential as a
set.
Inspection: Tooth contact of reduction gear

[Inspection]
• Apply red lead to three to four teeth at three equally spaced
points of the reduction gear.
• Give the reduction gear several turns to check for tooth contact.
Tooth contact off-center to the small end side under no load
comes to the center under load.
• Adjust tooth contact if it is remarkably offset.
27-28
27
[Adjustment]
• Optimize tooth contact by increasing or decreasing rear bearing
shim thickness or adjusting backlash between reduction gear
and reduction pinion (using side bearing nut).
CAUTION
• If teeth are abnormally worn or tooth contact is excessively
concentrated at the large end or small end side, always re-
place both the reduction gear and reduction pinion as a re-
duction gear set.
Tooth contact on reduction gear Adjustment procedure

Concentrated at addendum Advance reduction pinion to reduction gear
(shims are reduced)
Concentrated at dedendum Retard reduction pinion from reduction gear

(shims are added)
Concentrated at large end side Advance reduction gear to reduction pinion center
(less backlash)
Concentrated at small end side Retard reduction gear from reduction pinion center
(more backlash)
27-29
Inspection: Starting torque of side bearing
[Inspection]
• Measure the starting torque of the pinion assembly using a
torque wrench and calculate the starting torque of the side bear-
ing using the following formula.
Pinion bearing starting torque is the value obtained at earlier
measurement of pinion bearing starting torque.
(Total starting torque - Starting torque of the pinion bearing) ×

Final ratio = Starting torque of side bearing
• If the calculated value of side bearing starting torque deviates

from the standard value, adjust.
[Adjustment]
• Adjust by means of the right- and left-hand adjusting screws.
• Always adjust both adjusting screws by the same amount.
27-30
27
Differential
1 Reduction gear
2 Differential case right-hand
3 Side gear washer
4 Side gear
5 Pinion washer
6 Differential pinion
7 Pinion spider
8 Differential case left-hand
CAUTION
• Be sure to replace the differential
case right-hand and the differential
case left-hand as a differential case
set.
• Be sure to replace the side gear and
the differential pinion as a side gear
set.
Assembly sequence
verse.

4 Backlash between side gear and spline of axle shaft 0.05 to 0.15 0.5 Replace
4, 6 Backlash between side gear and differential pinion 0.15 to 0.20 0.5 Replace
6, 7 Clearance between differential pinion and pinion spider 0.17 to 0.27 0.5 Replace

Bolt (reduction gear mounting) 166.6 to 225.4 {17 to 23} Wet
Bolt (differential case right-hand and differential case left-
83.3 to 112.7 {8.5 to 11.5} Thread lock cement
hand mounting)

Entire bolt Rust preventive As required
Thread area of bolt
Bolt tip of differential case left-hand
27-31
Work before removal
Alignment marks: Reduction gear and differential case left-
hand
• Put alignment marks on the reduction gear and differential case
left-hand.
Inspection: Backlash between side gear and differential pin-

ion
• If backlash is found faulty, the thickness of the side gear washer
and pinion washer is probably inappropriate.
Inspection: Backlash between side gear and axle shaft
• If the measured value exceeds the limit, replace defective parts.
Installation: Differential case right-hand and differential
case left-hand
• Apply rust preventive to the entire surface of the bolt. After ap-
plying it, blow off the excess rust preventive on the bolt using
compressed air.
• Apply thread lock cement to the bolt threads.
• Tighten the bolt to the specified torque.
CAUTION
• Make sure to apply rust preventive when tightening the bolt
to the specified torque.
• Wait at least one hour after installation before actually run-
ning the vehicle to let the thread lock cement harden.
• Wait at least four hours after installation before operating
the vehicle at full torque to let the thread lock cement hard-
en.
27-32
27
Installation: Reduction gear and differential case left-hand
• Apply rust preventive to the entire surface of the bolt. After ap-
plying it, blow off the excess rust preventive on the bolt using
compressed air.
• Apply thread lock cement at the entry of bolt holes on differential
case left-hand.
• Tighten the bolt to the specified torque.
CAUTION
• Make sure to apply rust preventive when tightening the bolt
• Wait at least one hour after installation before actually run-
ning the vehicle to let the thread lock cement harden.
• Wait at least four hours after installation before operating
the vehicle at full torque to let the thread lock cement hard-
en.

Inspection: Backlash between side gear and differential pin-
ion
the side gear washer and pinion washer.
Thickness of side gear washers available
3.0 mm (one thickness)
Thickness of pinion washers available
1.6 mm (one thickness)
CAUTION
• Use side gear washers of the same thickness for the right
and left sides.
• Use pinion washers of the same thickness at four locations.
27-33
Pinion
1 Lock nut
2 Companion flange
3 Dust cover
4 Collar
5 Rear bearing inner race
6 Lock ring
7 Pinion pilot bearing
8 Reduction pinion
9 Oil seal
10 Front bearing inner race
11 Front bearing outer race
12 Rear bearing outer race
13 Bearing retainer
• Record the height of the collar to use it

as reference at assembly.
Assembly sequence
verse.
Service standards
2.0 to 2.9 N·m
When new bear- {0.20 to 0.30 kgf·m}
– Adjust
ing is used (tangential force: 34 to
Starting torque of pinion bearing 52 N {3.5 to 5.3 kgf})
– (tangential force at outer periphery
point of bearing retainer) 1.6 to 2.4 N·m
When old bearing {0.16 to 0.24 kgf·m}
– Adjust
is reused (tangential force: 27 to
41 N {2.8 to 4.2 kgf})

Lock nut (companion flange mounting) 372.4 to 470.4 {38 to 48} –

Lip area of oil seal Chassis grease [NLGI No. 1 (Li soap)] As required
27-34
27
Pinion bearing remover
A B MB999045 Removal of rear bearing inner race

0.5 26.5
Pinion bearing installer

Installation of rear bearing inner race
A B C MH061005
and front bearing inner race
φ62 φ52 125
Pinion pilot bearing

installer
MH061976 Installation of pinion pilot bearing
A B
φ45.2 φ39.2
Oil seal installer
A B MH061750 Installation of oil seal

φ112 φ88
A B MH061977 Installation of front bearing outer race

φ89 φ78
A B MH061264 Installation of rear bearing outer race

φ99 φ88
27-35
Removal procedure
Removal: Reduction pinion
Removal: Rear bearing inner race
Removal: Front bearing outer race

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

• Drive out the rear bearing outer race by tapping evenly at three
notches in the bearing retainer.
27-36
27
Installation: Rear bearing outer race
Installation: Front bearing outer race
Installation: Front bearing inner race

• Install the front bearing inner race with the pinion assembled into
the bearing retainer.
Installation: Pinion pilot bearing

• Install the pinion pilot bearing with its retaining ring placed on the
gear.
Installation: Rear bearing inner race
27-37
Inspection: Starting torque of pinion bearing
• Apply the specified load to the companion flange or tighten the
lock nut to the specified torque.
• Measure the tangential force at outer periphery point of the bear-
ing retainer using a spring balancer.
CAUTION
• Securely fix the companion flange to measure.
• Do not assemble the oil seal when measuring the tangential
force.
• If the measured tangential force is within the specified value, the

starting torque conforms to the standard value.
• If the measured value deviates from the standard value, adjust
by changing a collar.
Thickness of collars available
15.600 to 16.200 mm (25 thickness in 0.025 mm increments)

• Apply grease to the lip area of the oil seal and install it on the
bearing retainer in the illustrated direction.
27-38
GROUP 31 WHEEL, TIRE
SPECIFICATIONS............................................................................... 31-2

1. Inspection of Wheel Nuts for Looseness ...................................... 31-4
WHEEL, TIRE...................................................................................... 31-6
31-1
SPECIFICATIONS
Tire size Wheel type
205/80R17.5 120/118L 17.5 × 5.25-115-8
• Tire pressures specified for each tire size are shown on the tire pressure label.
31-2
TROUBLESHOOTING 31
Symptoms Tire tread wear
Worn in feather pattern from outside
Worn in concave (one spot or more)

Worn in pit over the entire periphery
Worn in feather pattern from inside
Reference Gr
Worn in wave pattern

Both shoulders worn
Worn in serration
Outside worn
Center worn
Inside worn
out
Possible causes
in
Overload O
Too low O O O O O
Tire pressure
Too high O
Excessive O O
Toe-in
Insufficient O
Excessive O
Wheel alignment Camber
Insufficient O
Gr26
Excessive toe-out O O
Multiple misalignment O O O O O O O O
Knuckle arm bent O O O O
Left and right tie-rods different in length O
Wheels out of balance O O O O
Wheel bearing loose O O O O Gr26, 27
Tie-rod end loose O Gr26
Brake drum eccentrically mounted <Drum brake> O O Gr27
Axle bent O O Gr27
Left and right wheels steered at improper angles O Gr26
Hard acceleration, braking, or steering O
Specific road surface conditions O O
31-3
1. Inspection of Wheel Nuts for Looseness

– Wheel nut 490 ± 49 {50 ± 5} –
(1) Single tire

• Tighten the wheel nuts to the specified torque using a torque
wrench.
• If frequent loosening of tightened wheel nut or other similar ab-
normality is found, check the wheel nuts, hub bolts, and disc
wheel for cracks or other damage which may cause the abnor-
mal condition. (See “WHEEL, TIRE.”)
(2) Double tire

• Loosen outer wheel nuts of half of the wheel bolts (alternately)
and then tighten the inner wheel nuts to the specified torque us-
ing a torque wrench.
• Retighten the loosened outer wheel nut to the specified torque
using a torque wrench.
• Follow the same procedure for the remaining outer wheel nuts
and inner wheel nuts of half of the wheel bolts.
• If frequent loosening of tightened wheel nut or other similar ab-
normality is found, check the wheel nuts, hub bolts, and disc
wheel for cracks or other damage which may cause the abnor-
mal condition. (See “WHEEL, TIRE.”)
31-4
31
M E M O
31-5
WHEEL, TIRE
CAUTION
• Use right-hand threaded wheel nuts marked “R” for right side wheels and left-hand threaded wheel nuts
marked “L” for left side wheels.
Removal sequence
1 Wheel nut <Single tire> 4 Tire <Double tire> (See later section.)
Wheel nut (outer) <Double tire>
2 Tire (See later section.)
3 Wheel nut (inner) <Double tire>
*a: Hub bolt
CAUTION
• The wheel nuts are designed to be tightened without any coating of grease. Never grease the wheel nuts.
Even if tightened to the specified torques, greased wheel nuts can become loose.
• Be sure to use genuine wheel nuts and tighten them to the specified torque, otherwise damage to hub
bolts and looseness of wheel nuts can be caused.

Correct or re-
2, 4 Tire lateral runout (sideway deflection) 3.5 or less –
place
31-6
31
Wheel nut 490 ± 49 {50 ± 5} –
Work before removal

Inspection: Tire lateral runout
[Inspection]
• If the measured value is equal to or exceeds the standard value,
correct as follows.
[Correction]
• Mark the tire, disc wheel, and one of the hub bolts in the illustrat-
ed locations.
• Remove the tire from the disc wheel.
• Measure the disc wheel for lateral runout.

• If the disc wheel’s maximum runout is located near the mark on
the wheel, install the tire such that the mark on the tire is 180°
away from the mark on the disc wheel.
• Measure the tire again for lateral runout.
• If the measured value still does not conform to the standard val-
ue, replace the tire.
31-7
WHEEL, TIRE
Installation: Tire
• To prevent hardware and parts from becoming loose and/or
damaged, thoroughly clean the following areas, removing rust,
dirt, paint and foreign matter, before installing the tire.
A : Threaded portion of hub bolt
B : Wheel mounting surface of hub
C : Wheel alignment area of hub
D : Mating surfaces of disc wheel
E : Wheel nut mounting surface of disc wheel
F : Threaded portion of wheel nut
G : Spherical portion of wheel nut
• Install the wheel nuts by tightening them with fingers as far as

they go to ensure that they smoothly turn. If there is any abnor-
mality such as a sticking point, replace the hub bolt. (See Gr26
and 27.)
• The wheel nuts should be tightened in the diagonal sequence in
a few steps. Lastly, use a torque wrench to retighten them to the
specified torque.
• When tightening the nuts with an impact wrench, use care of the
time of tightening, compressed air pressure intensity or the like
to prevent overtightening and use a torque wrench to retighten
them in the final step.
31-8
31
M E M O
31-9
WHEEL, TIRE
Tire
1 Tire
2 Air valve
3 Disc wheel
Assembly sequence
verse.

– Tire assembly static imbalance tolerance 30 g or less – Correct
Flatness 0.3 or less –
Lateral runout
1.8 or less –
3 Disc wheel (sideway deflection) Replace
Radial runout
1.7 or less –
(vertical deflection)

Nut (air valve mounting) 12.7 ± 1.4 {1.3 ± 0.14} –
31-10
31
Inspection: Disc wheel
• Visually inspect the disc wheel for deformation, crack, deteriora-
tion, damage, corrosion or stepped wear on the wheel hub
mounting surface. If any abnormality is found, replace the disc
wheel with a new one.
• If any abnormality is found on the disc wheel, inspect the wheel
hub. (See Gr26 and 27.)
(2) Flatness
• Measure flatness around the inner and outer circumferences of
hub bolt holes in the disc wheel.
replace the disc wheel.
(3) Runout
replace the disc wheel.
Installation: Tire
<Tire with no red mark>
• Install the tire such that the yellow mark (light point mark) on the
tire is aligned with the air valve on the disc wheel.
31-11
WHEEL, TIRE
<Tire with red mark>
• Install the tire such that the red mark (max. radial runout mark)
on the tire is aligned with mark A or B on the disc wheel.
A: Front face of disc wheel
B: Back face of disc wheel
Installation: Balance weight

• Install the balance weights on front and rear wheels to adjust the
wheel balance.
• To reduce allowable static unbalance value to standard value or
less, install the balance weight on outside of the disc wheel.
• Use a 1-pound plastic resin hammer to drive balance weights

into position.
• To install a balance weight, tap the clip of the weight in the cen-
ter at 1, 2 and 3 in that order.
• Leave a clearance of approx. 0 to 1 mm between the clip and

the disc wheel. Ensure that the balance weight is not loose after
installation.
• Do not use a balance weight that has been improperly tapped or
dropped to the floor during installation attempt.
• When 2 weights are being installed, these weights should be as
much equal to each other as possible in weight. Also remember
that the center point between the weights will become the sup-
port point for a balancer.
31-12
GROUP 33 FRONT SUSPENSION

1. Front Suspension Elements .......................................................... 33-2

1. Inspection of Leaf Springs for Damage ......................................... 33-4
2. Inspection of Suspension Mounting Points and Joints
for Looseness and Damage .......................................................... 33-4
3. Inspection of Shock Absorber for Oil Leakage ............................. 33-4
STABILIZER........................................................................................ 33-6
SHOCK ABSORBER .......................................................................... 33-8
LEAF SPRING................................................................................... 33-10
33-1
1. Front Suspension Elements
• The front suspension shown above uses a spring shackle connected to the rear end of the leaf spring (shackle-
link type suspension).
• The stabilizer prevents the vehicle from pitching during turning.
33-2
TROUBLESHOOTING 33
Symptoms
Road bumps/pits received as shocks
Cyclical shocks from underneath

Reference Gr
Feels as if floating
Tends to be noisy
Poor linearity
Heavy rolling
Vehicle tilted
Possible causes
Deformed stabilizer bar or worn bushing O
Substantial loss of oil and damping
O
capacity
Shock absorber
Rubber bushing worn O
Loose fitting O
Cracks or other damage O O
Broken O O
Leaf spring
Loose U-bolt O O
Rubber bushing worn O O
Uneven wear O O
Tire Tire and wheel needs balancing O O Gr31
Excessive tire pressure O
Wheels out of alignment O Gr26
33-3
1. Inspection of Leaf Springs for Damage
• Check the leaf spring visually for cracks and breakage.
• If there is any crack or breakage, replace the leaf spring.
(See “LEAF SPRING”.)
2. Inspection of Suspension Mounting Points and Joints for Looseness and Dam-
age
• Check the mounting points and joints of the leaf spring, shock
absorber, stabilizer, spring hanger and other components for
looseness.
• If there is any looseness, tighten the loose parts to the specified
torque. (See later sections.)
• Check the leaf spring, shock absorber, stabilizer, spring hanger
and other components and their mounting points and joints visu-
ally for damage.
• If there is any damage, replace the damaged parts. (See later
sections.)
3. Inspection of Shock Absorber for Oil Leakage

• Check the shock absorber visually for oil leaks.
• If there is any leak, replace the shock absorber.
(See “SHOCK ABSORBER”.)
33-4
33
M E M O
33-5
STABILIZER
Removal sequence
1 Washer 7 Stabilizer hanger
2 Rubber bushing 8 Rubber bushing
3 Washer 9 Stabilizer bracket
4 Washer 10 Stabilizer bushing
5 Rubber bushing 11 Stabilizer bar
6 Washer 12 Stabilizer hanger bracket

Nut (stabilizer hanger mounting) 70 to 95 {7.0 to 9.5} –
Nut (stabilizer bracket mounting) 34.3 to 53.9 {3.5 to 5.5} –
Nut (U-bolt mounting) 103 to 118 {10.5 to 12} Wet
Nut (stabilizer hanger bracket mounting) 80 to 110 {8.0 to 11} –
Nut (stabilizer hanger bracket mounting) 39 to 58 {3.9 to 6.0} –

Thread area of nut As required
33-6
33
Installation: Stabilizer bracket
• Install the stabilizer bracket by aligning it with the mark on the
stabilizer bar.
Installation: Stabilizer hanger

• Adjust the dimension A in the illustration to the following length
by tightening the nut.
A: 3 mm
33-7
SHOCK ABSORBER
Removal sequence
1 Washer 6 Washer
2 Rubber bushing 7 Rubber bushing
3 Rubber bushing 8 Shock absorber
4 Washer
5 Washer : Non-reusable parts

Lock nut (rubber bushing mounting) 13 to 17 {1.3 to 1.7} –
33-8
33
Installation: Rubber bushing
• Tighten the nut until the rubber bushing is squeezed to the illus-
trated dimension. Align the groove of the lock nut with the pin
hole in the front axle. The adjustment must be finished by tight-
ening the nut.
• Install the split pin as shown in the illustration.
33-9
LEAF SPRING
Removal sequence
1 U-bolt 5 Shackle plate 9 Front bump stopper
2 Front spring clamp 6 Spring shackle
3
4
Spring pin
Rubber bushing
7
8
Rubber bushing
Leaf spring (See later section.)
*a: Front spring hanger
NOTE
• The right-hand and left-hand leaf spring assemblies have different cambers from each other. Ensure that
both assemblies are installed correctly. Reversed installation results in a slanted vehicle.
33-10
33
Clearance between spring pin and rubber bushing in ra-
3, 4 0 to 0.04 – Replace
dial direction
Clearance between rubber bushing and front spring
*
4, a
hanger in axial direction
0 0.5 Replace
Clearance between shackle plate/spring shackle and

5 to 7 0 0.5 Replace
rubber bushing in axial direction
Clearance between spring shackle and rubber bushing
6, 7 0 to 0.04 – Replace
in radial direction
9 Height of front bump stopper 45 40 Replace

Nut (U-bolt mounting) 103 to 118 {10.5 to 12.0} Wet
Nut (spring pin mounting)
93.2 to 127 {9.5 to 13.0} –
Nut (spring shackle mounting)
Bolt (front bump stopper mounting) 80 to 110 {8.0 to 11} –

Thread area of nut As required
Inspection before removal

Inspection: Clearance between rubber bushing and front
spring hanger in axial direction
• Measure the clearance with a feeler gauge.
• If the measured value exceeds the limit, replace the rubber
bushing.
Inspection: Clearance between shackle plate/spring shack-

le and rubber bushing in axial direction
• Measure the clearance with a feeler gauge.
• If the measured value exceeds the limit, replace the rubber
bushing.
33-11
LEAF SPRING
Inspection: Spring shackle
• Check the pins of the spring shackle for wear and damage.
• If there is any abnormality, replace the spring shackle.
Inspection: Front bump stopper

• Perform the following inspections and replace the front bump
stopper if there is any abnormality.
(1) Height
• Measure the height of the front bump stopper to check that the
measured value is within the limit.
(2) Visual check

• Check the rubber and iron plate of the front bump stopper for
cracks.
• Install the spring pin by aligning the concave on the pin with the
convex on the frame.
33-12
33
M E M O
33-13
LEAF SPRING
Leaf Spring <Except Multi-leaf Spring>
1 Spacer (thickness: 6 mm) 8 Rivet
2 Spacer (thickness: 0.5 mm) 9 Clip
3 Collar 10 Leaf spring (No. 3)
4 Leaf spring (No. 1) 11 Spacer (thickness: 1 mm) <Wheelbase J, LH>
5 Leaf spring (No. 2) 12 Caster shim
6 Spacer (thickness: 0.5 mm)
7 Silencer : Non-reusable parts
Assembly sequence

Nut (assembly of leaf spring) 35 to 52 {3.5 to 5.5} –
33-14
33
Removal procedure
Compression: Leaf spring
• Compress the leaf spring using a press to prepare for the subse-
quent operations.
• Raise the bent portions of the clip with a chisel.
Removal: Clip
• Cut the flattened head of the rivet with a drill and remove the clip
from the leaf spring (No. 3).
Installation: Caster shim
• Install the caster shim with the chamfered (or rounded) portion
facing upward in order not to damage the seat and spring.
Installation: Clip
• Flatten the rivet with a riveting machine and install the clip.
Installation: Leaf spring

• Secure the leaf spring by temporarily tightening a bolt.
• Compress the leaf spring using a press and tighten a nut to the
specified torque.
• Bend the clip with a hammer.
33-15
LEAF SPRING
Leaf Spring <Multi-leaf Spring>
1 Collar 8 Rivet
2 Leaf spring (No. 1) 9 Clip
3 Leaf spring (No. 2) 10 Leaf spring (No. 5)
4 Rivet 11 Leaf spring (No. 6)
5 Clip 12 Caster shim
6 Leaf spring (No. 3)
7 Leaf spring (No. 4) : Non-reusable parts
Assembly sequence

33-16
33
Removal procedure
• Compress the leaf spring using a press to prepare for the subse-
quent operations.
• Raise the bent portions of the clip with a chisel.
Removal: Clip
• Cut the flattened head of the rivet with a drill and remove the clip
from the leaf spring (No. 3 and No. 5).
Installation: Clip
• Flatten the rivet with a riveting machine and install the clip.

• Secure the leaf spring by temporarily tightening a bolt.
• Compress the leaf spring using a press and tighten a nut to the
specified torque.
• Bend the clip with a hammer.
33-17
GROUP 34 REAR SUSPENSION

1. Structure of Rear Suspension ....................................................... 34-2

1. Checking Leaf Spring for Damage ................................................ 34-4
2. Checking Mounting and Connecting Sections of
Suspension for Looseness and Damage ...................................... 34-4
3. Checking Shock Absorber for Oil Leak ......................................... 34-4
STABILIZER........................................................................................ 34-6
SHOCK ABSORBER .......................................................................... 34-8
LEAF SPRING................................................................................... 34-10
34-1
1. Structure of Rear Suspension
• The rear suspension use a spring shackle at the rear end of the leaf spring (shackle-link type suspension).
• The stabilizer bar reduces the roll of the body during cornering.
34-2
TROUBLESHOOTING 34
Symptoms
Road bumps/pits received as shocks
Cyclical shocks from underneath

Reference Gr
Feels as if floating
Tends to be noisy
Heavy rolling
Possible causes
Stabilizer deformed, bushing worn O
Cracks or other damage O
Broken O
Leaf spring
Loose U-bolt O
Rubber bushing worn O
Spacer or bump stopper damaged or broken O
Spring pin over-tightened O
Substantial loss of oil and damping capacity O
Shock absorber Rubber bushing worn O
Loose fitting O
Tire and wheel unbalanced O
Tire Gr31
Excessive tire pressure O
34-3
1. Checking Leaf Spring for Damage
• Visually check the leaf springs for cracks and breaks.
• If any crack or break is found, replace the leaf spring. (See
“LEAF SPRING”.)
2. Checking Mounting and Connecting Sections of Suspension for Looseness and

Damage
• Check the mounting and connecting sections of leaf springs,
shock absorbers, stabilizer and spring hangers for looseness.
• If any looseness is found, tighten the corresponding fasteners to
the specified torque. (See later section.)
• Visually check the mounting and connecting sections of leaf
springs, shock absorbers, stabilizer and spring hangers for dam-
age.
• If any damage is found, replace the damaged part(s). (See later
section.)
3. Checking Shock Absorber for Oil Leak

• Visually check the shock absorbers for oil leak.
• If any oil leak is found, replace the shock absorber. (See
“SHOCK ABSORBER”.)
34-4
34
M E M O
34-5
STABILIZER
Removal sequence
1 Washer 7 Stabilizer clamp
2 Rubber bushing 8 Stabilizer bushing
3 Rubber bushing 9 Stabilizer bushing
4 Washer 10 Stabilizer bar
5 Stabilizer retainer 11 Stabilizer bracket
6 Stabilizer hanger 12 Stabilizer hanger bracket

Nut (stabilizer mounting) 33 to 49 {3.4 to 5.0} –
Nut (stabilizer hanger mounting) 17 to 26 {1.7 to 2.6} –
Nut (stabilizer retainer mounting) 35 to 54 {3.5 to 5.5} –
Nut (stabilizer hanger bracket mounting) 123 to 147 {12.5 to 15.0} –
34-6
34
Installation: Stabilizer clamp and bushing
• Mount stabilizer bushings with their end surfaces aligned with
marks on stabilizer bar and fix them with stabilizer clamps.
Installation: Stabilizer hanger

• Tighten the mounting nuts until the part A in the illustration be-
comes the following dimension.
A: 4 mm
34-7
SHOCK ABSORBER
Removal sequence
1 Washer
2 Washer
3 Rubber bushing
4 Rubber bushing
5 Shock absorber
6 Washer
7 Washer

Nut (shock absorber mounting) 26.5 to 33.3 {2.7 to 3.4} –
34-8
34
M E M O
34-9
LEAF SPRING
Removal sequence
1 U-bolt seat 8 Bushing
2 U-bolt 9 Leaf spring (See later section.)
3 Bump stopper 10 Spacer (8 mm)
4 Spring pin
5 Bushing
*b:
a: Rear spring hanger
6 Spring shackle
* Rear shackle hanger
7 Shackle plate
*c: Rear axle
34-10
34
4, 5 Radial clearance between spring pin and bushing 0 to 0.04 – Replace
Axial clearance between bushing and rear spring hang-
*
5, a
er
0 0.5 Replace
6, 8 Radial clearance between spring shackle and bushing 0 to 0.04 – Replace

7, 8 Axial clearance between shackle plate and bushing 0 0.5 Replace
9 Clearance between leaf spring and frame – 5 Replace

Nut (U-bolt mounting) 127.5 to 166.7 {13 to 17} Wet
Nut (spring pin mounting)
93.2 to 127 {9.5 to 13.0} –
Nut (spring shackle mounting)
Nut (spacer mounting) 12 to 15 {1.2 to 1.5} –

Threads of nut As required
Inspection before removal

Inspection: Axial clearance between bushing and rear
spring hanger
• Measure the clearance using feeler gauge.
• If the measured value exceeds the limit, replace the bushings.
Inspection: Axial clearance between shackle plate and

bushing
• Measure the clearance using feeler gauge.
• If the measured value exceeds the limit, replace the bushings.
34-11
LEAF SPRING
Inspection: Clearance between leaf spring and frame
• Measure the clearance between the leaf spring and frame. If the
measurement exceeds the limit, replace the bushings.
Inspection: Spring shackle
• Check the pins of the spring shackle for wear and damage.
• If any abnormality is found, replace the spring shackle.
Inspection: Rear shackle hanger

• Check the pipe section of the rear shackle hanger for cracks.
• If any crack is found, repair by welding.
CAUTION
• When welding, be careful not to protrude the welding bead
from the end of pipe.
• Install the spring pin while aligning its concave section with the
convex section on the rear spring hanger.
34-12
34
M E M O
34-13
LEAF SPRING
Leaf Spring <Except Multi-leaf Spring>
• The above drawing shows an example. The number of leaf springs and the components of the leaf spring assem-
bly may differ depending on the vehicle model.
1 Spacer 7 Silencer
2 Spacer 8 Rivet
3 Collar 9 Clip
5 Leaf spring (No. 2)
6 Spacer : Non-reusable parts
Assembly sequence

Nut (leaf spring assembling) 35 to 52 {3.5 to 5.5} –
34-14
34
Removal procedure
• Using a press, compress the leaf spring as illustrated for subse-
quent operations.
• Using a chisel or the like, open the bent ends of the clip.
Removal: Clip
• Using a drill, break the flattened head of the rivet and remove
the clip from the leaf spring (No. 3).
Installation: Clip
• Using a riveting machine, rivet a clip onto the leaf spring.

• Temporarily tighten the leaf springs with the bolt.
• Compress the leaf springs using a press and tighten the nut to
• Bend the clip using a hammer.
34-15
LEAF SPRING
Leaf Spring <Multi-leaf Spring>
2 Center spacer 12 Center spacer
3 Leaf spring (No. 5) 13 Rivet
4 Center spacer 14 Clip
5 Pipe 15 Leaf spring (No. 4)
6 Collar 16 Center spacer
7 Leaf spring (No. 1) 17 Spacer
8 Center spacer
9 Leaf spring (No. 2) : Non-reusable parts
10 Center spacer
Assembly sequence

34-16
34
Removal procedure
• Using a press, compress the leaf spring as illustrated for subse-
quent operations.
Removal: Clip
• Using a drill, break the flattened head of the rivet and remove
the clip from the leaf spring (No. 4).
Installation: Clip
• Using a riveting machine, rivet a clip onto the leaf spring.

• Temporarily tighten the leaf springs with the bolt.
• Compress the leaf springs using a press and tighten the nut to
34-17
GROUP 35 BRAKE
SPECIFICATIONS.................................. 35-2 14.Inspection of Vacuum Booster....... 35-31
STRUCTURE AND OPERATION VACUUM PUMP ................................... 35-35

1. Brake System .................................. 35-4
2. Vacuum Pump ................................. 35-6 BRAKE MASTER CYLINDER.............. 35-36
3. Vacuum Booster and
Brake Master Cylinder ..................... 35-7 BRAKE PEDAL AND
4. Front Drum Brake .......................... 35-11 VACUUM BOOSTER............................ 35-40
5. Front Disc Brake ............................ 35-14
FRONT DRUM BRAKE ........................ 35-42
6. Rear Drum Brake ........................... 35-15
FRONT DISC BRAKE .......................... 35-48
TROUBLESHOOTING ......................... 35-16
REAR DRUM BRAKE .......................... 35-52
ADJUSTMENT
1. Fluid Leaks from
the Brake System .......................... 35-20
2. Replacement of Brake Fluid ........... 35-20
3. Air Bleeding of Brake System ........ 35-21
4. Inspection of Fluid Level
in Fluid Tank .................................. 35-23
5. Inspection and Adjustment
of Brake Pedal ............................... 35-23
6. Inspection of Brake Master Cylinder,
Wheel Cylinder and Caliper for Function,
Wear and Damage.......................... 35-25
7. Inspection and Replacement of
Disc Brake Pad .............................. 35-26
8. Brake Disc and Pad Clearance
on Disc Brake ................................ 35-28
9. Measurement of Disc Brake
Drag Torque ................................... 35-28
10.Inspection of Drum Brake
Lining Thickness ........................... 35-29
11.Initial Setting of Brake Drum-to-Shoe
Clearance ...................................... 35-29
12.Inspection of Check Valve
in Vacuum Line Hose ..................... 35-30
13.Inspection of Vacuum Pump .......... 35-30
35-1
SPECIFICATIONS
Vacuum Booster and Brake Master Cylinder
Item Specifications
Boosting type Vacuum tandem type
Vacuum booster Diaphragm diameter inch φ9 + φ10
Manufacturer Bosch
Inner diameter mm φ31.75
Brake master Front mm 16.0
Stroke
cylinder Rear mm 16.0
Manufacturer Bosch
Front Disc Brake

Item Specifications
Brake type Twin caliper type
Effective diameter mm φ235
Disc rotor outer diameter × thickness mm φ293 × 40
Caliper piston inner diameter mm φ51.1
Pad thickness mm 14
Front Drum Brake

Item Specifications
Brake type 2-leading type
Wheel cylinder inner diameter mm φ31.75
Brake drum inner diameter mm φ320
Brake lining width × thickness mm 110 × 10.4
Adjusting type Auto
Rear Drum Brake

Item Specifications
Brake type Dual 2-leading type
Wheel cylinder inner diameter mm φ31.75
Brake drum inner diameter mm φ320
Brake lining width × thickness mm 110 × 10.4
Adjusting type Auto
Vacuum Pump
Item Specifications
Type Vane type
3
Output cm {mL} 60 {60}
Manufacturer MITSUBISHI ELECTRIC
35-2
35
M E M O
35-3
1. Brake System
1.1 Brake fluid line
1 Vacuum booster 5 Front wheel brake

2 Brake fluid level switch 6 Rear wheel brake
3 Brake fluid tank 7 Stop lamp switch
4 Brake master cylinder
• The brake system incorporating the vacuum booster uses vacuum to provide servo-assisted braking to all wheels
of the vehicle onto which it is mounted.
35-4
35
1.2 Vacuum booster line
35-5
2. Vacuum Pump
• The vacuum pump is mounted onto the front case of engine, and is driven by the timing gear.
• The check valve is provided to ensure that no air or engine oil flow back from the vacuum pump to the vacuum
tank when the engine is stopped.
2.1 Operation
• A rotor with 3 movable vanes is housed in a cylindrical housing.
As the rotor rotates, the vanes are pressed against the inner wall
of the housing by centrifugal force.
• The rotor is eccentrically mounted relative to the housing. As the
rotor rotates, air in the vacuum tank is sucked through the pump
inlet and then compressed before being discharged through the
outlet. The suction-compression-discharge cycle is repeated to
generate vacuum in the vacuum tank.
• The inside of the housing is lubricated and cooled by engine oil.
After lubrication/cooling, the engine oil together with the com-
pressed air is returned through the pump outlet and into the oil
pan.
35-6
35
3. Vacuum Booster and Brake Master Cylinder
• The vacuum booster magnifies the stepping force applied onto the brake pedal through the utilization of pressure
difference between the vacuum it generates and the atmospheric pressure to reduce the operator’s pedal effort.
The system is of a tandem type and has 2 vacuum chambers, achieving size reduction while offering a great ca-
pacity for highly efficient boosting performance.
• The brake master cylinder serves both the front and rear brake systems that are independent of each other.
Should fluid leakage occur in either the front or rear brake system, therefore, stopping power can still be provided
by the system that is intact.
35-7
(1) When brake pedal is depressed
(1.1) Vacuum booster operation
• With the brake pedal released and no
stepping force applied to the brake
pedal, the operating rod and the valve
plunger are held to the right by the
force of the valve return spring. The
atmospheric pressure valve remains
closed while the vacuum valve re-
mains open.
• The vacuum pump creates vacuum in
chamber A. As the atmospheric pres-
sure valve is closed, no outside air
flows into chamber B. Instead, vacu-
um in chamber A flows through the air
passage and into chamber B. Cham-
bers A and B are both filled with vacu-
um, and there is no pressure
difference between the chambers. No
boosting occurs.
• As the brake pedal is depressed, the
stepping force acts on the operating
rod. This seats the poppet onto the
valve body, closing the vacuum valve
and cutting off vacuum supply into
chamber B. As the brake pedal is de-
pressed further, the valve plunger sep-
arates from the poppet. This opens the
atmospheric pressure valve, allowing
outside air flow into chamber B. There
is now a pressure difference between
chambers A and B.
• The stepping force, boosted as a re-
sult of the pressure difference be-
tween chambers A and B, overcomes
the force of the diaphragm plate
spring, pushing the front and rear dia-
phragms and the push rod to operate
the brake master cylinder.
(1.2) Brake master cylinder operation
• As the push rod pushes the primary
piston, the return port is closed by the
packing cup. Fluid pressure now
builds up in chamber C.
• The pressure is sent to the front brake
system and at the same time pushes
the secondary piston.
• In the same manner as in chamber C,
fluid pressure builds up in chamber D
in front of the secondary piston. The
pressure is sent to the rear brake sys-
tem.
35-8
35
(2) Fluid leakage in front brake sys-
tem
push rod moves to push the primary
piston. As there is fluid leakage in the
front brake system, no fluid pressure
builds up in that system.
• As the brake pedal is depressed fur-
ther, the primary piston overcomes the
force of the primary piston return
spring and, via the retainer, pushes
the secondary piston. Fluid pressure is
now sent to the rear brake system.
(3) Fluid leakage in rear brake system

push rod moves to push the primary
and secondary pistons. As there is flu-
id leakage in the rear brake system,
no pressure builds up in that system.
• As the brake pedal is depressed fur-
ther, the tip of the secondary piston
contacts the cylinder body while the
primary piston continues to be
pushed. Fluid pressure builds up fur-
ther in the front brake system.
35-9
(4) When brake pedal is released
(4.1) Vacuum booster operation
• With the brake pedal depressed,
chamber A is filled with vacuum gener-
ated by the vacuum pump while cham-
ber B is open to the atmosphere.
When the brake pedal is released, the
stepping force no longer acts on the
operating rod. This causes the valve
plunger to seat on the poppet, closing
the atmospheric pressure valve and
cutting off air flow into chamber B.
• In further progression, the poppet sep-

arates from the seat of valve body.
This opens the vacuum valve, allowing
vacuum from the vacuum pump to flow
into chamber B. As there is now no
pressure difference between cham-
bers A and B, the diaphragm plate
spring pushes back the front and rear
diaphragms along with the push rod to
their original positions.
(4.2) Brake master cylinder operation

• As the push rod returns to its original
position, the secondary piston immedi-
ately starts to be pushed back by the
force of the secondary piston return
spring. However, the speed of return is
gradual as there is no difference be-
tween chambers C and D in fluid pres-
sure supplied by the brake master
cylinder.
• As the secondary piston starts to re-
turn to its original position, the pres-
sure in chamber D becomes lower
than the pressure in chamber C. The
pressure difference causes the pack-
ing cup to buckle, allowing the fluid
pressure in chamber C to flow through
the orifices and into chamber D.
35-10
35
• The secondary piston goes back to its
original position, making the fluid pres-
sures in chambers C and D the same.
The packing cup restores its original
shape, blocking the orifices. The fluid
pressure in the brake pipe now returns
to the brake fluid tank through the re-
turn port.
• In the same manner as the secondary

piston, the primary piston moves to its
original position to return the fluid
pressure in the brake pipe to the brake
fluid tank.
4. Front Drum Brake

• The front drum brake is of a 2-leading
type.
• Single-acting wheel cylinders activate
brake shoes, both as a leading shoe,
in forward-travel braking. By self-
boosting effect, the 2-leading shoe
brake generates a great stopping pow-
er.
35-11
4.1 Wheel cylinder
• The wheel cylinder is equipped with a
self-adjusting mechanism to compen-
sate for lining wear and maintain the
correct clearance between the lining
and the drum. The adjustment is made
each time braking is performed.
4.2 Self-adjusting mechanism

(1) Operation
• When the brake pedal is depressed,
fluid pressure from the brake master
cylinder enters into chamber and
pushes the piston, which then extends
the spring and fitting. The lever, which
is connected to the spring and fitting,
pivots about the pin.
• When the brake drum-to-lining clear-

ance is correct, the amount of lever
travel when the brake pedal is de-
pressed is not enough to turn the ad-
juster which therefore remains in the
same place.
35-12
35
• As the brake drum-to-lining clearance
grows, the amount of piston travel,
and therefore the amount of lever trav-
el, becomes greater.
• When the lever travels far enough to
turn the adjuster, the threads on the
adjuster causes the adjusting screw to
advance. As a result, the brake shoe
extends.
• As the brake pedal is released, the ad-

juster remains in the new position
while the lever retracts by one tooth.
The brake drum-to-lining clearance is
now correctly adjusted.
35-13
5. Front Disc Brake
• The front disc brake uses twin floating-
type calipers.
• The caliper houses one each of cylin-
der and piston. Stopping power is gen-
erated by squeezing the disc rotor
between the pads, with the outer pad
pressed against the disc rotor by reac-
tion.
• The inner pad is equipped with wear
indicator which serves to indicate re-
placement timing for both the inner
and outer pads.
• The front disc brake is equipped with
self-adjusting mechanism to compen-
sate for pad wear and maintain the
correct clearances between the disc
rotor and the inner and outer pads.
The adjustment is made each time
braking is performed.
5.1 Self-adjusting mechanism

(1) Operation
(1.1) When brake pedal is depressed
• The piston extends exceeding the
seal’s elastic deformation range by the
amount of inner pad wear (hatched ar-
ea).
(1.2) When brake pedal is released

• The piston retracts as much as the
amount of the seal’s elastic deforma-
tion, thus maintaining the correct
clearance between the disc rotor and
the inner pad.
35-14
35
6. Rear Drum Brake
• The rear drum brake is of a dual 2-
leading type.
• Double-acting wheel cylinders activate
both brake shoes as a leading shoe in
forward- and rearward-travel braking.
By self-servo effect, both leading
shoes generate great stopping power.
6.1 Wheel cylinder

• The wheel cylinder is equipped with a
self-adjusting mechanism which com-
pensates for the wears of brake drum
and lining and maintains the correct
clearance between them. The adjust-
ment is made each time braking is
performed.
• The self-adjusting mechanism oper-
ates in the same manner as that of the
front drum brake.
35-15
TROUBLESHOOTING
Wheel Brake
Symptoms Noise and shock
Uneven braking when brake ped-
al depressed
Continuous noise during brake application (at low vehicle

Noise generated when wheels are turned with jacked-up
Brake drag (slow disengagement after pedal release)
Stopping power different from right to left
Refer-
ence Gr
Insufficient stopping power

Unstable stopping power
Reduced pedal travel

Locking point varies
vehicle
speed)
Other
Other
Possible causes
Surface of the ledge of the backing plate is
O O
rough
Backing plate deformed or incorrectly installed O
Lubricant or moisture on brake pad or lining
O O
surface
Deterioration or incorrect material used for
O
brake pad or lining
Brake pad or lining unevenly worn or with
O
rough surface
Fade (brake pad or lining surface deteriora-
O
tion)
Brake pad or lining worn to limit O
Incorrect contact of brake pad or lining O O O
Brake lining radius uneven O
Wheel brake
Wheel cylinder malfunction O O O O
Shoe return spring fatigued or broken O O
Disc rotor or brake drum worn unevenly O
Disc rotor or brake drum deformed O
Disc rotor or brake drum worn O
Disc rotor or brake drum surface rough O
Disc rotor or brake drum inaccurately ma-
O
chined
Brake drum cracked O
Foreign matter in brake drum O
Brake shoe deformed or damaged O
Shoe hold cup broken O
Movable parts insufficiently lubricated O
35-16
35
Symptoms Noise and shock
Uneven braking when brake ped-
al depressed
Continuous noise during brake application (at low vehicle

Noise generated when wheels are turned with jacked-up
Brake drag (slow disengagement after pedal release)
Stopping power different from right to left
Refer-
ence Gr
Insufficient stopping power

Unstable stopping power
Reduced pedal travel

Locking point varies
vehicle
speed)
Other
Other
Possible causes
Incorrect pedal travel O
Brake pedal
Incorrectly adjusted, too much play O
Fluid level low O
Fluid leakage O
Brake fluid
Air ingress O
Vapor lock O
Vacuum system Vacuum drop O
Vacuum booster Faulty vacuum booster O O
Tire pressure uneven between wheels O
Tire Gr31
Different tire sizes from left to right O
Wheel hub bearing incorrectly adjusted O O
Gr26, 27
Axle Wheelbase different from left to right O
Incorrect wheel alignment O Gr26
35-17
TROUBLESHOOTING
Symptoms Brake drum
Brake noise
overheating
Noisy when vehicle is new, or after brake
Brakes used under severe conditions

Overheating on specific wheel(s)
Abnormal brake pedal return

Refer-
Overheating on all wheels

ence Gr
lining replacement
Brake drag
Judder
Other
Possible causes
Rough ledge surface of backing plate O
Shoe trapped on backing plate ledge surface O
Backing plate deformed or incorrectly installed O
Fading of brake pad or lining (deterioration of sur-
O
face material)
Wear powder attached on brake pad or lining O
Brake pad or lining worn O
Incorrect contact of brake pad or lining O
Wheel brake
Wheel cylinder malfunction O O
Faulty wheel cylinder piston cup O O
Shoe return spring fatigued or broken O O
Disc rotor or brake drum glazed O
Brake drum deformed or center deviation O
Uneven disc rotor thickness O
Brake shoe deformed or damaged O
Brake shoe twisted or sagged O
Abnormal pedal return O
Pedal play insufficient O
Brake pedal Linkage rusted or deformed O
Return spring fatigued or broken O
Vacuum booster operating rod thrust O
Brake fluid Poor fluid return due to over-tightened brake pipes O
Vacuum booster Faulty vacuum booster O
Brake master Faulty piston cup O
cylinder Clogged return port O
Wheel hub bearing incorrectly adjusted O O O Gr26, 27
Axle
King pin bushing worn O Gr26
35-18
35
M E M O
35-19
1. Fluid Leaks from the Brake System
• Check the hose and pipe connections for fluid leak, and check the hose for blister, damage and cracked.
• If any fluid leak is found, check the connections for looseness or replace the faulty part.
2. Replacement of Brake Fluid

• Brake fluid is shared by the brake and clutch systems, and is divided in the brake fluid tank into the two systems.
This section describes the replacement of the brake fluid for the brake system. In order to completely replace the
brake fluid, the brake fluid in the clutch system should also be replaced.

– Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

Brake fluid (SAEJ1703 or FMVSS
No. 116 DOT3)
WARNING
• Be sure to use new brake fluid. Do not mix it with brake fluid of different properties or mineral oil (gas oil,
engine oil, gear oil, automatic transmission fluid, etc.). This will alter the original properties of brake fluid,
causing the boiling point to drop as well as the brake rubber parts to swell. Faulty operation of the brake
will result.
brake operation.
CAUTION
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork. If brake fluid is spilled
onto the paintwork, immediately wipe it off.
• During brake fluid replacement operation, a change in color of the brake fluid being discharged indicates
that the old brake fluid in the system has been replaced with new brake fluid.
• During the replacement, be sure to keep the brake fluid level at the “MAX” mark on the tank.
2.1 Work before replacement

• In order to ensure that the vacuum booster functions properly,
start the engine and keep it running at idle until the replacement
is completed.
• Install one end of a vinyl pipe onto each air bleeder. Place the
2.2 Replacement of brake fluid

• Loosen each bleeder screw, and depress and release the brake
pedal repetitively until brake fluid is no longer discharged from
the pipes.
• While filling the brake fluid tank with new brake fluid up to the
“MAX” mark, cycle the brake pedal repetitively until the old brake
fluid being discharged is replaced with new brake fluid. Tighten
each air bleeder screw to the specified torque.
• Proceed to Air Bleeding of Brake System.
35-20
35
3. Air Bleeding of Brake System
• Brake fluid is shared by the brake and clutch systems, and is divided in the brake fluid tank into the two systems.
This section describes the air bleeding of the brake system. For the air bleeding of clutch system, see Gr21.

– Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

No. 116 DOT3)
WARNING
• Be sure to use new brake fluid. Do not mix it with brake fluid of different properties or with mineral oil
(gas oil, engine oil, gear oil, automatic transmission fluid, etc.). This will alter the original properties of
brake fluid, causing the boiling point to drop as well as the brake rubber parts to swell. Faulty operation
of the brake will result.
brake operation.
CAUTION
• Brake fluid is corrosive on paintwork. Be careful not to spill it onto the paintwork. If brake fluid is spilled
onto the paintwork, immediately wipe it off.
• Brake fluid level drops during the air bleeding operation. Be sure to keep the brake fluid level at the
“MAX” mark on the tank.
3.1 Work before air bleeding

• In order to ensure that the vacuum booster functions properly,
start the engine and keep it running at idle until the replacement
is completed.
• Install one end of a vinyl pipe onto each air bleeder. Place the
3.2 Air bleeding of brake system

(1) Air bleeding of primary (standard brake) circuit
• Perform the air bleeding sequence described below on each of
the 4 wheels in the order of the following table.
Order of air bleeding Brake system Wheel
1 Front right
Front
2 Front left
3 Rear right
Rear
4 Rear left
35-21
Loosen the air bleeder.
Slowly depress and release the brake pedal. Repeat this

several times until a sufficient amount of brake fluid is
discharged from the pipe.
Tighten the air bleeder.
Cycle the brake pedal several times, and finally depress

and hold it.
Loosen the air bleeder.
With the brake pedal still depressed, allow the brake fluid
to drain.
Tighten the air bleeder to the specified torque.
Repeat the above procedures on all of the remaining

wheels.
Air bleeding is completed.
35-22
35
4. Inspection of Fluid Level in Fluid Tank
• Check that the fluid level is between the “MAX” and “MIN”
marks.
• If the fluid level is lower than “MIN”, add the brake fluid.
5. Inspection and Adjustment of Brake Pedal

• The inspection and adjustment of the brake pedal should be performed after completing the following inspections
and adjustments.
• Air bleeding of brake system
• Measurement of brake disc dragging torque
• Initial setting of clearance between brake drum and shoe

– Installed height of brake pedal 250 ± 3.0 – Adjust
Pedal-to-floor clearance when brake pedal is de-
– 45 or more – Adjust
pressed
– Brake pedal play 10 to 15 – Adjust
Brake pedal to thread end of stop lamp switch clear-
– 0.5 to 1.5 – Adjust
ance
– Brake pedal to stop lamp switch harness clearance 5 or more – Adjust

– Lock nut (operating rod securing) 21.6 {2.2} –
5.1 Installed height of brake pedal

[Inspection]
• With the engine stopped and the brake pedal released, measure
the height from the center of the pedal pad to the center of the
brake master cylinder.
• If the measurement does not conform to the standard value, ad-
just by turning the vacuum booster operating rod.
[Adjustment]
• Loosen the lock nut and turn the operating rod to adjust the in-
stalled height of the brake pedal to the standard value.
• Tighten the lock nut to the specified torque.
• After tightening the lock nut, inspect the pedal-to-floor clearance
when the brake pedal is depressed and brake pedal play.
• After adjustment, check the clearance between the brake pedal
and the thread end of the stop lamp switch.
CAUTION
• When the brake pedal is fully depressed, the vacuum boost-
er operating rod functions as a stopper for the brake pedal.
35-23
5.2 Brake pedal-to-floor clearance when the brake pedal
is depressed
[Inspection]
• Fold the floor mat aside for measurement.
• With the engine idling, depress the brake pedal by 490 N {50
kgf} and measure the pedal-to-floor clearance.
• If the measurement is out of the standard value, adjust the in-
stalled height of the brake pedal.
[Adjustment]
• See “5.1 Installed height of brake pedal”.
5.3 Brake pedal play

[Inspection]
• With the engine stationary, measure the brake pedal play.
• If the measurement is out of the standard value, adjust the in-
stalled height of the brake pedal.
[Adjustment]
• See “5.1 Installed height of brake pedal”.
5.4 Brake pedal to thread end of the stop lamp switch

clearance
• Measure the clearance between the brake pedal stopper and
the thread end of the stop lamp switch.
• If the measurement is out of the standard value, adjust the clear-
ance and then tighten the lock nut.
CAUTION
• Do not contact the thread end of the stop lamp switch with
the brake pedal stopper as it may cause brake dragging.
• After adjustment, check the clearance between the brake pedal

and the stop lamp switch harness.
5.5 Brake pedal to stop lamp switch harness clearance

• Measure the clearance between the brake pedal and the stop
lamp switch harness.
• If the measurement is out of the standard value, relocate the
harness.
35-24
35
6. Inspection of Brake Master Cylinder, Wheel Cylinder and Caliper for Function,
Wear and Damage
• Perform the following inspections and, if any abnormality is
found, replace the faulty part(s).
(1) Brake master cylinder
• Visually check the brake master cylinder for damage and fluid
leak.
(2) Wheel cylinder <Drum brake>

• With the brake drum removed, visually check the wheel cylinder
(including inside the boot) for damage and fluid leak.
(3) Caliper <Disc brake>

• With the wheel removed, visually check the caliper for damage
and fluid leak.
35-25
7. Inspection and Replacement of Disc Brake Pad
– Thickness of outer/inner pad 14 4 Replace

– Slide pin 83.3 to 93.1 {8.5 to 9.5} Wet

– Threads and seating surface of slide pin As required
No. 116, DOT3)

Piston expander
Pressing piston during brake pad re-

A B MB990520
placement
50 5
[Inspection]
• When a brake pad has worn down to a thickness of approxi-
mately 4 mm, the pad wear indicator contacts the disc rotor. This
breaks the circuit, illuminating the disc brake warning lamp on
the meter cluster to tell the operator that the brake pads need re-
placement.
• Through the inspection hole in the caliper, measure the brake

pad thickness. If the measured value is less than the limit, re-
place all of the brake pads on that axle with new ones.
35-26
35
[Replacement]
• Remove the lower slide pin. Flip the caliper upwards and sus-
pend it in place using a wire or the like.
CAUTION
• The caliper needs to be suspended firmly in place so that it
does not drop, without stretching, squeezing or otherwise
forcing the brake hosing or harness.
• The slide pin is coated with grease. Do not wipe off this
grease and keep it away from dust.
• Inspect the piston for fluid leakage. Inspect the piston boots for
damage. Faulty parts must be replaced.
• Remove the following parts. Installation follows the removal pro-

cedure in reverse. When installing shims onto the pads, be sure
to face them in the illustrated directions.
• The pad wear indicators are provided on both right and left inner
pads.
• Install a pad wear indicator onto the inner pad (included in the
pad kit) using a clip (included in the pad wear indicator kit).
35-27
• Using , screw in the piston of the caliper until it bottoms on
the back of the caliper.
• Move the caliper back to the original place while taking care not
to damage the piston boots.
• Bleed the pin boots of air.
• Ensure that the pin boots are firmly attached into the groove on
the slide pin.
• Tighten the slide pin to the specified torque.
• Correctly route the harness(es) for the pad wear indicator(s).
• Measure the drag torque of the disc brake.
• Cycle the brake pedal several times, and check the brake fluid
level in the tank. The fluid level should be at the “MAX” mark on
the tank. Add brake fluid as required.
8. Brake Disc and Pad Clearance on Disc Brake

• Jack up the vehicle. Depress the brake pedal several times to
stabilize the brake pad condition. Then rotate the wheel several
times by hands to check for brake dragging.
• If the brake is dragging, measure the dragging torque.
9. Measurement of Disc Brake Drag Torque

Service standards
9.8 N·m {1.0 kgf·m} or
Approx. 5 sec. after re-
less (tangential force: 95 –
leasing brake pedal
Drag torque of disc brake N {9.7 kgf})
– Inspect
(tangential force at hub bolts) 6.9 N·m {0.7 kgf·m} or
After turning disc rotor
less (tangential force: 67 –
10 revolutions
N {6.8 kgf})
• Ensure that the starting torque of the wheel hub bearings con-
forms to the standard value.
• Using a spring balance, measure the tangential force at the hub
bolts.
• If the measured tangential force conforms to the specified value,
this means that the drag torque of the disc brake conforms to the
standard value.
• If the measured value does not conform to the specified torque,
check the sliding portions of the piston and piston seal.
35-28
35
10.Inspection of Drum Brake Lining Thickness
CAUTION
• To ensure correct operation of the brakes, be sure to inspect both linings on each wheel.

4.0
(Side shoul-
– Brake lining thickness – Replace
der means
wear limit.)
• Remove the inspection hole plug from the inspection hole in the
backing plate. Through the inspection hole, measure the thick-
ness of the brake lining.
• If any lining is worn down to the step on the side, replace all lin-
ings or shoes on that axle.
• After the inspection, be sure to install the plug onto the inspec-
tion hole.
11. Initial Setting of Brake Drum-to-Shoe Clearance

CAUTION
• To ensure correct operation of the brakes, be sure to inspect both shoes on each wheel.

Inspect, and ad-
– Brake drum-to-shoe clearance 0.2 –
just as required
[Inspection]
• Cycle the brake pedal a couple of times to bring the brake shoes
to conditions appropriate for the inspection.
• Through the inspection hole, insert a feeler gauge between the
brake drum and lining. The gauge should be able to be inserted
and out with slight resistance.
• If the clearance does not conform to the standard value, perform
the following adjustment.
[Adjustment]
• Jack up the wheel being adjusted. Ensure that the wheel hub
bearings are not loose.
• With a 0.3 mm feeler gauge inserted through the inspection
hole, adjust the drum-to-lining clearance in the following man-
ners such that the gauge can be inserted and out with slight re-
sistance.
• If the feeler gauge can be inserted and out with no resistance,
turn the adjuster through the inspection hole in the direction of
the arrow on the backing plate.
35-29
• If the clearance is too small to insert the feeler gauge or there is
considerable resistance when inserting the gauge, remove the
cover and insert a φ2 mm wire through the hole to lift the adjust
lever for the wheel cylinder. Then, through the inspection hole
turn the adjuster in the direction opposite to the arrow on the
backing plate to increase the clearance between the brake drum
and shoe.
• Then, cycle the brake pedal a couple of times. This will automat-
ically bring the brake drum-to-shoe clearance to 0.2 mm.
• Insert a 0.2 mm feeler gauge between the brake drum and lin-
ing. It should be able to be inserted and out with slight resis-
tance.
• Check the disc brake for normal operation. If faulty, disassemble
and inspect the wheel cylinders.
12.Inspection of Check Valve in Vacuum Line Hose

CAUTION
• The vacuum hose is a periodical replacement part. Be sure
to replace the vacuum hose at the specified interval irre-
spective of the results of inspections.
• Be careful not to allow moisture into the check valve.
• During the inspection, ensure that the check valve opens as
well as closes correctly.
• Do not attempt to remove the check valve from the vacuum
hose.
• Inspect the vacuum hose (with check valve inside) as follows,

and replace if defective. If inhaling and exhaling for inspection is
difficult, connect an appropriate hose with φ10 mm outer diame-
ter to the engine side of the vacuum hose and perform inspec-
tion.
• Check the hose for crack or other damage.
• Blow into the hose from its engine connecting end. The check
valve should be closed to prevent air passage.
• Inhale from the engine connecting end of the hose. The check
valve should be opened to allow air passage.
• When replacement, be sure to connect the end of the vacuum
hose with check valve to the engine.
13.Inspection of Vacuum Pump

Service standards
Time to reach vacuum of At 1500 rpm Within 20 sec. – Disassemble,
–
80 kPa {600 mmHg} At 3000 rpm Within 12 sec. – inspect
35-30
35
• Install a vacuum gauge between the vacuum tank and the vacu-
um pump.
• Start the engine and measure the time taken to reach the speci-
fied degree of vacuum.
• If the measured time does not conform to the standard value,
disassemble and service the vacuum pump.
14.Inspection of Vacuum Booster

• The vacuum booster can be inspected in 2 ways: one without using any tester and the other using a simplified
tester. In either way, ensure that the brake pipes, hoses and their connections are free of leakage, damage, or
other faults.
Service standards
Airtightness inspection (vacuum loss) (vacuum of 3.3 kPa {25 mmHg} or
– – Replace
67 kPa {500 mmHg}, 15 sec. after engine stop) less
3920 kPa {40 kgf/cm2}
(pedal depressed with a –
force of 98 N {10 kgf})
– Fluid pressure at vacuum of 67 kPa {500 mmHg} Replace
8820 kPa {90 kgf/cm2}
196 kPa {2 kgf/cm2}
– Fluid pressure at vacuum of 0 kPa {0 mmHg} Replace
140 kPa {15 kgf/cm2}
14.1 Inspection of check valve in vacuum hose

CAUTION
• Be careful not to allow moisture into the check valve.
• During the inspection, ensure that the check valve opens as
well as closes correctly.
• Do not attempt to remove the check valve from the vacuum
hose.
• Start the engine and charge the vacuum tank with vacuum.
• Stop the engine, and immediately remove the clamp fixing the
vacuum hose onto the vacuum pipe, and hold the hose in your
mouth.
• Blow into the hose. The check valve should be closed, prevent-
ing the breath from passing it.
• Suck on the hose and depress the brake pedal. The check valve
should be opened immediately, allowing air to pass.
• If any fault is encountered during the above inspections, replace
the vacuum hose with check valve.
35-31
14.2 Operational check of vacuum booster
CAUTION
• The vacuum booster operational checks described below
are only of summary nature. If the vacuum booster contin-
ues to malfunction, perform a bench test specified by a ser-
vice station of the manufacturer on the vacuum booster
after removing it from the vehicle.
• If the vacuum booster is found to be faulty during the spec-
ified testing, ask the service station of the manufacturer for
repair.
(1) Operational check without any tester

• Inspect the check valve in the vacuum hose for normal opera-
tion.
• Perform the checks described below. If any fault is found dur-
ing these checks, replace the vacuum booster or disassemble
and service the vacuum pump.
[Check 1]
• Start the engine and run it for 1 to 2 minutes. Stop the engine.
• Depress the brake pedal repetitively with the normal stepping
force.
• The pedal stroke should become smaller each time the pedal is
depressed.
[Check 2]
• With the engine stationary, depress the brake pedal several
times.
• With the brake pedal depressed, start the engine. The pedal
should sink slightly.
[Check 3]
• With the engine running and the brake pedal depressed, stop
the engine.
• The brake pedal should maintain the same height for approxi-
mately 30 seconds.
35-32
35
(2) Operational check with a simplified tester
(2.1) Airtightness check
• Inspect the check valve in the vacuum hose for normal opera-
tion.
• Remove the vacuum hose from the vacuum booster and con-
nect it to the vacuum gauge.
• Connect another hose (not equipped with a check valve) onto
the vacuum booster and the vacuum gauge.
• Install 2 pressure gauges and 1 stepping-force gauge as illus-
trated. Bleed the pressure gauges of air.
• Perform the following checks. If any fault is encountered during
these checks, inspect the vacuum booster.
[Check 1]
• Start the engine. When the reading on the vacuum gauge has
reached 67 kPa {500 mmHg}, stop the engine.
• The vacuum lost in approximately 15 seconds of the engine stop
should conform to the standard value.
[Check 2]
• Start the engine, and depress the brake pedal. When the read-
ing on the vacuum gauge has reached 67 kPa {500 mmHg},
stop the engine.
• The vacuum lost in approximately 15 seconds of the engine stop
should conform to the standard value.
(2.2) System characteristics check

• Perform the following system characteristics checks after the air-
tightness check described above is completed.
• Perform the following checks. If any fault is encountered during
these checks, inspect the vacuum booster.
[Check 1]
reached 67 kPa {500 mmHg}, depress the brake pedal with the
specified stepping forces.
• The fluid pressures indicated on the pressure gauges should
conform to the specified values.
[Check 2]
reached 0 kPa {0 mmHg}, depress the brake pedal with the
specified stepping forces.
• The fluid pressures indicated on the pressure gauges should
conform to the specified values.
35-33
35-34
VACUUM PUMP 35
1 Check valve
2 Cylinder
3 O-ring
4 Vane
5 Rotor
6 Housing
: Locating pin
• For removal and installation proce-

dures, see Gr11.
Assembly sequence
verse.

Bolt (cylinder and housing assembling) 8.8 ± 2 {0.9 ± 0.2} –

O-ring Engine oil As required
35-35
BRAKE MASTER CYLINDER
1 Bracket 6 Connector
2 Retaining ring 7 Clamp
3 Primary piston 8 Cylinder body
4 Set bolt
5 Secondary piston : Non-reusable parts
CAUTION
• To clean the parts, use brake fluid.
Assembly sequence
Repair kit: Master cylinder repair kit
35-36
35
Distance from the end of brake pedal and brake booster 0
– 8.25 – Adjust
to the end of push rod –0.25
φ31.75 100 to 125 N 93 N

3 Primary piston spring load Replace
(installed length: 36.3) {10.5 to 12.7 kgf} {9.5 kgf}
Clearance from primary and secondary pistons to cylin-
3, 5, 8 0.02 to 0.10 0.2 Replace
der body
Secondary piston spring φ31.75 76 to 92 N 72 N
5 Replace
load (installed length: 29.6) {7.8 to 9.4 kgf} {7.3 kgf}

Nut (brake master cylinder mounting) 8.8 to 13.7 {0.9 to 1.4} –
Set bolt (set pin mounting) 6.9 to 8.8 {0.7 to 0.9} –
Clamp (connector mounting) 1.47 to 2.45 {0.15 to 0.25} –

Sliding face of primary piston
Rust preventive As required
Sliding face of secondary piston
Retaining ring entire periphery Rubber grease As required
35-37
BRAKE MASTER CYLINDER
Support tool
MK528895
A B
No. of splines: 23 30
Measurement support
tool
Adjustment of vacuum booster push
MK528896
A B rod
36 φ11.5
Box spanner
MB999062
A B C
Width across flats: 8 120 120
Removal procedure
Removal: Secondary piston
• While pushing the secondary piston with a rod, loosen the bolt to
remove the piston.
• With ports A blocked, feed compressed air in the direction of the

arrow, gradually increasing pressure from 0 kPa {0 kgf/cm2}, to
remove the secondary piston.
WARNING
• Do not apply compressed air suddenly and at high pres-
sure. Otherwise, the secondary piston may fly out with full
force.
35-38
35
Installation: Secondary piston
• While pushing the secondary piston with a rod, tighten the bolt to
• If the secondary piston groove does not align with the set pin in-
sertion hole, rotate the piston to align them.
Inspection: Brake pedal & vacuum booster

• Before installing the brake master cylinder, perform the following
check and if the measurement is out of the standard value, ad-
just as necessary.
[Inspection]
• Remove the vacuum hose from the brake pedal & vacuum
booster to fill the vacuum booster with the atmospheric pres-
sure.
CAUTION
• The vacuum booster needs to be filled with the atmospheric
pressure to obtain accurate results from the inspection.
• Measure the distance (illustrated) between the push rod and the
end of the brake pedal & vacuum booster.
[Adjustment]
• Set the distance to the specified value by turning the push rod in
or out.
35-39
BRAKE PEDAL AND VACUUM BOOSTER
1 Clevis pin 7 Brake pedal
2 Vacuum booster 8 Stop lamp switch
3 Return spring 9 Brake pedal support
4 Collar
5 Pedal pad : Non-reusable parts
6 Bushing
CAUTION
• Do not attempt to disassemble the vacuum booster.
Assembly sequence
• After installation, inspect and adjust the brake pedal. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Nut (brake pedal mounting) 34.3 to 53.9 {3.5 to 5.5} –
Nut (stop lamp switch locking) 18.6 to 27.5 {1.9 to 2.8} –

Outer periphery of clevis pin
Chassis grease
Return spring As required
Inner and outer peripheries of collar
35-40
35
M E M O
35-41
FRONT DRUM BRAKE
1 Return spring 8 Brake lining 14 Cover
2 Shoe hold-down cup 9 Brake pipe 15 Cover
3 Shoe hold-down spring 10 Spacer 16 Backing plate
4 Shoe hold-down cup 11 Connector
5 Shoe hold-down pin 12 Wheel cylinder
*a: Brake drum
6 Rivet (See later section.) : Non-reusable parts
7 Brake shoe 13 Cover
• For removal and installation procedures of the rear drum brake, see Gr26.
Assembly sequence
CAUTION
• Do not smear the surface of the brake lining with lubricant. Otherwise, braking performance will drop se-
riously.
• When replacing the brake shoe, clean the threaded portions of the wheel cylinder adjuster and adjust
screw and coat them with rubber grease.
• After assembly, make the adjustment of brake shoe clearance. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
35-42
35
215 ± 22 N 175 N
1 Return spring load (installed length: 190) Replace
{22 ± 2.2 kgf} {18.0 kgf}
4.0
(Side shoul-
7 Brake lining thickness 10.4 Replace
der means
wear limit.)
Inner diameter 320 322 ( 321)
*a Brake drum
Cylindricity 0.05 0.20
Repair or replace
: Repair limit

Brake pipe 12.75 to 14.71 {1.3 to 1.5} –
Bolt (connector mounting) 7.85 to 11.77 {0.8 to 1.2} –
Bolt (wheel cylinder mounting) 79.43 to 107.9 {8.1 to 11.0} –
Bolt (wheel cylinder mounting on adjust screw side) 22.6 to 32.4 {2.3 to 3.3} –

Contact areas between brake shoe and wheel cylinder
Brake grease As required
Contact areas between backing plate and brake shoe
Removal procedure
Removal: Return spring
• Using a flat-blade screwdriver, remove the return spring. To do
this, rest the screwdriver on the wheel cylinder adjust screw.
Then, with the adjust screw as a fulcrum, engage the screwdriv-
er with the spring hook and pry away the spring.
Removal: Brake lining

• Using a drilling machine, break the flattened rivet heads on the
brake shoe side to release the brake lining.
35-43
FRONT DRUM BRAKE
Inspection: Brake lining thickness
• If any brake lining has worn to the side shoulder, replace the
brake linings of both brakes on the same axle.
Inspection: Brake drum

• If any abnormal wear or damage is found on the inner surface of
the brake drum, correct by grinding the brake drum inner diame-
ter within the repair limit (as mounted to the wheel hub), or re-
place the drum.
(2) Inner diameter
• If the measurement exceeds the limit, replace the brake drum.
(3) Cylindricity
• If the measurement exceeds the limit, correct by grinding the
brake drum inner diameter within the repair limit or replace the
drum.
Installation: Backing plate
• Grease the backing plate at the illustrated locations.
Installation: Brake pipe

• Position the spacer correctly on the bracket as shown so that the
brake pipe and spacer assembly will not get clear of the backing
plate surface.
• After making sure that the brake pipe and spacer assembly is
centered on the bracket, close the bracket to secure the brake
pipe in such a way that the brake pipe is held pressed evenly by
the spacer.
35-44
35
Installation: Brake lining
• Using cleaning fluid, clean the surface of the brake shoe to
which the brake lining is to be mounted. Then dry the brake
shoe.
• Insert rivets from the lining to the shoe. Stake them, starting from
the center of the shoe and moving towards the ends. Ensure
that the shoe-to-lining clearances conform to the following spec-
ifications.
• Around the rivets: 0.05 mm or less
• Along the shoe/lining sides:
0.3 mm or less
• Along the shoe/lining ends:
0.5 mm or less
• Stake the rivets with a force of 21 ± 1.0 kN {2100 ± 100 kgf}.
CAUTION
• Brake linings used on the same axle should be in the same
size and have the same identification mark. Otherwise, un-
even braking will occur.
• After assembly, check the drum-to-lining contact and correct as

required.
Installation: Brake shoe

• Grease the brake shoe at the illustrated locations.
Installation: Return spring

• Engage a small Phillips screwdriver into the return spring hook.
Then, using the screwdriver, insert the spring hook into the hook
hole in the brake shoe and attach the hook onto the shoe.
35-45
FRONT DRUM BRAKE
Wheel Cylinder
1 Spring 6 Washer 11 Air bleeder
2 Spring & fitting 7 Washer 12 Body
3 Lever 8 Piston
4 Adjust screw 9 Piston cup : Non-reusable parts
5 Adjuster 10 Boot
Assembly sequence
Repair kit: Wheel cylinder kit

8, 12 Piston-to-body clearance 0.02 to 0.12 0.2 Replace

Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

Sliding face of piston
Threaded portion of adjust screw
Rubber grease As required
Sliding face of adjuster
Both sides of washer
35-46
35
M E M O
35-47
FRONT DISC BRAKE
1 Slide pin 13 Inner pad
2 Piston boot 14 Pad liner A
3 Piston 15 Pad liner B
4 Piston seal 16 Pad liner C
5 Air bleeder 17 Pad liner D
6 Caliper 18 Pin boot
7 Outer shim 19 Bushing
8 Outer pad 20 Torque member
9 Inner shim A
10 Inner shim B
*a: Disc rotor
11 Clip : Non-reusable parts
12 Pad wear indicator
• For removal and installation procedures of the front disc brake and disc rotor, see Gr26.
Assembly sequence
Repair kit: Pad kit

Seal kit
Pad wear indicator kit
35-48
35
CAUTION
• Rubber parts that are disassembled must be replaced with the ones in the seal kit.
• Items included in the seal kit must be lubricated with grease supplied with the kit before installation.
• Do not smear the surfaces of outer and inner pads with lubricant. Otherwise, braking performance will
drop seriously.
• After installation, inspect the disc brake drag torque. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

8, 13 Thickness of outer/inner pad 14 4 Replace
Runout (measured by in-
0.07 or less 0.10
stalling to knuckle)
*a Disc rotor
Thickness 40 38
Replace

Slide pin 83.3 to 93.1 {8.5 to 9.5} Wet
Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

Outer periphery of piston Brake fluid (SAEJ1703 or FMVSS
As required
Threads and seating surface of slide pin No. 116 DOT3)
Inner periphery of piston seal
Inner periphery of cylinder lip of caliper
Outer periphery of pin of slide pin
Inner periphery of bushing Rubber grease As required
Connecting sections of bushing and pin boot with slide
pin
Pin boot groove and entire periphery of guide hole of
torque member
Inspection: Disc rotor
• If abnormal wear or damage is found on the disc rotor, replace
the disc rotor.
(2) Thickness
• If the measured value is lower than the limit, replace the disc ro-
tor.
Installation: Slide pin, bushing, and torque member
• Using a rod with φ8 mm outer diameter, install the bushings into
the torque member.
• Apply grease to the entire inner periphery of bushing and the
connecting section with slide pin.
• Apply grease to the outer periphery of slide pin and connecting
section with bushing, then install the slide pins.
• Confirm that the sealing section of bushing is attached to the
bushing mating portion of the slide pin.
35-49
FRONT DISC BRAKE
Installation: Slide pin, pin boot, and torque member
• Apply grease to the pin boot mounting groove and entire periph-
ery of guide hole of the torque member.
• Apply grease to the outer periphery of slide pin and mating sec-
tion with slide pin on pin boot, then install the pin boot.
• Apply grease to the outer periphery of slide pin and mating sec-
tion with bushing, then install the slide pin.
• Confirm that the sealing section of pin boot is fitted to the pin
boot mating portion of the slide pin.
Installation: Shim
• Install the shims to the pads in the directions shown in the draw-
ing.
Installation: Piston boot, piston, and piston seal

• Apply the brake fluid on the outer periphery of piston. Then in-
sert the piston boot into the piston.
• Spread the grease applied on the piston seal evenly. Then fit the
piston seal into the seal groove on the caliper.
• Spread the grease evenly over the inner periphery of cylinder lip
on caliper.
• Fit the caliper side seal of the piston boot into the boot groove on
the caliper.
• Press in the piston. Confirm that the piston side seal of the pis-
ton boot is fitted into the boot groove on the piston.
35-50
35
M E M O
35-51
REAR DRUM BRAKE
1 Return spring 8 Brake lining 14 Cover
2 Shoe hold-down cup 9 Brake pipe 15 Backing plate
3 Shoe hold-down spring 10 Spacer
4
5
Shoe hold-down cup
Shoe hold-down pin
11 Wheel cylinder
*a:: Brake drum
Non-reusable parts
6 Rivet 12 Cover
7 Brake shoe 13 Cover
• For removal and installation procedures of the rear drum brake, see Gr27.
Assembly sequence
CAUTION
• Do not smear the surface of the brake lining with lubricant. Otherwise, braking performance will drop se-
riously.
• When replacing the brake shoe, clean the threaded portions of the wheel cylinder adjuster and adjust
screw and coat them with rubber grease.
• After assembly, make the adjustment of brake shoe clearance. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
35-52
35
215 ± 22 N 175 N
1 Return spring load (installed length: 190) Replace
{22 ± 2.2 kgf} {18.0 kgf}
4.0
(Side shoul-
8 Brake lining thickness 10.4 Replace
der means
wear limit.)
Inner diameter 320 322 ( 321)
*a Brake drum
Cylindricity 0.05 0.20
Repair or replace
: Repair limit

Brake pipe 12.75 to 14.71 {1.3 to 1.5} –
Bolt (wheel cylinder mounting) 79.43 to 107.9 {8.1 to 11.0} –

Contact areas between brake shoe and wheel cylinder
Brake grease As required
Contact areas between backing plate and brake shoe
Removal procedure
Removal: Return spring
• Using a flat-blade screwdriver, remove the return spring. To do
this, rest the screwdriver on the wheel cylinder adjust screw.
Then, with the adjust screw as a fulcrum, engage the screwdriv-
er with the spring hook and pry away the spring.
Removal: Brake lining

• Using a drilling machine, break the flattened rivet heads on the
brake shoe side to release the brake lining.
35-53
REAR DRUM BRAKE
Inspection: Brake lining thickness
• If any brake lining has worn to the side shoulder, replace the
brake linings of both brakes on the same axle.
Inspection: Brake drum

• If any abnormal wear or damage is found on the inner surface of
the brake drum, correct by grinding the brake drum inner diame-
ter within the repair limit (as mounted to the wheel hub), or re-
place the drum.
(2) Inner diameter
• If the measurement exceeds the limit, replace the brake drum.
(3) Cylindricity
• If the measurement exceeds the limit, correct by grinding the
brake drum inner diameter within the repair limit or replace the
drum.
Installation: Backing plate
• Grease the backing plate at the illustrated locations.
Installation: Brake pipe

• Position the spacer correctly on the bracket as shown so that the
brake pipe and spacer assembly will not get clear of the backing
plate surface.
• After making sure that the brake pipe and spacer assembly is
centered on the bracket, close the bracket to secure the brake
pipe in such a way that the brake pipe is held pressed evenly by
the spacer.
35-54
35
Installation: Brake lining
• Using cleaning fluid, clean the surface of the brake shoe to
which the brake lining is to be mounted. Then dry the brake
shoe.
• Insert rivets from the lining to the shoe. Stake them, starting from
the center of the shoe and moving towards the ends. Ensure
that the shoe-to-lining clearances conform to the following spec-
ifications.
• Around the rivets: 0.05 mm or less
• Along the shoe/lining sides:
0.3 mm or less
• Along the shoe/lining ends:
0.5 mm or less
• Stake the rivets with a force of 21 ± 1.0 kN {2100 ± 100 kgf}.
CAUTION
• Brake linings used on the same axle should be in the same
size and have the same identification mark. Otherwise, un-
even braking will occur.
• After assembly, check the drum-to-lining contact and correct as

required.
Installation: Brake shoe

• Grease the brake shoe at the illustrated locations.
Installation: Return spring

• Engage a small Phillips screwdriver into the return spring hook.
Then, using the screwdriver, insert the spring hook into the hook
hole in the brake shoe and attach the hook onto the shoe.
35-55
REAR DRUM BRAKE
Wheel Cylinder
1 Spring 7 Adjust screw 13 Boot
2 Spring & fitting 8 Adjuster 14 Air bleeder
3 Lever 9 Washer 15 Body
4 Piston 10 Washer
5 Piston cup 11 Piston : Non-reusable parts
6 Boot 12 Piston cup
Assembly sequence
Repair kit: Wheel cylinder kit

4, 11, 15 Piston-to-body clearance 0.02 to 0.12 0.2 Replace

Air bleeder 6.9 to 8.8 {0.7 to 0.9} –

Sliding face of piston
Threaded portion of adjust screw
Rubber grease As required
Sliding face of adjuster
Both sides of washer
35-56
GROUP 36 PARKING BRAKE
SPECIFICATIONS............................................................................... 36-2

1. Parking Brake Control .................................................................. 36-3
2. Parking Brake Ratchet Bar............................................................ 36-3
3. Parking Brake ............................................................................... 36-4

1. Inspection of Parking Brake Drum Mount for Looseness .............. 36-6
2. Adjustment of Parking Brake Shoe Clearance .............................. 36-6
3. Inspection and Adjustment of
Parking Brake Ratchet Bar Pulling Stroke..................................... 36-7
PARKING BRAKE CONTROL............................................................ 36-8
PARKING BRAKE RATCHET BAR .................................................... 36-9
PARKING BRAKE............................................................................. 36-10
36-1
SPECIFICATIONS
Item Specifications
Type Internal expanding type acting on propeller shaft
Brake
Operation type Mechanical cable type
Type Duo servo type
Parking brake Brake drum I.D. mm φ190
Lining width × thickness mm 45 × 4.0
36-2
1. Parking Brake Control
2. Parking Brake Ratchet Bar

• The idle rotation angle at the handle of
the ratchet bar prevents inadvertent
return of the ratchet bar.
• To release when locked, twist handle
of ratchet bar into lock release range,
disengage ratchet pole from the ratch-
et bar, and then return the ratchet bar.
36-3
3. Parking Brake
• The parking lever that actuates the shoe and lining is a built-in
component of the parking brake body. Pulling the parking brake
ratchet bar pulls the parking brake cable, which in turn pulls the
parking lever.
• When the parking lever is pulled, one shoe and lining is forced to
expand with the medium of strut. At the same time, the parking
lever directly expands the other shoe and lining. Thus, each
shoe and lining works as a leading shoe.
• When the parking brake ratchet bar is returned to the released
position, the repercussive force of the shoe return spring releas-
es the brake.
36-4
TROUBLESHOOTING 36
Symptoms
Parking brake lever operating force is too
Parking brake lever operating force is too

Parking brake is released sluggishly
Parking brake does not work
Reference
Gr
(drags)
small
large
Possible causes
Inner cable elongated or damaged O O O O
Parking brake cable Inner cable rusted O O O
Inner spring fatigued or broken O O
Ratchet pawl to ratchet bar engagement abnormal O
Parking brake ratchet bar Pulling stroke too small O O
Pulling stroke too large O O
Shoe-to-drum clearance too small O O
Shoe-to-drum clearance too large O O
Parking brake drum inside surface deformed/distorted O O
Parking brake drum inside surface smeared with oil or
Parking brake main body O O
grease
Linings worn unevenly O
Lining surfaces smeared with oil or grease O
Shoe return springs weakened or broken O
36-5
1. Inspection of Parking Brake Drum Mount for Looseness

– Nut (parking brake drum mounting) 100 to 120 {10 to 12} –
• Inspect the parking brake drum mounting nut for looseness us-
ing a spanner or similar tool.
• If any looseness is found, tighten it to the specified torque.
2. Adjustment of Parking Brake Shoe Clearance

– Brake shoe clearance 0.2 to 0.25 – Adjust
• Apply chocks to the front wheels and raise the rear wheels with
a jack.
• Operate the parking brake ratchet bar to release the parking
brake (the parking lever becomes free of pull forces).
• Using a screwdriver or similar tool inserted through the shoe ad-
justing hole in the parking brake drum, turn the adjusting screw
in the shoe expanding direction until the shoes closely contact
the brake drum.
• From the above point, turn the screw in the shoe contracting di-
rection by 8 notches; the shoe-to-drum clearance is now adjust-
ed to the standard value.
36-6
36
3. Inspection and Adjustment of Parking Brake Ratchet Bar Pulling Stroke

Ratchet bar pulling stroke (with operating force of 294 N
– 80 to 120 – Adjust
{30 kgf})

– Lock nut 18.7 to 27.5 {1.9 to 2.8} –
[Inspection]
• Measure the pulling stroke when the parking brake ratchet bar is
pulled from the released position by an operating force of 294 N
{30 kgf}.
• If the measurement deviates from the standard value, adjust
with the adjusting nut of the parking brake cable.
[Adjustment]
• Tighten the adjusting nut until the mark can be seen.
• Tighten the lock nut to the position of the adjusting nut.
• Tighten the lock nut to the specified torque.
• Check the clearance is to the illustrated dimension when the out-
er cable of the parking brake cable is pulled by an operating
force of 59 to 98 N {6 to 10 kgf}.
• Operate the ratchet bar two or three times after adjusting to veri-
fy the pulling stroke to make sure that the parking brake is oper-
ating properly and that the parking brake drum does not drag
when the parking brake is released.
• If there is any abnormality, inspect the parking brake ratchet bar,
parking brake cable, and parking brake.
36-7
PARKING BRAKE CONTROL
Removal sequence
1 Parking brake ratchet bar (See later section.)
2 Parking brake cable
*a: Parking brake (See later section.)
• Perform the inspection and adjustment of the parking brake ratchet bar after installation. (See “ON-VEHICLE IN-
SPECTION AND ADJUSTMENT”.)
36-8
PARKING BRAKE RATCHET BAR 36
1 Push nut
2 Pin
3 Ratchet pawl
4 Ratchet spring
5 Push nut
6 Pin
7 Return spring
8 Ratchet bar
9 Parking brake switch
10 Grommet
11 Clip
12 Support
Assembly sequence
verse.

Sliding areas between pin and ratchet bar As required

Inspection: Ratchet bar
• Ensure that the ratchet bar is positioned at the angles as illus-
trated.
• Ensure that the ratchet bar play is 10° or less.
• Ensure that the ratchet bar operates smoothly without scratching
or twisting when operated.
• If the ratchet bar is faulty, replace it.
36-9
PARKING BRAKE
1 Shoe return spring
2 Washer
3 Strut spring
4 Shoe hold down cup
5 Shoe hold down spring
6 Shoe hold down cup
7 Shoe hold down pin
8 Adjuster
9 Adjuster spring
10 Strut
11 Retainer
12 Shoe and lining
13 Parking lever
14 Backing plate
*a: Parking brake drum

*b: Retainer
• See Gr22 for removal and installation

of the parking brake.
Assembly sequence
verse.
CAUTION
• To prevent poor working of the brake, do not smear the surface of shoe and lining with grease or oil.
• Perform the adjustment of the brake shoe clearance after installation. (See “ON-VEHICLE INSPECTION AND
ADJUSTMENT”.)

Installed load of shoe return spring 58.8 ± 5.9 N 49 N
1 Replace
(installed length: 67.1) {6 ± 0.6 kgf} {5 kgf}
29.4 ± 2.9 N 26 N
3 Installed load of strut spring (installed length: 49) Replace
{3 ± 0.3 kgf} {2.7 kgf}
Installed load of shoe hold down spring 78.5 ± 7.9 N 71 N
5 Replace
(installed length: 15.5) {8 ± 0.8 kgf} {7.2 kgf}
58.8 ± 5.9 N 49 N
9 Installed load of adjuster spring (installed length: 78.2) Replace
{6 ± 0.6 kgf} {5 kgf}
12 Lining thickness of shoe and lining 4.0 1.4 Replace
Inner diameter φ190 +0.2
0 φ191
Squareness 0 to 0.05 –
Concentricity 0 to 0.1 –
*a Parking brake drum
Cylindricity 0 to 0.05 –
Replace
0 to 0.0049 N·m
Static rotation imbalance –
{0 to 0.5 gf·m}
36-10
36
Shoe and lining contact points on both ends of adjuster
screw
Brake grease AKB100 As required
Anchor pins and shoe and lining contact surface on back-
ing plate
Inspection: Shoe and lining
• If the measured value is lower than the limit, replace the shoe
and lining.
Inspection: Parking brake drum

• If an abnormal wear or damage is found in the parking brake
drum, replace the parking brake drum.
(2) Inner diameter, squareness, concentricity, cylindricity and
static rotation imbalance
• If the measurement exceeds the limit or deviates from the stan-
dard value, replace the parking drum.
36-11
GROUP 37 STEERING
SPECIFICATIONS............................................................................... 37-2

1. Steering System ........................................................................... 37-3
2. Oil Flow ........................................................................................ 37-3
3. Power Steering Gear Assembly .................................................... 37-4
4. Power Steering Oil Pump .............................................................. 37-6

1. Steering Wheel Play .................................................................... 37-10
2. Steering Column Looseness ....................................................... 37-10
3. Inspection of Rods and Arms for Looseness .............................. 37-10
4. Inspection of Power Steering System Mounts for Looseness ......37-11
5. Inspection and Replacement of Power Steering Oil .....................37-11
6. Performance Verification Test of Power Steering System ........... 37-13
STEERING COLUMN........................................................................ 37-14
POWER STEERING GEAR ASSEMBLY AND DRAG LINK ............ 37-22
POWER STEERING OIL PUMP ....................................................... 37-28
POWER STEERING OIL TANK ........................................................ 37-32
37-1
SPECIFICATIONS
Steering wheel, steering shaft and power steering gear
Specifications
Item
BE63DE BE63DG, BE63DJ
Type 2-spoke type
Steering wheel
Outer diameter mm 400
Steering shaft Type Universal joint type (high-tilt type)
Manufacturer JTEKT Corporation
Type Ball nut type
Power steering gear
Form Integral form
assembly
Gear ratio 22.6
Cylinder diameter mm 78 85
Power steering oil pump

Item Specifications
Manufacturer KYB
Type Vane type
Delivery rate cc/rev. 9.6
3
Adjusted flow volume dm {L}/min. 6 to 8 {6 to 8}
Adjusted pressure (relieve valve) MPa {kgf/cm2} 9.3 +0.20 +2
–0.30 {95 –3 }
Permissible revolutions rpm 600 to 6500
37-2
1. Steering System
2. Oil Flow
37-3
3. Power Steering Gear Assembly
• A rotary valve is adopted for the valve, the center of the power steering. For steering reaction force and return of
the valve, the valve operates lightly and smoothly at low speed by means of the torsion bar, and provides stable
steering feel up to high speed.
37-4
37
3.1 When moving straight forward
• As equal pressure is applied to cylinder chambers A and B on
both sides of the piston, the piston is placed in neutral position.
3.2 When turning the steering wheel

• When the steering wheel is turned, the stub shaft is twisted,
which causes the rotor to shut off oil supply passages to cylinder
chamber B. As a result, pressure difference is caused between
cylinder chamber A and cylinder chamber B, and the piston
moves, facilitating rotation of the worm shaft.
The illustration shows a condition when the steering wheel is
turned to the left.
3.3 When hydraulic circuit fails

• The turning force of the stub shaft alone turns the worm shaft.
37-5
4. Power Steering Oil Pump
• The power steering oil pump is a hydraulic source pump with the vane in the rotor groove and is geared to the en-
gine.
• The power steering oil pump consists of a cartridge that discharges oil, a flow control valve that controls the oil
flow rate and a relief valve that prevents free oil pressure rise.
• The flow control valve maintains constant the quantity of oil to the power steering gear during steering wheel ma-
nipulation.
The relief valve assembly is provided in the flow control valve to prevent oil pump pressure from rising beyond
necessary level during stationary swing operation.
37-6
37
4.1 Flow control valve
(1) Operation of flow control valve as-
sembly
(1.1) When not functioning (oil pump
in operation at low speed)
• Oil pressure in the chamber A is weak-
er than the combined force of oil pres-
sure in the chamber B and tension of
the flow control spring, and the flow
control valve remains stationary.
(1.2) When functioning (oil pump in

operation at middle to high
speeds)
• Oil pressure in the chamber A over-
comes the combined force of oil pres-
the flow control spring, and the flow
control valve is shifted.
• Port is made open to release oil pres-
sure, and the flow rate from the cham-
ber C is maintained constant.
(2) Operation of relief valve

• When the combined force of oil pres-
the flow control spring overcomes oil
pressure in the chamber A, the flow
control valve is shifted. Further in-
creased oil pressure in the chamber B
pushes the relief valve to open port,
thus preventing excessive oil pressure
from going to the chamber C.
37-7
TROUBLESHOOTING
Symptoms
Steering angle insufficient or different

Steering wheel play excessive and
Noise from oil pump (low whirring)

Steering wheel pulled to one side
Steering wheel return not smooth
Noise from oil pump (squeaking)

Steering wheel heavy to operate
Oil pump oil pressure abnormal

Noise from oil pump (grinding)
Steering wheel does not turn
Steering wheel vibration
Reference Gr
between right and left

Oil leakage
unstable
Possible causes
Oil quantity insufficient O O
Faulty power steering mechanism
Oil quantity excessive O

Air bleeding insufficient O O O
Oil viscosity unsuitable O
Hydraulic circuit clogged O
Power steering gear assembly faulty O O O O O O
Power steering gear assembly improperly
O O O
installed
Gear engagement rotating torque incor-
O O
rectly adjusted
Pitman arm mounting position incorrect O
Steering shaft universal joint abnormally
O O
worn or damaged
Faulty steering column and
Steering linkage deformed O O

link mechanism
Drag link ball joint abnormally worn or

O O
damaged
Tie rod ball joint abnormally worn or dam-
O O
aged
Steering angle off-center O
Tie rod bent O
Steering shaft poorly greased O O
Kingpin poorly greased O O
Front wheel alignment (toe-in, camber
O O O O
and caster) incorrect
Thrust bearing damaged O Gr26
Wheel hub bearing worn out or damaged O O O
Faulty front axle, etc.
Kingpin or bushing worn out or damaged O O O

Front axle deformed O O
Knuckle arm, tie rod arm, knuckle, etc. im-
O
properly tightened
Front spring U-bolt, nut, etc. loose O Gr33
Front tire radial and lateral runout or static
O Gr31
and dynamic balance incorrect
Front axle parts overtightened O
Steering angle incorrectly adjusted O O
Gr26
Mounted parts, connections loose O
Knuckle stopper bolt improperly adjusted O
37-8
37
Symptoms
Steering angle insufficient or different

Steering wheel play excessive and
Noise from oil pump (low whirring)

Steering wheel pulled to one side
Steering wheel return not smooth
Noise from oil pump (squeaking)

Steering wheel heavy to operate
Oil pump oil pressure abnormal

Noise from oil pump (grinding)
Steering wheel does not turn
Steering wheel vibration
Reference Gr
between right and left

Oil leakage
unstable
Possible causes
Oil pump housing faulty O
O-ring, oil seal faulty O
Bolt improperly tightened O
Maximum generated oil pressure insuffi-
Faulty oil pump
O
cient
Oil line crushed or clogged O
Air caught in oil pump O
Oil pump interior seized O O O
Mounting bolt and nut loose O
Pump body faulty O
Valve malfunctioning O
Difference excessive in wheelbase be-
O
tween left and right
Propeller shaft runout excessive O Gr25
Rear axle housing bent O Gr27
Final drive gear and final drive pinion
Other abnormalities
O Gr27
damaged or improperly engaged
Tire pressure insufficient O
Tire pressure excessive O
Difference excessive in degree of wear
O
between left and right tires
Gr31
Left and right tires different in outer diam-
O
eter
Front tire radial and lateral runout, static
O
and dynamic balance incorrect
Braking force unbalanced O Gr35
37-9
1. Steering Wheel Play
Steering wheel play (measured at At engine start 5 to 50 – Replace
–
outer periphery of wheel) Engine stopped 10 to 20 – Adjust
• With the vehicle placed straight forward, perform the following

checks.
1.1 At engine start
• Start the engine and gently turn the steering wheel left and right
to measure its peripheral play.
• If the play deviates from the standard value check tightening
points of steering shaft and steering linkage parts as pitman arm
to knuckle, and replace those parts if they have any looseness.
1.2 When engine is stopped

• Stop the engine and turn the steering wheel left and right within
the range where the drag link does not move (tangential force on
the periphery: 5 N {0.5 kgf}) to measure its peripheral play.
• If the play deviates from the standard value, adjust the play with
the adjusting screw of the power steering booster.
2. Steering Column Looseness

• Push and pull the steering wheel by hand to check the steering
column for looseness.
• With the steering column tilted all the way forward, pull the steer-
ing wheel backward and check the steering column for loose-
ness.
• If the steering column is loose, adjust the lock lever.
3. Inspection of Rods and Arms for Looseness

• Check the drag link, pitman arm,
knuckle arm and power steering gear
assembly for damage and loose instal-
lation.
• If any abnormality is found, replace the
faulty parts and tighten the loose parts
37-10
37
4. Inspection of Power Steering System Mounts for Looseness
• Check the mounting sections of power steering oil tank, power
steering oil pump and power steering gear assembly for loose-
ness.
• Check the connections of hose and pipe for looseness.
• If any looseness is found, tighten the loose parts to the specified
torque.
5. Inspection and Replacement of Power Steering Oil

– Feed pipe 29 to 39 {3 to 4} –
– Return pipe 39 to 49 {4 to 5} –

Between MIN
Automatic transmission fluid
and MAX of
– Power steering oil tank (DEXRON, DEXRON II, DEXRON III
level gauge of
type)
filler cap
5.1 Oil leakage

• Check the power steering oil tank, power steering oil pump,
power steering gear assembly and hose and pipe connections
for oil leak. Check also the hoses for blister due to deterioration,
damage and crack.
• If any oil leak is found, tighten the connection or replace the
faulty parts.
5.2 Oil level check

• Check that the hydraulic fluid is within the specified oil level
range.
• Pour additional fluid if necessary.
5.3 Replacement
[Draining]
• Jack up the front wheels.
• Clean the port areas of feed and return pipes to prevent ingress
of dirt, dust, and other foreign matters inside the power steering
gear assembly.
• Loosen feed and return pipes connected to the power steering
gear assembly.
• Repeatedly turn the steering wheel fully left and right to drain the
fluid from the power steering gear assembly.
• After draining the fluid, tighten the feed and return pipes to spec-
ified torque.
37-11
[Filling]
• Pour fluid into the power steering oil tank up to the bottom of the
strainer.
• Bleed the power steering system of air.
5.4 Air bleeding

• Pour fluid into the power steering oil tank up to the bottom of the
strainer.
• With the engine stopped, jack up the front wheels.
• Repeatedly turn the steering wheel fully left and right. When the
fluid level has dropped, add enough fluid to maintain the fluid
level within the specified range.
• Start the engine to idle.
• When the fluid level has dropped, stop the engine and add
enough fluid to maintain the fluid level within the specified range.
• Restart the engine. While checking for a drop in fluid level, turn
the steering wheel fully left and right and add fluid as much as
necessary. Repeat this practice until the fluid level is stabilized
within the specified range.
• Turn the steering wheel fully left and right repeatedly.
CAUTION
• To avoid seizure of the power steering oil pump, do not
keep the steering wheel turned fully to left or right for more
than 10 seconds when the engine is running.
• Do not rev the engine during air bleeding; otherwise, the
power steering pipe may be broken. Run the engine at idle.
• If there is any abnormal noise or a fluid level fluctuation, there is

likely still some air trapped in the power steering system. Turn
the steering wheel several times to raise the fluid temperature to
approximately 60 to 80°C.
• Stop the engine and wait for approximately five minutes.
• Lower the front wheels and turn the steering wheel several
times. If there is no noise or fluid level fluctuation, the bleeding of
the power steering system is completed.
• Repeat starting and stopping the engine several times to remove
small air bubbles left in the power steering oil tank.
• If air bubbles are not removed completely, drive the vehicle for a
while, then check for abnormal noise and oil level fluctuation.
• When bleeding is finished, check that fluid in the power steering
oil tank is within the specified level range. Also check pipe and
hose connections for fluid leaks.
37-12
37
6. Performance Verification Test of Power Steering System
Service standards
Power steering system fluid pressure (steering wheel 0 to 490 kPa
– – Repair or replace
not turned) {0 to 5 kgf/cm2}
9.3 +0.20
–0.30 MPa
– Relief set pressure {95 +2 2 – Replace
–3 kgf/cm }
• Perform the test in the following conditions to verify normal oper-

ation of the power steering gear assembly and power steering oil
pump.
• Install an oil pressure gauge capable of measuring at least 11
MPa {110 kgf/cm2} and a stop valve between the power steer-
ing oil pump and the power steering gear assembly. Then,
bleed the system.
• Fully open the stop valve, start the engine and let it idle.
• Turn the steering wheel several times to raise the fluid tem-
perature to approximately 50 to 60°C.
CAUTION
• Do not keep the stop valve closed more than 10 seconds.
Otherwise, the power steering oil pump may seize up.
6.1 Operation check of steering wheel

• With the front wheels jacked up, fully turn the steering wheel left
and right to check if it operates smoothly.
• If any abnormality is found, disassemble and perform mainte-
nance for each unit.
6.2 Fluid pressure check of power steering system

• Measure the fluid pressure with your hands off the steering
wheel. If the measured value deviates from the standard value,
check the power steering gear assembly and hydraulic circuits
for clogging. If no clogging is found, inspect the power steering
oil pump and replace the faulty parts.
6.3 Relief set pressure check

• Gradually increase the engine speed to 1,000 to 1,500 rpm.
Then close the stop valve and measure the maximum fluid pres-
sure. Never close the stop valve longer than 10 seconds.
• If the measured value deviates from the standard value, inspect
the power steering oil pump and replace the faulty parts.
37-13
STEERING COLUMN
37-14
37
Removal sequence
1 Column cover outer lower 11 Twist-off bolt
2 Column cover outer upper 12 Starter switch
3 Column cover inner lower 13 Spring
4 Column cover inner upper 14 Steering column (See later section.)
5 Horn pad 15 Dust cover
6 Horn spring 16 Dust cover
7 Contact plate <Optional steering wheel> 17 Dust cover
8 Cover
9
10
Steering wheel
Combination switch
*a:: Power steering gear assembly
Non-reusable parts
• After installation, check the steering column for looseness. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)

Nut (steering column and power steering gear assembly
53 to 65 {5.4 to 6.6} –
mounting)
Nut (steering wheel mounting) 39 to 49 {4.0 to 5.0} –
Screw (combination switch mounting) 2.5 ± 0.5 {0.25 ± 0.05} –
Twist-off bolt (starter switch mounting) 12.7 to 15.7 {1.3 to 1.6} –
Bolt (steering column mounting) 17 to 26 {1.7 to 2.6} –

Contact surface between cover and combination switch Wheel bearing grease
As required
(horn contact) [NLGI No. 2 (Li soap)]
Work before removal

Alignment mark: Steering column and power steering gear
assembly
• Provide alignment marks on the steering column and power
steering gear assembly.
37-15
STEERING COLUMN
Removal procedure
Removal: Horn pad
• Insert a flat-blade screwdriver into the gap between the steering
wheel and the horn pad at the shoulder section of the horn pad.
Pry up the horn pad until it clicks and comes off.
• Insert your finger into the gap and remove the horn pad.
Removal: Starter switch

• Drill a hole of 5.5 to 6 mm in diameter and a depth of 10 to 15
mm in the twist-off bolt.
• Screw the screw extractor counterclockwise into the twist-off bolt
and remove it.
Removal: Steering column

• Remove the nut connecting the steering column with the power
steering gear assembly along with the mounting bolts in the col-
umn to remove it.
37-16
37
Installation: Steering column
• If the spline comes off the steering column, assemble it with the
yokes facing in the same direction.
• The threads of the two bolts shown in the illustration must be el-
liptical to ground the horn circuit.
Installation: Starter switch

• Install the starter switch using new twist-off bolts. Tighten the
bolts to the specified torque and snap off their heads.
Installation: Steering wheel

• Align the three slits of the steering wheel with the three cancel
cam protrusions of the combination switch and install the steer-
ing wheel.

Inspection: Noise from steering wheel
• Lightly turn the steering wheel left and right and check for noise
and other abnormalities.
• If any abnormality is found, disassemble the steering wheel, re-
move the cause and reassemble it.
37-17
STEERING COLUMN
Steering Column
37-18
37
1 Support bracket 11 Lock plate
2 Spring seat 12 Wave washer
3 Stopper 13 Lever support
4 Bearing spacer 14 Clevis pin
5 Steering shaft 15 Column support upper
6 Lock lever 16 Telescopic shaft
7 Return spring 17 Column support lower
8 Return spring
9 Snap ring : Non-reusable parts
10 Cam
Assembly sequence

Nut (support bracket mounting) 17 to 25 {1.7 to 2.6} –
Nut (steering shaft and telescopic shaft mounting) 53 to 65 {5.4 to 6.6} –
Nut (lock lever mounting) 4 to 6 {0.4 to 0.6} –
Bolt (lever support mounting) 7 to 10 {0.7 to 1.0} –
Bolt (column support upper and lower mounting) 15 to 20 {1.5 to 2.0} –

Friction side of return spring washer
Friction side of snap ring lever support
Friction surfaces of lock plate and cam Wheel bearing grease
As required
[NLGI No.2 (Li soap)]
Friction surfaces of column support upper and mounting
bolt
Lock plate mounting pin of column support lower
ThreeBond thread lock super 103Q
Column support upper mounting bolt threads As required
or Loctite 271
Work before removal

Alignment mark: Steering shaft and telescopic shaft
• Be sure to provide alignment marks on the steering shaft and
telescopic shaft before removal.
37-19
STEERING COLUMN
Installation: Clevis pin
• Install the clevis pin with the dimension shown in the drawing.
Installation: Cam
• Position the crest of the cam as shown in the drawing by the le-
ver support and install the cam.
• Bend the split pins in the direction shown in the drawing.
Installation: Lock lever

• Install the lock lever with the dimension shown in the drawing
(when locked).
Installing: Steering shaft

• When replacing the steering shaft or telescopic shaft, reassem-
ble them so that their yokes are in the same phase or the phase
shifted by 90°.
• This drawing shows 90° shifted phase.
37-20
37
Inspection: Operating force of lock lever
• Check that the operating force of the lock lever is 49 N {5 kgf} or
lower.
• Set the lock lever in “free” position and check that the steering tilt
operation can be performed smoothly.
37-21
POWER STEERING GEAR ASSEMBLY AND DRAG LINK
Removal sequence
1 Grease nipple 7 Drag link
*b:
a: Knuckle arm
2
3
End plug
Ball seat
8
9
Feed pipe
Return pipe
*: Pitman arm
Non-reusable parts
4 Ball seat 10 Power steering gear assembly
5 Spring (See later section.)
6 Grease seal

Feed pipe 29 to 39 {3 to 4} –
Return pipe 39 to 49 {4 to 5} –
Bolt or nut (power steering gear assembly mounting) 83.5 to 108 {8.5 to 11} –
37-22
37
Entire surface of ball seat
Arm mounting points of grease seal Wheel bearing grease
As required
Inside of drag link [NLGI No. 2 (Li soap)]
Through grease nipple
Installation: Drag link
• Fully tighten the end plug and then loosen it a half turn.
• Insert the split pin with its head pointing outside of the vehicle.
• Bend the split pin. Adjust its head to the dimension shown in the
illustration.
• Attach the identification label on the drag link on the forward side
of the vehicle.
37-23
Power Steering Gear Assembly
1 Pitman arm 9 Adjusting plate 16 O-ring
2 Dust cover A 10 Sector shaft 17 Oil seal
3 Side cover 11 Dust cover B 18 Needle bearing
4 O-ring 12 Seal ring 19 Y-packing
5 Backup ring 13 O-ring 20 Backup ring
6 Y-packing 14 O-ring 21 Gear box
7 Needle bearing 15 Valve housing and
8 Adjusting bolt ball screw set shaft : Non-reusable parts
• Do not attempt to disassemble the valve housing and ball screw set shaft because it is of a unit construction.
Assembly sequence
Repair kit: Seal kit

Repair kit
37-24
37
0.98 N·m
Starting torque –
{0.1 kgf·m} or less
Adjust
0.2 to 0.49 N·m
– Power steering gear assembly Engagement torque –
{0.02 to 0.05 kgf·m}
0.15 to 0.69 N·m
Normal turning torque – Replace
{0.015 to 0.07 kgf·m}
8, 10 End play of adjusting bolt and sector shaft 0 to 0.1 – Adjust
Stepped wear of sliding area of gear box with sector
10 – 0.003 Replace
shaft
15, 21 Clearance between ball screw set shaft and gear box 0.022 to 0.069 – Replace
BE63DE 78.012 to 78.034 78.05
21 Inner diameter of gear box Replace
BE63DG, BE63DJ 85.012 to 85.034 85.05

BE63DE 245 to 294 {25 to 30} –
Nut (pitman arm mounting)
BE63DG, BE63DJ 294 to 343 {30 to 35} –
Bolt (side cover mounting)
98 to 118 {10 to 12} –
Bolt (valve housing mounting)
Thread-locking
Nut (adjusting bolt mounting) 29 to 39 {3 to 4}
compound

Inside of dust cover A 2g
Inside of dust cover B 1g
Y-packing inner surfaces
Contact area between adjusting bolt and side cover As required
Oil seal lip
Thread area of nut ThreeBond 1141 As required

Measurement of staring torque of

Preload socket MB991006
power steering gear assembly
Pitman arm puller
A B MH062472 Removal of pitman arm

49 76
37-25
Work before removal
Inspection: Starting torque
• Measure the starting torque before disassembly for reference at
the time of reassembly.
A: Starting torque
(= engagement torque + normal turning torque)
B: Engagement torque
C: Normal turning torque
Removal procedure
Removal: Pitman arm
Removal: Sector shaft

• Before removal, set the sector shaft in the neutral position as fol-
lows.
• Turn the ball screw set shaft counterclockwise in the lock posi-
tion and turn back approximately 2.6 turns to place the V-groove
slit on the end surface of the sector shaft perpendicular to the
axis of the ball screw set shaft.
37-26
37
• Loosen the nut and remove the sector shaft by tapping the shaft
end with a plastic hammer.
• If the sector shaft is stuck, it may be deviated from neutral posi-
tion. In this case, set the shaft in the neutral position. Do not at-
tempt to force it out by hammering.
Installation: Sector shaft
• Set the sector shaft in the neutral position and insert it in the
gear box.
• When inserting the sector shaft, cover up its threaded end and
serration portions for protection.
• Turn the ball screw set shaft to check that it makes roughly five
turns lock to lock.
• If the number of turns is insufficient, check the engagement of
the ball screw set shaft with the sector shaft.

Inspection: Starting torque
[Inspection]
• Measure the starting torque in the same manner as the mea-
surement before removal. If the measured value deviates from
the standard value, adjust or replace the power steering gear as-
sembly.
[Adjustment]
• Loosen the nut.
• Rotate the ball screw set shaft approximately 1/4 turns left and
right, while making adjustment for proper starting torque with the
adjusting bolt.
37-27
POWER STEERING OIL PUMP
1 Eye joint 8 Vane 15 Flow control valve
2 Hose 9 Rotor 16 Flow control spring
3 Suction connector 10 Cam ring 17 O-ring
4 O-ring 11 O-ring 18 O-ring
5 Pin 12 Side plate 19 Body
6 Cover 13 O-ring
7 Cartridge assembly 14 Connector : Non-reusable parts
• See Gr11 for removal and installation of the power steering oil pump.
• Do not attempt to disassemble the flow control valve and body because they are of unit construction.
Assembly sequence
Repair kit: Seal repair kit
37-28
37
Stepped wear on rotor and vane contact surfaces of
6 – 0.05 Replace*
cover
8, 9 Clearance between vane and rotor 0.01 0.06 Replace
Stepped wear on rotor and vane contact surfaces of
12 – 0.05 Replace*
side plate
Air leakage of flow control valve
15 0 cm3 {0 mL} – Replace*
(applying pressure 390 to 490 kPa {4 to 5 kgf/cm2})
15, 19 Clearance between flow control valve and body 0.01 to 0.02 0.03 Replace*
16 Free length of flow control spring 36.5 33.5 Replace
*: Replace the power steering oil pump.

Nut (eye joint mounting) 29.4 to 39.2 {3 to 4} –
Bolt (cover mounting) 22 to 26 {2.2 to 2.7} –
Connector 49 to 69 {5.0 to 7.0} –
Bolt (suction connector mounting) 7.8 to 11.8 {0.8 to 1.2} –

Automatic transmission fluid
Bearing surface of cover (DEXRON, DEXRON II, DEXRON III As required
type)
Inspection: Cover
• Check if there is not stepped wear or scratch that causes finger-
nail to catch on the sliding surface of the rotor and vane. If any
abnormality is found, replace the cover.
37-29
POWER STEERING OIL PUMP
Inspection: Vanes and rotor
• Check if there is not scratch or wear on the sliding surface of the
cover and the side plate by watching and touching.
• Check if there is not scratch on the slit surface of the rotor and
the vanes by watching and touching.
• Install each vane on the rotor with its rounded end facing out,
and check all vanes for smooth movement.
• Apply light to the rotor with installing the vanes and check if
there is not light leakage from the slit between the vane and ro-
tor.
• If any abnormality is found, replace the cartridge assembly.
Inspection: Side plate

• Check if there is not stepped wear or scratch that causes finger-
nail to catch on the sliding surface of the rotor and vane. If any
abnormality is found, replace the side plate.
Inspection: Flow control valve and body

(1) Air leakage of flow control valve
• Block the port A of the flow control valve by the finger.
• Apply the specified air pressure to port B.
• Check if there is not air leakage from port C.
• If any abnormality is found, replace the power steering oil pump.
(2) Inspection of aspect of flow control valve and body

• Check if there is not scratch, wear or edge on the sliding surface
of the body and the flow control valve by watching and touching.
• If any abnormality is found, replace the flow control valve or
body.
(3) Flow control valve-to-body clearance

• If the measurement exceeds the limit, replace the flow control
valve and body.
37-30
37
Installation: Cam ring
• Install the cam ring in the illustrated direction to the body.
Installation: Vane
• Fit the vane into the rotor, with its round edge facing toward out-
side.
Installation: Eye joint

• Install the eye joint with its notch engaged with the suction con-
nector.
37-31
POWER STEERING OIL TANK
1 Hose
2 Filler cap
3 Strainer
4 Filter
5 Packing
6 Tank
Assembly sequence
verse.

Screw (filter mounting) 1.3 ± 0.3 {0.13 to 0.03} –
37-32
GROUP 41 FRAME
SPECIFICATIONS............................................................................... 41-2

1. Frame ........................................................................................... 41-3
FRAME ................................................................................................ 41-4
41-1
SPECIFICATIONS
Item Specifications
Frame type Ladder type
Cross section configuration of side member shaped (open) channel section
41-2
1. Frame
• The frame has cross members fastened to the web of the side members (lateral linkage) so that stress on the
joints is minimal. This allows joint rivets to maintain tightness and ensures long-lasting high torsional rigidity.
41-3
FRAME
CAUTION
• Do not reuse the mounting bolts or nuts of cross members and spring hangers, etc.

M10 bolt or nut 60 to 80 {6 to 8} –
M12 bolt or nut 98 to 120 {10 to 12} –
Nut (hook mounting) 120 to 160 {12 to 16} –
M16 bolt or nut 180 to 240 {18 to 24} –
Inspection: Frame
• Thoroughly remove mud, grease, rust etc. from the outer and in-
ner surfaces of the frame.
(1) Inspection for deformation
• If deformation or any other defect is found, repair the frame.
(2) Inspection for cracks

• Remove paint from suspected areas and carefully inspect ex-
posed surfaces for cracks.
• If visual inspection is difficult, perform dye check or any other
suitable examination.
If a crack is found, repair as follows.
41-4
41
(3) Repair of crack in frame
• With the vehicle unloaded, level the frame.
• Drill a hole with a diameter roughly twice the thickness of the
frame plate, 10 mm from the inside end of the crack.
• If the crack is within the frame plate, drill holes at both ends of
the crack.
• If the edges of the crack are uneven, even them out.
• Using a grinder, cut a 90° V-channel at the crack to a depth of

approximately 2/3 of the frame plate thickness, then fill the chan-
nel with filler metal by welding.
CAUTION
• Avoid gas welding because heat embrittles the material of
welded area. Be sure to use electric welding.
• Electric welding could allow the welding current to reverse
through ground circuit and burn electrical components. To
prevent this, be sure to disconnect negative cable from the
battery and ground the welding machine at a point near the
weld zone before work.
• For electric welding, follow other precautions given else-
where. (See Gr00.)
• If there are any combustibles, such as pipeline, wiring har-
ness, rubber part and fuel tank, near the weld zone, be sure
to cover them for protection.
• Use low-hydrogen type coated CO2 and arc welding elec-
trodes for welding and check that there are no harmful de-
fects such as undercut and blow hole after welding.
• Preheat the area around weld zone to approximately 50 to
350°C before welding when the workshop temperature is
below 0°C.
• Be sure to protect mountings that may be affected by heat,
such as main sills, using heat insulators or the like.
41-5
FRAME
• Next, make a similar V-channel on the opposite side of the weld
and fill it with filler metal, also by electric welding as well. At the
same time, deposit metal to cover up the hole or holes at both
ends of the crack by welding.
• In cold climates, heat the weld zone to approximately 200°C af-
ter welding.
• After welding, run a grinder over the bead at right angles A.

• Remove the hatched area of the bead and finish the ground sur-
faces flat to a thickness equal to the original plate thickness.
[Repairing crack from rivet or bolt hole]

• To make the edges of the cracked hole even, temporarily tighten
the bolt in the hole.
• First, weld to close the crack at a point at least 20 mm apart from
the center of the bolt.
For this welding, see the aforementioned welding procedures for
crack repair.
• Remove the temporary bolt. After making hole edges even, weld
to close the rest of the crack B. Simultaneously fill the hole with
weld metal.
• Drill a hole at the location of original hole, and install a rivet or
bolt in it.
[Repairing using reinforcement plate]
• To prevent the concentration of welding stress at both ends C of
the reinforcement plate, cut the ends at a bevel of 30° or less for
welding. Do not weld at points D.
• The reinforcement plate must have enough to cover the cracked
area.
Reinforcement plate thickness: Equal to frame plate thickness
Reinforcement plate material: As specified below or equivalent
SAPH440 (Hot rolled steel for automobiles), or
SS400 (Rolled steel for general structures)
• After welding, heat the hatched area to 600 to 700°C.

CAUTION
• Be sure to protect mountings that may be affected by heat,
such as main sills, using heat insulators or the like.
41-6
41
(4) Inspection of rivets for looseness
• Lightly tap the head of each rivet using an inspection hammer
and feel or listen for the echo to determine if the rivet is loose.
• Rusting between rivet and frame plate is an indication of loos-
ened rivet.
CAUTION
• Loose rivets could break off or allow frame cracks to devel-
op from the rivet holes, leading to an accident.
(5) Replacement of rivet

• To remove a loosened rivet, eliminate its head using a drill or
grinder. When a drill is used, make a dent in the middle of the
rivet’s head and align the drill bit with the dent as shown.
CAUTION
• The rivet hole must be intact.
• Before riveting, clamp the two plates closely together near the
rivet hole using a C vice.
• Using a riveting machine, drive the rivet (cold rivet) into the rivet
hole.
• If riveting is unfeasible, ream the rivet hole, drive a reamer bolt
into the hole, fully tighten the nut, then weld it in place.
Similarly to the reamer bolt and nut, you can also use a flange
bolt and a flange nut.
(6) Inspection of bolts and nuts for looseness

• Inspect the bolts attaching cross members to the side rails for
looseness. If any loose bolt is found, retighten it to specified
torque.
(7) Drilling hole in frame

• When required to drill holes in the frame, heed the following
warning.
• When drilling holes in the side rail, avoid the illustrated ranges
A to prevent cracking.
• Avoid drilling a hole in the vicinity of a point where the rigidity
of the side rail change sharply, such as an area near the joint
to the cross member or an end of the stiffener.
• The diameter of drilled holes must be 11 mm or smaller and
the hole-to-hole distance must be 20 mm or larger.
• Grind the edge of drilled hole smooth.
41-7
GROUP 55 HEATER, AIR-CONDITIONER,
VENTILATION
SPECIFICATIONS.................................. 55-2 REAR HEATER AND

HOT WATER PIPING ........................... 55-30
1. Air Conditioner Schematic
Diagram ........................................... 55-3
2. Air Conditioner System ................... 55-3
3. Air Duct ........................................... 55-4
4. Air Conditioning Switching .............. 55-5
5. Heater Schematic Diagram .............. 55-7
TROUBLESHOOTING ........................... 55-8

ADJUSTMENT
1. Discharging Refrigerant................. 55-12
2. Charging Refrigerant ..................... 55-13
3. Refrigerant Level Inspection .......... 55-13
4. Adding Refrigerant ........................ 55-13
AIR CONDITIONER PIPING ................ 55-14
CONNECTING AIR CONDITIONER

PIPING.................................................. 55-16
COMPRESSOR.................................... 55-18
CONDENSER AND RECEIVER........... 55-20
EVAPORATOR AND
COOLER DUCT ................................... 55-22
HEATER CONTROL ............................ 55-26
HEATER AND AIR DUCT .................... 55-28
FRONT HEATER, DUCT AND

BLOWER.............................................. 55-29
55-1
SPECIFICATIONS
Specifications
Item
BE63DE, BE63DG BE63DJ
Model – BM372
Cooling capacity W {kcal/h} – 12800 {11000}
System
Type – HFC134a
Refrigerant
Quantity kg – 2.7
Manufacturer DENSO
Heat radiation W {kcal/h} 4400 ± 440 {3780 ± 378}
Front heater Temperature control system Air mixing type
Type Sirocco fan type
Blower
Rated voltage V 24
Manufacturer DENSO
Fan motor type Sirocco fan type
Rear heater Rated voltage V 24
Heat radiation W {kcal/h} 3500 ± 350 {3010 ± 301}
3/h
Air capacity m 220 ± 22
MITSUBISHI HEAVY
Manufacturer –
INDUSTRIES, LTD.
Model – MSC90BA
3
Compressor Ejection amount cm {mL}/rev – 90 {90}
Type – S-PAG56
Lubrication oil Quantity LH : 235 +20 +20
0 {235 0 }
–
cm3 {mL} RH : 235 0 {235 +20
+20
0 }
MITSUBISHI HEAVY
Manufacturer –
INDUSTRIES, LTD.
Condenser
Rated voltage V – 24
Fan motor W – 200 + 170
MITSUBISHI HEAVY
Manufacturer –
INDUSTRIES, LTD.
Evaporator Rated voltage V – 24
3/h
Air capacity m – 1620
Motor input W – 96
55-2
1. Air Conditioner Schematic Diagram
2. Air Conditioner System
55-3
3. Air Duct
• Depending on open/closed status of each damper in the heater unit, outside and inside air introduced from the
blower flow as shown above.
55-4
55
4. Air Conditioning Switching
4.1 Mode switching
• Mode switching (opening and closing of the damper) is performed by transmitting the movement of the mode
switching lever via the mode switching control wire.
4.2 Air-mix switching
• Air-mix switching is performed by changing the opening of the damper to adjust the amount of warm air from the
heater core and cool air that does not pass through the heater core.
55-5
4.3 Inside/outside air switching
55-6
55
5. Heater Schematic Diagram
<Front heater>
<Front and rear heater>
• The heater system is a hot water system that consists of the rear heater and hot water piping and uses coolant
(hot water) circulating from the engine.
55-7
TROUBLESHOOTING
Front Heater
Symptoms
Air volume cannot be adjusted.

Defroster is not effective.
Heater is not effective.
Reference Gr
No warm air.
Possible causes
Fuse blown O
Connector improperly connected, harness open-circuited, grounding improper O Gr54
Front heater switch operation defective O O
Foreign object catching fan O O
Fan motor operation defective O O O
Heater core clogged O
Belt incorrectly adjusted O
Water pump operation defective O
Thermostat does not close O Gr14
Cooling system defective O
Insufficient coolant amount O
Air-mix damper operation defective O
Gap between internal components and floorboard mount area O
Gaps around the body O
Duct connection defective O
Air-mix damper operation defective O
Duct clogged by foreign objects O
Register operation defective O
Defroster hose warped, bent, connection defective O
Defroster duct incorrectly attached O
Foreign objects have fallen into defroster duct O
Mode switching control wire incorrectly adjusted O
55-8
55
Rear Heater
Symptoms
Air volume cannot be adjusted.

Reference Gr
No warm air.
Possible causes
Fuse blown O
Connector improperly connected, harness open-circuited, grounding improper O Gr54
Rear heater switch operation defective O O
Foreign object catching fan O O
Fan motor operation defective O O O
Water valve closed O
Heater core clogged O
Belt incorrectly adjusted O
Water pump operation defective O
Thermostat does not close O Gr14
Cooling system defective O
Insufficient coolant amount O
Gap between internal components and floorboard mount area O
Gaps around the body O
Register operation defective O
55-9
TROUBLESHOOTING
Air Conditioner System
Symptoms
Inside/outside air switching is not possible.

Discharge port switching is not possible.
There is a draft from the discharge port.
Air cannot leave the discharge port.
Temperature cannot be adjusted.

Air conditioner is not effective.
Reference Gr

Possible causes
Compressor seizure O *a
Fuse blown O O
Harness, connector defective O O O O O O
Gr54
Ground defective O O O O O O
Air conditioner relay contacts fused, coil disconnected, short circuit O
Condenser fan motor coil disconnected, short circuit O
Condenser fan relay contacts fused, coil disconnected, short circuit O
Insufficient coolant O O
Air conditioner piping blockage, loose piping, faulty connection O
Cooler duct connection defective O
Condenser clogged O
Condenser core collapse, foreign objects present O
*a
Receiver clogged, drying agent defective O
Evaporator clogged O
*a: See MITSUBISHI BUS AIR CONDITIONER BM372 WORKSHOP MANUAL.
55-10
55
M E M O
55-11
1. Discharging Refrigerant
• See MITSUBISHI BUS AIR CONDITIONER BM372 WORKSHOP MANUAL.
55-12
55
2. Charging Refrigerant
3. Refrigerant Level Inspection

• Inspection of the refrigerant level is carried out at the sight glass
(refrigerant inspection window) to visually examine the condition
of refrigerant. If the refrigerant level is low, add refrigerant.
• Inspection must be performed under the following condition.
• Engine speed: 1400 rpm
• Air conditioner switch: ON
• Fan switch: HI
• Temperature control dial: maximum cooling position
• Inside/outside air switching: outside air
• Doors and side window glasses: fully open
CAUTION
• Operating the air conditioner without refrigerant will result
in breakdown of the compressor.
Normal Insufficient coolant Almost no coolant
Condition at sight glass

A foggy liquid is flowing quite Bubbles can be seen con- Almost transparent. Even if
slowly. stantly. White or transparent bubbles are seen, they disap-
bubbles may be present. pear whenever the engine
speed increases or decreas-
es.
High pressure pipe is hot; low High pressure pipe is hot; low Hardly any temperature differ-
Conditions at high and low pressure pipe is slightly cold. pressure pipe is cold. There is ence can be felt between the
pressure pipes a marked difference in temper- high pressure pipe and low
ature. pressure pipes.
4. Adding Refrigerant
55-13
AIR CONDITIONER PIPING
Removal sequence
1 Discharge hose 4 Low pressure pipe
*a: Compressor
2 High pressure pipe 5 Liquid pipe
*b: Condenser
3 Suction hose 6 Sight glass
*c: Evaporator
55-14
55
Bolt (installation of discharge hose and suction hose) 19.6 to 29.4 {2.0 to 3.0} –
Bolt (installation of pipes and hoses) 4.9 to 6.0 {0.5 to 0.7} –
Installation of discharge hose and high pressure pipe 19.6 to 24.5 {2.0 to 2.5} –
Installation of high pressure pipe and condenser 34.3 to 39.2 {3.5 to 4.0} –
Installation of suction hose and low pressure pipe 29.4 to 34.3 {3.0 to 3.5} –
Installation of low pressure pipe and evaporator 63.7 to 93.2 {6.5 to 9.5} –
Installation of low pressure pipe 49 to 56.7 {5 to 5.85} –
Installation of liquid pipe and condenser –
Installation of liquid pipe and sight glass 11.8 to 14.7 {1.2 to 1.5} –
Installation of liquid pipe and evaporator –

Periphery of pipe and hose ends, O-ring Refrigeration oil S-PAG56 As required
Work before removal

Draining refrigerant
• Drain refrigerant off before removal. (See “1. Discharging Re-
frigerant”.)
Installation: Connecting hoses and pipes
• (See “CONNECTING AIR CONDITIONER PIPING”.)
55-15
CONNECTING AIR CONDITIONER PIPING
1 Nut
2 Pipe or hose
3 O-ring
4 Union
5 Pipe or hose
A: Refrigeration oil application

region
• Care should be taken regarding the following items when connecting the air conditioner pipes and hoses.
• For the tightening torque of the nut and the refrigeration oil, see “AIR CONDITIONER PIPING”.
CAUTION
• Do not twist the O-ring that seals the connection area. It may be damaged.
• The O-ring cannot be reused since it is a special part of refrigerant HFC134a.
• Do not tighten the union since it will cause the pipe to deform, resulting in possible coolant leaks. Tighten
the nut.
55-16
55
M E M O
55-17
COMPRESSOR
Removal sequence
1 Discharge hose 4 Belt 9 Collar
(high pressure side) 5 Compressor (left-hand) 10 Tension pulley shaft
2 Suction hose 6 Compressor (right-hand) 11 Tension pulley bracket A
(low pressure side) 7 Tension pulley cover 12 Tension pulley bracket B
3 Pipe stay 8 Tension pulley
• Recover the refrigerant before disconnecting the hose. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
• See the CONNECTING AIR CONDITIONER PIPING section for the installation of hose and pipe.
• After installation, tension the belt to specification. (See Gr14.)

Bolt (installation of discharge hose and suction hose) 19.6 to 29.4 {2 to 3} –
Nut (tension pulley mounting) 50 {5.1} –
55-18
55
Inspection: Compressor
• Perform the following inspections. If any abnormality is found,
replace or overhaul the compressor at your nearest service sta-
tion.
(1) Operation and oil leakage
• Check the compressor proper for malfunction and oil leakage.
(2) Magnetic clutch

• Disconnect the magnetic clutch harness connector and supply
power from the positive terminal of the battery to check if the
magnetic clutch operates normally.
CAUTION
• Do not allow the lead wire connected to the positive termi-
nal of the battery to touch any other component around the
connector. Otherwise, a short circuit will occur and the
component may fail.
55-19
CONDENSER AND RECEIVER
Removal sequence
1 High pressure pipe 6 Panel
2 Liquid pipe 7 Condenser
3 Insulator
4 Lower panel : Non-reusable parts
5 Protector

Installation of receiver and liquid pipe 11.8 to 14.7 {1.2 to 1.5} –
Installation of condenser and high pressure pipe 34.3 to 39.2 {3.5 to 4.0} –

High pressure pipe ends
Refrigeration oil S-PAG56 As required
Periphery of liquid pipe end
55-20
55
Inspection: Condenser
• Clean the fins of the condenser if they are clogged with dirt,
dust, etc. Use a spatula or the like to repair any distortion of the
fins.
55-21
EVAPORATOR AND COOLER DUCT
Removal sequence
1 Front inner duct 6 Outside duct 11 Drain port
2 Cooler duct cover (See Gr63.) 7 Panel 12 Bracket
3 Air outlet grill (See Gr63.) 8 Inside duct 13 Low pressure pipe
4 Cooler duct (See Gr63.) 9 Cooler duct inner sheet 14 Liquid pipe
5 Air outlet duct 10 Drain hose 15 Evaporator

Installation of evaporator and low pressure pipe 63.7 to 93.2 {6.5 to 9.5} –
Installation of evaporator and liquid pipe 11.8 to 14.7 {1.2 to 1.5} –

Drain hose floor penetration area Cemedine 366E As required
Low pressure pipe end
Refrigeration oil S-PAG56 As required
Periphery of liquid pipe end
55-22
55
Removal procedure
Removal: Evaporator
• Disconnect the connectors that connect the evaporator with the
body harness.
• Pull out the drain hose.
• Disconnect the connection with the low pressure pipe and liquid
pipe.
• Remove each mounting bolt to remove the bracket and evapora-

tor.
CAUTION
• Support the evaporator when removing the bolts since it
may fall.
55-23
EVAPORATOR AND COOLER DUCT
Installation: Drain hose
• Be sure to seal the drain hose floor penetration area with seal-
ant.
55-24
55
M E M O
55-25
HEATER CONTROL
Removal sequence
1 Air-mix control wire 4 Front heater switch
2 Mode switching control wire 5 Heater control
3 Inside/outside air switching control wire 6 Rear heater switch
CAUTION
• Do not disconnect the wires from the heater control except when they are replaced to avoid heater con-
trol clip tabs being deformed.
Installation: Air-mix control wire
• Place the temperature control lever on the heater control in the
maximum heating (MAX HOT) position on the extreme right.
• Move the air-mix damper lever in the heater unit to the MAX
HOT position.
• Connect the air-mix control wire to the air-mix damper lever
while still in this condition, and secure it firmly with a clip.
55-26
55
Installation: Mode switching control wire
• Place the mode switching lever on the heater control in the de-
froster (DEF) position.
• Move the mode switching damper lever in the heater unit to the
defroster position.
• Connect the mode switching control wire to the mode switching
damper lever while still in this condition, and secure it firmly with
a clip.
Installation: Inside/outside air switching control wire

• Place the inside/outside air switching lever on the heater control
in the recirculation (RECIRC) position.
• Move the inside/outside air switching damper lever in the blower
assembly to the recirculation position.
• Connect the inside/outside air switching control wire to the in-
side/outside air switching damper lever while still in this condi-
tion, and secure it firmly with a clip.
55-27
HEATER AND AIR DUCT
Removal sequence
1 Heater duct LH 7 Defroster duct RH
2 Heater duct RH 8 Center side defroster duct RH
3 Passenger face duct 9 Center side defroster duct LH
4 Driver face duct 10 Center duct
5 Center face duct
6 Defroster duct LH
*a: Front heater
55-28
FRONT HEATER, DUCT AND BLOWER 55
Removal sequence
1 Front heater 5 Blower
2 Duct
3 Blower register
*a: Water hose (See “REAR HEATER AND HOT WA-
4 Drain hose TER PIPING”.)

Screw (installation of duct) 1.96 to 3.43 {0.2 to 0.35} –
Bolt (installation of front heater and blower) 9 to 13.4 {0.9 to 1.4} –
55-29
REAR HEATER AND HOT WATER PIPING
Front Part
55-30
55
Rear Part
Removal sequence
1 Rear heater 4 Water valve *a: Front heater
2 Water hose 5 Bracket
3 Water pipe

Nut (installation of rear heater) 8.8 to 12.7 {0.9 to 1.3} –
Nut (installation of water hose and water pipe) 3.9 to 5.9 {0.4 to 0.6} –
Bolt (installation of water pipe) 9.8 to 15.0 {1.0 to 1.5} –
Nut (installation of water pipe and water hose) 4.9 to 6.9 {0.5 to 0.7} –

Rear heater mounting surface and mounting hole Cemedine 369 As required
Each joint of water hose Hermeseal No. 201 As required
55-31
REAR HEATER AND HOT WATER PIPING
Work before removal
Alignment mark: Water hose
• Be sure to make alignment marks before removal.
Removal procedure
Removal: Rear heater
• Remove the nuts and disconnect the body harness connector
from under the floor.
• Push the heater harness grommet and connector into the vehi-
cle from under the floor to remove the rear heater.
Installation: Rear heater
• Apply sealant to the mounting surfaces for the rear heater and
mounting hole for the heater harness grommet.
55-32
55
• Apply sealant to the water hose joints.
Installation: Water pipe

• For the water pipes with white markings, clamp the pipes at the
marked positions.
55-33
GROUP 63 BODY
SPECIFICATIONS.................................. 63-2 EMERGENCY DOOR ........................... 63-58
STRUCTURE AND OPERATION TRUNK LID........................................... 63-64

1. Body ................................................ 63-4
2. Front Door Locking System ............. 63-4 AUTOMATIC DOOR SYSTEM
3. Side Door Locking System .............. 63-5 <FOLDING DOOR> ............................. 63-66
4. Back Door Locking System ............. 63-6 <SWING DOOR> ................................. 63-70
5. Emergency Door Locking System.... 63-6
WINDSHIELD AND
6. Trunk Lid Locking System ............... 63-7
REAR WINDOW GLASS...................... 63-74
7. Automatic Door System
<Folding Door> ................................ 63-8 SAFETY WINDOW GLASS.................. 63-78
8. Automatic Door System
<Swing Door> ................................ 63-10 SIDE WINDOW GLASS
9. Front Wiper and Washer ................ 63-14 <SLIDING WINDOW> .......................... 63-80
10.Rear Wiper and Washer ................. 63-15 <FIXED WINDOW> .............................. 63-84
11.Seat Belt with Emergency
Locking Retractor ......................... 63-16 FRONT BUMPER ................................. 63-88
TROUBLESHOOTING ......................... 63-18 REAR BUMPER ................................... 63-89
ON-VEHICLE INSPECTION AND GARNISH ............................................. 63-90

ADJUSTMENT
INSTRUMENT PANEL ......................... 63-92
1. Front Door Fitting Adjustment ....... 63-24
2. Side Door <Folding Door> HEAD LINING
Fitting Adjustment ......................... 63-26 <FRONT> ........................................... 63-98
3. Side Door <Swing Door> <CENTER> ....................................... 63-100
Fitting Adjustment ......................... 63-27 <REAR> ........................................... 63-102
4. Back Door Fitting Adjustment........ 63-29
5. Emergency Door Fitting OUTSIDE REAR VIEW MIRROR
Adjustment .................................... 63-31 <DRIVER SIDE> ................................ 63-104
6. Trunk Lid Fitting Adjustment ......... 63-33 <PASSENGER SIDE> ........................ 63-105
7. Fuel Lid Fitting Adjustment ........... 63-35
FRONT WIPER AND WASHER ......... 63-106
FRONT DOOR...................................... 63-36
REAR WIPER AND WASHER ........... 63-110
SIDE DOOR
<FOLDING> ........................................ 63-42 SEAT BELT......................................... 63-113
<SWING> ........................................... 63-46
BACK DOOR........................................ 63-52
63-1
SPECIFICATIONS
Door engine <Automatic door>
Specifications
Item
Folding door Swing door
Manufacturer TOSHIN TEC CO., LTD.
Type Vacuum type Electric type
Magnetic valve V–W 24 – 10.7 –
Stroke mm 175 –
Cylinder Output force N {kgf} / kPa {mmHg} 735 {75} / 60 {450} –
3
Displacement cm {L} Approx. 2100 {2.1} –
Airtightness kPa {mmHg} / sec 2 {15} or less/15 –
Voltage range during use V – 22 to 30
Temperature range during use °C – –30 to 60
Angle of rotation ° – 139 or more
Maximum rotational torque N·m {kgf·m} – 98 or more {10 or more}
Rated load torque N·m {kgf·m} – 2.94 {0.3}
Door opening and closing time sec – 3.0 to 4.5
Rated operating current under load
– 10 or less
(when the rated voltage at room temperature is 26 V) A
63-2
63
M E M O
63-3
1. Body
2. Front Door Locking System
63-4
63
3. Side Door Locking System
3.1 Folding door
3.2 Swing door
63-5
4. Back Door Locking System
5. Emergency Door Locking System
63-6
63
6. Trunk Lid Locking System
63-7
7. Automatic Door System <Folding Door>
7.1 Outline
• The automatic door system consists of a door engine, an automatic door switch, vacuum piping, a limiting valve
and other components. The piston rod in the cylinder is connected to the door side.
• Pushing the automatic door switch supplies vacuum to the door engine to activate the cylinder piston rod, which
opens and closes the door.
• With the automatic door switch OPEN, the door opening magnetic valve is activated, the door closing magnetic
valve is deactivated. As a result, the piston rod is moved to the door opening side.
• With the automatic door switch CLOSE, the door opening magnetic valve is deactivated, the door closing magnet-
ic valve is activated. As a result, the position rod is moved to the door closing side.
• With the starter switch in the ACC or LOCK position, the doors can be opened and closed manually.
• Even when the starter switch is in the ON position, placing the emergency switch in the MANUAL position allows
the doors to be opened and closed manually.
63-8
63
7.2 Door open/close and each switch and device operation
Starter switch Automatic door switch Neutral switch Brake indicator lamp Door status
ACC, LOCK Free
ON OPEN OFF Goes off Does not open
ON OPEN ON Goes off Opens
ON OPEN OFF Comes on Opens
ON OPEN ON Comes on Opens
ON NEUTRAL Stops
ON CLOSE Closes
ON Shift lever in neutral

Neutral switch
OFF Shift lever in gear
• With the starter switch in the ACC or LOCK position, the doors can be opened and closed manually.
• Even when the starter switch is in the ON position, placing the emergency switch in the MANUAL position allows
the doors to be opened and closed manually.
63-9
8. Automatic Door System <Swing Door>
8.1 Outline
• The automatic door system consists of a door engine unit, an automatic door switch and other components. The
link on the door engine is connected with the swing door arm.
• Pushing the automatic door switch turns the door arm, which opens and closes the door.
63-10
63
8.2 Door open/close and each switch and device operation
Automatic door Brake indicator
Starter switch Neutral switch Door lock actuator Door status
switch lamp
ON OPEN OFF Goes off Locks Stay closed
ON OPEN OFF Comes on Operates Opens
ON OPEN ON Goes off Operates Opens
ON OPEN ON Comes on Operates Opens
ON CLOSE Locks Stay closed
ON Shift lever in neutral

Neutral switch
OFF Shift lever in gear
• Even when locked with the key from outside the vehicle or by pushing the lock button inside, the door can be au-
tomatically unlocked and opened by placing the red handle in the AUTOMATIC position and setting the automatic
door switch to the OPEN position. With the red handle in the MANUAL position, the door lock cannot be released.
63-11
8.3 Flow chart
<When open> <When closed>
Starter switch ON Starter switch ON
Automatic door switch Automatic door switch

OPEN CLOSE
Warning buzzer sounds Warning buzzer sounds

for 1 second for 1 second
Door lock released

Is door in NO
almost closed position
or fully closed
Door low-speed position?
operation
YES
Is an Door high-speed Door low-speed

exessive YES operation operation
load applied?
NO Is an Is an
YES
Fully opens and stops Stops immediately exessive exessive
and intermittent load applied? load applied?
buzzer sounds
NO NO
Has 5 seconds
passed after the Fully closes and stops Stops immediately
NO emergency stop? and intermittent
buzzer sounds
YES
Intermittent Has 5 seconds

buzzer sounds passed after the
NO emergency stop?
YES
Intermittent
buzzer sounds
63-12
63
8.4 Timing chart
63-13
9. Front Wiper and Washer
63-14
63
10.Rear Wiper and Washer
63-15
11. Seat Belt with Emergency Locking Retractor
63-16
63
11.1 Webbing sensing locking

• If a strong impact force such as collision is applied to the vehicle, the webbing will be pulled out to rotate the
spindle according to movement of the occupants.
• Once the rotating speed of the spindle exceeds the specified value, the sensor spring can no longer hold the
lock arm in place: the lock arm protrudes to engage with the clutch.
• Continued rotation of the spindle makes the clutch raise the pawl, which then engages with the ratchet gear.
The rotation of the spindle is thus completely stopped.
11.2 Vehicle body sensing locking

• If the vehicle tilts significantly, the mechanism weight will tilts accordingly to make the mechanism lever engage
with the locking gear.
• The rotation of the spindle is stopped in the same manner as with the webbing sensing locking.
63-17
TROUBLESHOOTING
Entire Body
Symptoms
Body or steering wheel high-frequency vi-

Body shimmy (pitching and rolling
bration (above 20 Hz) or noise

Reference Gr
vibration)
Possible causes
Body mounting section loose, too much play O O
Body-related
Body installation faulty O O
Cross axes angle of propeller shaft excessive due to
increased tilt caused by deteriorated engine mount- O
ing Gr11
Engine-related
Engine installation faulty O
Intake and exhaust system installation faulty O Gr15
Transmission-related Transmission installation faulty O Gr22
Propeller shaft swing excessive O
Universal joint worn excessively O
Slip yoke joint spline loose O
Propeller shaft-related Center bearing play excessive O Gr25
Cross axes angle of mounting dimension excessive
O
due to deteriorated center bearing cushion rubber
Cross axes angle of propeller shaft excessive due to
O
increased drive shaft tilt caused by overload
Front axle-related Axle seat resonance O Gr26
Reduction gear engaged incorrectly O
Rear axle-related Gr27
Differential gear engaged incorrectly O
Wheel and tire swing excessive O
Wheel and tire unbalanced O
Wheel and tire-related Gr31
Size and kind of tire unequal O
Wheel mounting surface warped O
Suspension-related Leaf spring friction between leaves excessive O Gr33, 34
Brake drum unbalanced O
Brake-related Brake drum eccentric O Gr35
Disc brake rotor eccentric O
63-18
63
Door Lock
Symptoms
Door does not lock when door lock knob
Door does not lock when key is turned
Door does not open with outside door
Door does not open with inside door
Door inside handle self-return poor

Door inside handle self-return poor
Door does not shut completely
Door does not open with lever

Reference Gr
is pressed
handle
handle
Possible causes
Door installation faulty O O
Striker installation faulty O
Door latch rod deformed O O O O O
Door latch rod removed O O O O O
Front door
Door latch rod interference O O O O O
Key cylinder deformed O O
Joint screw installation faulty O
Inside door handle spring fatigued O
Side door <Folding> Stopper installation faulty O
Door lock faulty O O
Door latch rod deformed O O O O O
Side door <Swing> Door latch rod removed O O O O O
Door latch rod interference O O O O O
Key cylinder deformed O
Remote control faulty O O O O
Striker installation faulty O O O O O
Back door Door latch rod deformed O O O O O
Door latch rod removed O O O O O
Key cylinder deformed O
Emergency door Door latch rod deformed O O
Door latch rod removed O O
Door latch rod interference O O
63-19
TROUBLESHOOTING
Automatic Door System <Folding Door>
Symptoms
Start is poor when door is closed

Door does not open and close
Reference Gr
Door does not open

Possible causes
Fuse blown O
Gr54
Door open switch faulty O
Automatic door switch not “ON” O O
Door locked O O
Emergency switch in “manual” position O O
Cylinder assembly defective O O
Door upper roller and guide rail contact faulty O
Cylinder assembly installation position faulty O O
Dead point in start position O
Stroke insufficient O
Cushion O-ring worn O
Door hinge faulty O
Vacuum pressure not transmitted to door engine O
Magnetic valve not energized O
Magnetic valve does not change O
Limiting valve faulty O
63-20
63
Automatic Door System <Swing door>
Symptoms
Buzzer sounds but door does not open or

Door does not open and close
Door opens but does not shut

Door shuts but does not open
Buzzer does not sound

Reference Gr
Does not lock out

close
Possible causes
Fuse blown O
Harness or connector faulty O O O
Gr54
Door open switch faulty O O O
Buzzer faulty O
Microswitch faulty O O O
Motor faulty O
Control box faulty O O O O O O O
Door engine red handle in “manual” position O
Open/close capability (vehicle slant angle 12°) is exceeded O
Vehicle lock faulty O O O
Door fitting faulty O
Parking brake lever not pulled or shift lever not in neutral O
Door lock out actuator faulty O O
63-21
TROUBLESHOOTING
Wiper and Washer
Symptoms
Abnormal noise during wiper operation

Wiper intermittent operation does not
Wiper blade stop position incorrect
Wiper does not work with washer

Washer fluid spraying insufficient
Washer fluid does not spray out
Washer motor does not work
Wiper operation inadequate
Reference
Gr
Wiper does not work

Wiper does not stop
work
Possible causes
Wiper motor faulty O O O O
Washer motor faulty O O O
Wiper and washer switch faulty O O O O O
Wiper control unit faulty O O
Gr54
Wiper relay faulty O O
Fuse/high-current fuse blown O O
Connector improperly connected, harness open-circuited, ground-
O O O O O
ing improper
Wiper motor crank arm set position incorrect O
Wiper link and wiper arm connection faulty O
Wiper blade faulty O O
Wiper arm defective O
Washer hose twisted O O
Washer hose connection faulty O O
Washer nozzle clogged O O
Washer fluid insufficient O
63-22
63
M E M O
63-23
1. Front Door Fitting Adjustment

– Bolt (installation of door hinge) 17 to 26 {1.7 to 2.6} –
– Screw (installation of striker) 9 to 14 {0.9 to 1.4} –
• Adjust front door fitting using the door hinge and striker.
1.1 Adjustment of door hinge

• Adjust clearance with the bolts indicated with .
• Adjust stepped dimensions with the bolts indicated with .
1.2 Adjustment of striker

• Adjust the striker with the screw.
• To engage the striker with the door lock latch firmly, use the opti-
mal number of shims.
63-24
63
1.3 Front door fitting dimensions
63-25
2. Side Door <Folding Door> Fitting Adjustment
• Adjust the fitting of the side door <Folding door> at hinges and
weatherstrips.
2.1 Adjustment of hinge positions

• If the resistance of the weatherstrips to the door movement is
large due to disagreement in width between the door and body-
side opening, loosen the hinge bolts and adjust the spacing be-
tween the 2 door panels.
2.2 Adjustment of weatherstrips

• If the weatherstrips under the door are resistive, adjust their in-
stalled position upward.
2.3 Adjustment of stopper

• Adjust the stopper position so that the door panel end fits into
the stopper.
63-26
63
3. Side Door <Swing Door> Fitting Adjustment

– Bolt (installation of pillar side arm bracket)
35 to 55 {3.5 to 5.5} –
– Bolt (installation of door side arm bracket)
– Bolt (installation of step side arm bracket) 17 to 26 {1.7 to 2.6} –
– Nut (tightening of guide arm) 19 to 28 {1.9 to 2.8} –
– Screw (installation of striker) 8.8 to 14 {0.9 to 1.4} –
• Adjust side door <Swing door> fitting using the arm bracket,
guide arm and striker.
3.1 Vertical direction adjustment

• After adjusting the pillar side arm bracket and step side arm
bracket, tighten the bolt to the specified torque.
NOTE
• Adjustment range by the arm brackets is ± 2 mm at a maxi-
mum. If further adjustment is required, change the number
of shims.
• Remove the step side arm bracket and adjust with the shims.
3.2 Longitudinal direction adjustment

• After adjusting the door side arm bracket, tighten the bolt to the
specified torque.
Adjustment range: ± 2.5 mm
63-27
3.3 Lateral direction adjustment
• After loosening and adjusting the nut of the guide arm, tighten it
3.4 Opening dimension and protruding amount adjust-

ment
• Thrust cushion rubber into place and fully open the door auto-
matically (620 mm in opening width (effective width) and 154
mm in protruding amount from the vehicle body).
• Holding the door in this position, adjust the cushion rubber so
that it contacts the entrance pillar.
• Close the door, give the cushion rubber bolt one turn and half
counterclockwise and secure it with a lock nut.
• Check that the crushed width of the cushion rubber is 0 to 2 mm
when the door is fully opened.

• Adjust the striker with screw.
• To engage the striker with the door lock actuator firmly, use the
optimal number of shims.
63-28
63
4. Back Door Fitting Adjustment

– Bolt (installation of hinge) 16.6 to 25.5 {1.7 to 2.6} –
• Adjust back door fitting using the hinge and striker.
4.1 Adjustment of hinge

• Adjust back door fitting with the mounting bolt of the hinge.

• Adjust the striker with the bolt.
• To engage the striker with the latch firmly, use the optimal num-
ber of shims.
63-29
4.3 Back door fitting dimensions
63-30
63
5. Emergency Door Fitting Adjustment

– Bolt (installation of hinge) 16.6 to 25.5 {1.7 to 2.6} –
• Adjust emergency door fitting using the hinge and striker.

• Adjust back door fitting with the mounting bolt of the hinge.

• To engage the striker with the door lock latch firmly, use the opti-
mal number of shims.
63-31
5.3 Emergency door fitting dimensions
63-32
63
6. Trunk Lid Fitting Adjustment
• Adjust trunk lid fitting using the hinge and striker.


• To engage the striker with the latch firmly, use the optimal num-
ber of shims.
63-33
6.3 Trunk lid fitting dimensions
63-34
63
7. Fuel Lid Fitting Adjustment
• Adjust fuel lid fitting using the door
hinge and hook.
• Using the door hinge and hook mount-
ing screws, adjust the entire circumfer-
ence clearance between the body and
lid to the dimension shown in the illus-
tration.
63-35
FRONT DOOR
Door Hinge and Striker
Removal sequence
1 Door harness 6 Weatherstrip
2 Door hinge 7 Weatherstrip
3 Door panel (See later section.) 8 Grommet
4 Striker 9 Door switch (See Gr54.)
5 Shim
• After installation, perform front door fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Bolt (installation of door)
17 to 26 {1.7 to 2.7} –
Bolt (installation of door hinge)
Screw (installation of striker) 9 to 14 {0.9 to 1.4} –
63-36
63
M E M O
63-37
FRONT DOOR
Front Door Panel
63-38
63
1 Handle 10 Outer handle 19 Door glass
2 Door pocket 11 Joint cover 20 Lock plate
3 Inner side handle 12 Trim 21 Tap plate
4 Door trim 13 Clip 22 Door check
5 Water-proof cover 14 Sash 23 Front door panel
6 Inner lock knob 15 Run channel
7 Bushing 16 Plate : Non-reusable part
8 Plate 17 Plate
9 Lock link 18 Lock lever
Assembly sequence

Bolt (installation of outer handle)
Bolt (installation of lock link) 4 to 6 {0.4 to 0.6} –
Bolt (installation of door check)

Adhesive surface between bushing and front door panel Cemedine 3000 Super K As required
Rotating part As required
Trim mounting surface of sash
Butyl rubber tape As required
Water-proof cover mounting surface of front door panel
Removal procedure
Removal: Door trim
• Remove all the clips but the clip A (10 pieces) from the front door
panel.
• Slide the door trim toward the rear of the vehicle to remove it
with the clip A left on the front door panel.
CAUTION
• The clip A is secured to the front door panel. Pulling off the
door trim by force can break the door trim.
63-39
FRONT DOOR
Removal: Sash
• Remove the joint cover and trim. Move the door glass forward or
backward to remove the upper and lower clips.
• Using a flat-blade screwdriver, separate the adhesive surface of

the sash.
• Push off the side window sash to the outside.
Installation: Trim
• Apply butyl rubber tape to the entire circumference of the sash to
install the trim.
• Attach butyl rubber tape with its joint under the door.
63-40
63
Installation: Bushing
• Apply an appropriate instant adhesive to the bushing or the door
panel at the illustrated position. Make sure that the adhesive is
applied neatly within the area. (Double-stick tape can be used
instead of the instant adhesive.)
• Fit the bushing into the door panel.
Installation: Water-proof cover

• Apply butyl rubber tape to the entire circumference of the water-
proof cover mounting surface as shown in the illustration and
then install the water-proof cover.
63-41
SIDE DOOR <FOLDING>
1 Bracket 9 Stopper 18 Seal rubber
2 Ball bushing 10 Cover 19 Hand rail
3 Plate 11 Hinge 20 Weatherstrip
4 Bearing 12 Hinge (handle side) 21 Side door glass
5 Bearing 13 Weatherstrip (pillar side) 22 Shaft
6 Check plate 14 Weatherstrip (door side) 23 Side door panel
<Except automatic door> 15 Door lock 24 Weatherstrip
7 Stopper bracket 16 Cushion rubber 25 Weatherstrip
8 Shim 17 Plate 26 Stopper
Assembly sequence
• After installation, perform side door <Folding door> fitting adjustment. (See “ON-VEHICLE INSPECTION AND
ADJUSTMENT”.)
63-42
63
Bolt (installation of bracket)
Bolt (installation of stopper) 4 to 6 {0.4 to 0.6} –
Bolt (installation of stopper bracket)

Rotating area of bracket and shaft
Rotating area of bearing and shaft Chassis grease
As required
Bearing contact surface [NLGI No.1 (Li soap)]
Sliding surface of check plate
Right and left weatherstrip adhesive surfaces Cemedine 575 As required
Entire circumference of side door panel flange outside
Nitto Sealant No.687 or equivalent As required
surface
Removal procedure
Removal: Side door glass
• While lifting the lip area of the weatherstrip with a screwdriver,
push off the side door glass from the door from inside.
Work before installation

Preparation: Installation of side door glass
• Remove the sealant stuck to the side door panel. Mend the paint
coating if it is scratched or rusted.
• Clean the entire adhesive surface of the side door panel with un-
leaded gasoline and let it dry for at least 3 minutes.
Installation: Weatherstrip
• Apply an appropriate adhesive to the positions shown in the il-
lustration and install the weatherstrips in place.
63-43
SIDE DOOR <FOLDING>
Installation: Side door glass
• Apply an appropriate sealant to the entire outside circumference
of the flange of the side door panel.
• Install the weatherstrip in the glass.
• Overlap a strong string in the door mounting groove of the

weatherstrip as shown in the illustration.
• Apply soapy water to the weatherstrip and fit the glass properly
into the side door.
• Firmly push the glass from outside while pulling one end of the
string from inside to fit the cab side mounting groove of the
weatherstrip to the flange part of the side door.
• Pull the string in the numerical order shown in the illustration

while tapping the glass from outside with a rubber hammer to
stabilize it.
A: Approximately 100 mm from lower end of straight line
B: Upper end of straight line
63-44
63
Adjustment after installation
Adjustment: Stopper
• Adjust the number of shims so that the contact area between the
stopper and door lock falls within the range of dimension shown
in the illustration.
63-45
SIDE DOOR <SWING>
Guide Arm and Swing Door Arm
1 Bracket 7 Shim 12 Striker
2 Plate 8 Boot 13 Shim
3 Guide arm 9 Cushion rubber 14 Door check
4 Arm bracket (door side) 10 Swing door arm 15 Check plate
5 Arm bracket (pillar side) 11 Swing door panel
6 Arm bracket (step side) (See later section.)
Assembly sequence
• After installation, perform side door <Swing door> fitting adjustment. (See “ON-VEHICLE INSPECTION AND AD-
JUSTMENT”.)
63-46
63
Nut (installation of guide arm) 19 to 28 {1.9 to 2.9} –
Bolt (installation of plate)
17 to 26 {1.7 to 2.7} –
Bolt (installation of arm bracket)
Bolt (installation of arm bracket) 35 to 55 {3.6 to 5.6} –
Nut (installation of cushion rubber) 34 to 50 {3.5 to 5.1} –
Bolt (installation of striker) 8.8 to 14 {0.9 to 1.4} –
Bolt (installation of door check arm bracket)
Bolt (installation of door check arm) 4 to 6 {0.4 to 0.6} –
Nut (installation of door check arm bracket and door check
arm)
Adjustment after installation

Adjustment: Check plate
• Adjust the position of the check plate so that the door check
does not ride onto the raised part of the check plate when the
door is fully opened.
63-47
SIDE DOOR <SWING>
Swing Door Panel
1 Side door glass 12 Latch
2 Molding 13 Cover
3 Glass clip 14 Inside lock knob
4 Trim edge 15 Sub link
5 Clip 16 Link
6 Trim 17 Key cylinder
7 Water-proof film 18 Swing door panel
8 Vent cover 19 Weatherstrip
9 Outside handle 20 Weatherstrip
10 Inside handle
11 Latch : Non-reusable parts
Assembly sequence
Follow the assembly sequence in reverse.
63-48
63
Glass clip surface Yokohama Rubber RC-50E As required
Side door glass surface Yokohama Rubber GM-78 As required
Adhesive surface between glass clip and side door glass Yokohama Rubber WS-30 As required
Side door glass surface Sika Cleaner No.1 As required
Adhesive surface of side door glass Sika Flex 250PC-JM1 As required
Water-proof film mounting surface on swing door panel Butyl rubber tape As required
Removal procedure
Removal: Side door glass
• Insert a piano wire or a cutting machine in between the side door
glass and swing door panel and separate them.
Leave a layer of adhesive at least 1 mm in thickness to prevent
the paint coating (ceramic film in the case of glass) from coming
off.
• If the paint coating is come off, apply primer VP209. If the ce-
ramic film of the glass is come off, mend the glass by applying
black primer.

Preparation: Installation of side door glass
• Remove the adhesive stuck to the swing door panel and side
door glass. Leave a layer of adhesive at least 1 mm in thickness
to prevent the paint coating (ceramic film in the case of glass)
from coming off. Mend the coating if it is scratched or rusted.
• Clean the entire adhesive surface with unleaded gasoline and
let it dry for at least 3 minutes.
Installation: Vent cover and water-proof film
proof film and vent cover mounting surface as shown in the illus-
tration and install them.
63-49
SIDE DOOR <SWING>
Installation: Trim edge
• Appropriately cut (2550 mm long) the trim edge and install it with
its joint at the center of the door.
Installation: Glass clip

• Apply the primer A (Yokohama Rubber RC-50E) to the adhesive
surface of the glass clip.
• Apply the primer B (Yokohama Rubber GM-78) to the adhesive
surface of the side door glass.
CAUTION
• Leave the primer A (Yokohama Rubber RC-50E) for at least
3 minutes and the primer B (Yokohama Rubber GM-78) for
at least 5 minutes after application.
• Fit the glass clips within 24 hours after the primer is ap-
plied.
• After the primer is dried, bond the glass clips to the side door
glass with adhesive (Yokohama Rubber WS-30). The fitting po-
sitions of the glass clips are as shown in the illustration. Make
sure that the difference of dimension C and D is less than 1 mm.
Installation: Side door glass

• Fit the side door glass into the molding groove.
• Reinforce the corners with tape as shown in the illustration.
• Apply Sika Cleaner No.1 to the adhesive surface between the

swing door panel and side door glass and leave it for 5 to 10
minutes.
CAUTION
• Carefully apply the cleaner to the spot dents and sheet
joints.
• Do not touch or let lubricant adhere to the adhesive surface
after the cleaner is applied.
63-50
63
• Apply adhesive (Sika Flex 250PC) to the entire circumference of
the swing door panel as shown in the illustration.
CAUTION
• The adhesive application cross section should form a trian-
gle that has a bottom 8 mm wide and a height of 12 mm.
• Be sure to apply the adhesive evenly. The amount of the ad-
hesive tends to decrease or increase at the beginning and
end points of application and the corners.
• Since the adhesive is quick to dry, work on one window at a
time and finish installing the glass within 8 minutes after the
start of adhesive application.
• Since the adhesive is urethane, it has poor compatibility
with silicone sealer. For this reason, adhesion failure may
occur if their locations are not taken into consideration. If
the distance between them is less than 1 m, apply one of
them 24 hours after the other was applied. When the dis-
tance is more than 1 m, work on the vehicle in a sufficiently
ventilated place though this case poses no danger normal-
ly.
• Lift the window using suction cups or the like to keep the appli-
cation surface clean and insert the glass clips on the side door
glass into the three holes in the swing door panel to install the
glass.
CAUTION
• If you should touch the application surface with bare hands
or lubricant should adhere to it, apply the adhesive again.
• Quickly remove adhesive that oozed out of the joints before it

dries and clean the glass with unleaded gasoline.
63-51
BACK DOOR
Hinge and Catch
Removal sequence
1 Spring pin 7 Spacer
2 Door check 8 Rubber
3 Hinge 9 Weatherstrip
4 Back door panel (See later section.) 10 Weatherstrip
5 Catch
6 Skid : Non-reusable part
• After installation, perform back door fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Bolt (installation of hinge)
16.6 to 25.5 {1.7 to 2.6} –
Bolt (installation of back door panel)

Sliding surface of door check Chassis grease [NLGI No.1 (Li soap)] As required
63-52
63
Back Door Panel
Removal sequence
1 Weatherstrip 9 Rubber
2 Back door glass 10 Spacer
3 Outer weatherstrip 11 Striker
4 Inner weatherstrip 12 Shim
5 Assist grip 13 Back door panel
6 Back door trim
7 Water-proof film : Non-reusable parts
8 Skid

Corners of adhesive surface between weatherstrip and
Cemedine 3000RS As required
back door panel
Adhesive surface between weatherstrip and back door
Cemedine CS3061-6AL As required
glass
Adhesive surface between inner weatherstrip and back
Sunstar C8021D As required
door panel
Butyl rubber tape
Water-proof film mounting surface of back door panel As required
(Sundine 60 or equivalent)
63-53
BACK DOOR
Removal procedure
Removal: Back door glass
push off the back door glass from the door from inside.

Preparation: Installation of back door glass
• Remove the adhesive stuck to the back door panel. Mend the
paint coating if it is scratched or rusted.
• Clean the entire adhesive surface of the back door panel with
unleaded gasoline and let it dry for at least 3 minutes.
• If the removed back door glass is reused, remove the adhesive
from the glass, clean the adhesive surface with unleaded gaso-
line and let it dry for at least 3 minutes.
Installation: Inner weatherstrip
• Apply sealant to the adhesive surface between the weatherstrip
and the back door glass.
• Install the back door glass with its joint under the door.
Installation: Back door glass

• Overlap a strong string in the body mounting groove of the
weatherstrip.
63-54
63
• Firmly push the back door glass from outside while pulling one
end of the string from inside to fit the cab side mounting groove
of the weatherstrip to the flange lip area of the body.

while tapping the back door glass from outside with a rubber
hammer to stabilize it.
• If the edge of weatherstrip does not stick on the flange lip area of
the body at the corners (4 places), apply adhesive to stick it fast.
63-55
BACK DOOR
Door Lock System
1 Lock knob 6 Lock 11 Latch
2 Bushing 7 Outer handle 12 Back door panel
3 Inner handle 8 Retainer
4 Remote control 9 Key cylinder : Non-reusable parts
5 Insulator 10 Door lock controller
Assembly sequence

3 Play in inner handle 0 to 12 – Adjust or replace
7 Play in outer handle 0 to 5 – Adjust or replace
Distance between rod end of Inner handle side 15 –
10 door lock controller and center Adjust or replace
of regulation pin Outer handle side 7.5 –

Adhesive surface of insulator with rod Cemedine 180 As required
Showa Shell Sekiyu Sunlight Grease
Sliding surface of door lock controller As required
LA-2 or equivalent
63-56
63
Installation: Door lock controller
• Turn the regulation pin of the door lock controller to adjust the
distance between the rod end and the center of the regulation
pin to the dimension as shown in the illustration.
• Apply adhesive to the slits of the insulators.
• Install the insulators in the lock at regular intervals.

Inspection: Play in inner handle
[Inspection]
• If the measured value deviates from the standard value, make
an adjustment.
[Adjustment]
• Adjust the play in the inner handle to the standard value by turn-
ing the regulation pin of the rod that links the inner handle with
the door lock controller.
• If there is any abnormality, replace the inner handle or the door
lock controller.
Inspection: Play in outer handle

[Inspection]
• If the measured value deviates from the standard value, make
an adjustment.
[Adjustment]
• Adjust the play in the outer handle to the standard value by turn-
ing the regulation pin of the rod that links the outer handle with
the door lock controller.
• If there is any abnormality, replace the outer handle or the door
lock controller.
63-57
EMERGENCY DOOR
Door Check, Hinge and Catch
1 Door check 5 Shim
2 Hinge 6 Stopper
3 Emergency door panel (See later section.) 7 Weatherstrip
4 Striker 8 Weatherstrip
Assembly sequence
• After installation, perform emergency door fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)

4 to 6 {0.4 to 0.6} –
Bolt (installation of stopper)
Bolt (installation of hinge)
16.6 to 25.5 {1.7 to 2.6} –
Bolt (installation of door panel)

Chassis grease
Sliding surface of door check As required
63-58
63
Emergency Door Panel
1 Door pull handle 6 Emergency door glass
2 Cover 7 Inner weatherstrip
3 Edge molding 8 Outer weatherstrip
4 Emergency door trim 9 Lever cover
5 Weatherstrip 10 Emergency door panel
Assembly sequence

Corners of adhesive surface between weatherstrip and
Cemedine 3000RS As required
emergency door panel
Adhesive surface between weatherstrip and emergency
Cemedine CS3061-6AL As required
door panel
63-59
EMERGENCY DOOR
Removal procedure
Removal: Emergency door glass
push off the emergency door glass from the door from inside.
Removal: Lever cover

• Remove the inner weatherstrip.
• Push off the lever cover to the outside.

Preparation: Installation of emergency door glass
• Remove the adhesive stuck to the emergency door panel. Mend
the paint coating if it is scratched or rusted.
• Clean the entire adhesive surface of the emergency door panel
with unleaded gasoline and let it dry for at least 3 minutes.
• If the removed emergency door glass is reused, remove the ad-
hesive from the glass, clean the adhesive surface with unleaded
gasoline and let it dry for at least 3 minutes.
Installation: Lever cover
• Fit the inner weatherstrip into the lever cover. The weatherstrip
should be a little longer at the joint.
CAUTION
• Do not pull the inner weatherstrip too tightly when fitting it.
Otherwise, it will shrink later, forming gaps.
• Apply sealant to the adhesive surface between the weatherstrip
and the emergency door glass.
• Install the emergency door glass with its joint under the door.
63-60
63
Installation: Emergency door glass
weatherstrip.
• Firmly push the emergency door glass from outside while pulling
one end of the string from inside to fit the cab side mounting
groove of the weatherstrip to the flange lip area of the body.

while tapping the emergency door glass from outside with a rub-
ber hammer to stabilize it.
• If the edge of weatherstrip does not stick on the flange lip area of
the body at the corners (4 places), apply adhesive to stick it fast.
63-61
EMERGENCY DOOR
Door Locking System
1 Controller panel
2 Door lock controller
3 Insulator
4 Upper door lock
5 Latch
6 Stopper
7 Striker
8 Shim
9 Emergency door panel
Assembly sequence
verse.

2 Play in handle of door lock controller 0 to 5 – Adjust or replace

Adhesive surface of insulator Cemedine 180 As required
Installation: Upper door lock
• Turn the regulation pin of the upper door lock to adjust the dis-
tance between the rod end and the center of the regulation pin to
the dimension as shown in the illustration.
• Apply adhesive to the slits of the insulators.
• Install the insulators in the upper door lock at regular intervals.
63-62
63
Installation: Door lock controller
• Turn the regulation pin of the door lock controller to adjust the
distance between the rod end and the center of the regulation
pin to the dimension as shown in the illustration.
Inspection after installation

Inspection: Play in handle of door lock controller
• If the measured value deviates from the standard value, turn the
regulation pin of the rod to adjust the play.
• If there is any abnormality, replace the door lock controller.
63-63
TRUNK LID
1 Ball joint 7 Retainer 13 Shim
2 Damper stay 8 Lock cylinder 14 Weatherstrip
3 Hinge 9 Latch 15 Weatherstrip
4 Christmas tree clip 10 Handle
5 Trim 11 Trunk lid panel : Non-reusable part
6 Water-proof film 12 Striker
Assembly sequence
• After installation, perform trunk lid fitting adjustment. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)

Water-proof film mounting surface of trunk lid panel Butyl rubber tape As required
63-64
63
Installation: Water-proof film
proof film mounting surface as shown in the illustration and then
install the water-proof film.
63-65
AUTOMATIC DOOR SYSTEM <FOLDING DOOR>
Removal sequence
1 Clevis pin 6 Tail bracket 12 Cover
2 Cylinder cover 7 Door bracket 13 Vacuum reservoir tank
3 Vacuum hose 8 Vacuum pipe
4 Emergency switch (See 9 Vacuum hose
*a: Side door (See “SIDE DOOR
Gr54.) 10 Vacuum hose <FOLDING>”.)
5 Cylinder (See later section.) 11 Limiting valve
* b: Vacuum pipe

Bolt (installation of tail bracket) 9 to 14 {0.9 to 1.4} –
Bolt (installation of limiting valve) 4 to 6 {0.4 to 0.6} –
Bolt (installation of cover) 10 to 15 {1.0 to 1.5} –
63-66
63
Installation: Vacuum pipe and vacuum hose
• Install the vacuum hose and vacuum pipe with the insertion
depth shown in the illustration and secure them with the hose
clip.
Installation: Cylinder
• Check that cylinder mounting surface is flat. If there are irregu-
larities, mend the surface.
CAUTION
• If the cylinder is installed in the irregular mounting surface,
the door will not open and close smoothly.
• Determine the temporary installation positions for tail bracket

and door bracket in relation to the cylinder mounting hole. Then,
open and close the door to check that the stroke is as shown in
the illustration.
• After making sure that the door can be properly opened and
closed in the above temporary installation positions, secure the
tail bracket and set the adjustment screw.
• Open the door and pull out the clevis of the cylinder to the fully
closed position.
• Install the cylinder by aligning the door bracket with the center of
the play in clevis in the vertical direction.
63-67
AUTOMATIC DOOR SYSTEM <FOLDING DOOR>
• Loosen the nuts of the clevis part of the cylinder and door brack-
et to adjust the dimensions to those shown in the illustration
when the door is opened and closed.
• After installation, supply air to the cylinder, insert the clevis pin
into the door bracket and secure it with the cotter pin.
• Move the door manually again to make sure that it moves
smoothly and there is sufficient stroke.
CAUTION
• Make sure that the area around the door is safe when begin-
ning to supply air since the cylinder may suddenly operate.
63-68
63
Cylinder
1 Front hose 8 Cylinder tail 15 X-ring
2 Wiring harness 9 Clevis 16 Cylinder head
3 Solenoid valve unit 10 Boot 17 Felt
4 Stud bolt 11 Packing 18 Cylinder shell
5 Adjustment screw 12 O-ring
6 O-ring 13 Piston rod : Non-reusable parts
7 Packing 14 Packing
Assembly sequence
CAUTION
• Clean the cylinder tail, piston rod, cylinder head and cylinder shell with cleaning oil before assembly.

O-ring
Multipurpose grease
Sliding surface of cylinder inner surface As required
Packing
63-69
AUTOMATIC DOOR SYSTEM <SWING DOOR>
Removal sequence
1
2
Door lock actuator (See later section.)
Door engine cover
*a: Swing door arm
(See “SIDE DOOR <SWING>”.)
3
4
E-ring
Link collar
* b: Trim
(See “Swing Door Panel”.)
5 Door engine (See later section.)

Bolt (installation of door lock actuator) 4 to 9 {0.4 to 0.9} –
Bolt (installation of door engine)
17 to 26 {1.7 to 2.7} –
Nut (installation of door engine)
63-70
63
Removal procedure
Removal: Door lock actuator
• Remove the trim.
(See “Swing Door Panel”.)
• Remove the rod clip to disconnect the connection with the re-
mote control.
• Remove the mounting bolt to remove the door lock actuator.
Installation: Door engine
• Check that the door engine mounting surface is flat. If there are
irregularities, mend the surface.
CAUTION
• If the door engine is installed in the irregular mounting sur-
face, the door will not open and close smoothly.

Inspection: Operation of side door
• After installation, check that the door moves smoothly when op-
erated by hand.
Adjustment: Operation of micro switch (full open switch)

• Move the lever to adjust the clearance between the door and
front entrance pillar to 26 to 32 mm when the micro switch
makes a clicking sound.
63-71
AUTOMATIC DOOR SYSTEM <SWING DOOR>
Door Lock Actuator
1 E-ring
2 Link
3 Wave washer
4 Motor bracket
5 Lock motor
Assembly sequence
verse.
63-72
63
Door Engine
1 E-ring 8 Dog collar 15 Grommet
2 Joint pin 9 Rubber cover 16 Box bracket
3 Link 10 Wire harness set 17 Automatic door control box
4 Plate 11 Separator 18 Motor
5 Arm 12 Retainer 19 Gearbox
6 Plate spring 13 Red handle
7 Collar 14 Lever
Assembly sequence
63-73
WINDSHIELD AND REAR WINDOW GLASS
Removal sequence
1 Weatherstrip
2 Windshield
3 Weatherstrip
4 Rear glass

Glass fitting portion of weatherstrip Cemedine CS3061-6AL As required
Upper corners of windshield mounting surface Orotex BM4 × 8 As required
Entire periphery of windshield and rear glass mounting
Nitto Sealant No. 687 or equivalent As required
surfaces
63-74
63
Removal procedure
Removal: Windshield
push off the side door glass from the body from inside.

Preparation: Installation of windshield and rear glass
• Remove the sealant stuck to the body. Mend the paint coating if
it is scratched or rusted.
• Clean the entire adhesive surface of the body with unleaded
gasoline and let it dry for at least 3 minutes.
• If the removed glass is reused, remove the adhesive from the
glass, clean the adhesive surface with unleaded gasoline and let
it dry for at least 3 minutes.
Installation: Windshield and rear glass
<Windshield>
• Apply the sealant A (Orotex BM4 × 8) to the areas of the body
shown in the illustration.
• Apply the sealant B (Nitto Sealant No.687) to the entire periph-
ery of the windshield mounting surface of the body.
• Install the weatherstrip in the windshield so that the water drain

holes and joints come at the positions shown in the illustration.
63-75
WINDSHIELD AND REAR WINDOW GLASS
<Rear glass>
• Apply the sealant B (Nitto Sealant No.687) to the entire periph-
ery of the rear glass mounting surface of the body.
• Install the weatherstrip with its joint at the center of the door.
<Windshield and rear glass>

weatherstrip as shown in the illustration.
• Apply soapy water to the weatherstrip and fit the windshield or
the rear glass properly into the body.
• Firmly push the windshield or the rear glass from outside while
pulling one end of the string from inside to fit the cab side mount-
ing groove of the weatherstrip to the flange part of the body.

while tapping the windshield or the rear glass from outside with a
rubber hammer to stabilize it.
63-76
63
• Fill the glass fitting portion of weatherstrip with the sealant.
63-77
SAFETY WINDOW GLASS
Removal sequence
1 Safety window glass
2 Fastener
3 Dam

Safety window glass surface Sika Cleaner No. 1 As required
Safety window glass adhesive surface Sika Flex 250PC-JM1 As required
Removal procedure
Removal: Safety window glass
• Insert a piano wire or a cutting machine in between the safety
window glass and body and separate them. Leave a layer of ad-
hesive at least 1 mm in thickness to prevent the paint coating
(ceramic film in the case of glass) from coming off.
• If the paint coating is come off, apply primer VP209. If the ce-
ramic film of the glass is come off, mend the glass by applying
black primer.

Preparation: Installation of safety window glass
• Remove the adhesive stuck to the safety window glass and
body. Leave a layer of adhesive at least 1 mm in thickness to
prevent the paint coating (ceramic film in the case of glass) from
coming off. Mend the coating if it is scratched or rusted.
• Clean the entire adhesive surface with unleaded gasoline and
let it dry for at least 3 minutes.
63-78
63
Installation: Safety window glass
• Fit the dam to the entire body side periphery of the safety win-
dow glass.
• Fit the fasteners to the appropriate positions in the glass and
body shown in the illustration.
• Apply the cleaner to the adhesive surface between the safety

window glass and body and leave it for 5 to 10 minutes.
CAUTION
• Carefully apply the cleaner to the spot dents and sheet
joints.
• Do not touch or let lubricant adhere to the adhesive surface
after the cleaner is applied.
• Apply adhesive to the entire circumference of safety window

glass as shown in the illustration.
CAUTION
• The adhesive application cross section should form a trian-
gle that has a bottom 8 mm wide and a height of 12 mm.
• Be sure to apply the adhesive evenly. The amount of the ad-
hesive tends to decrease or increase at the beginning and
end points of application and the corners.
• Since the adhesive is quick to dry, work on one window at a
time and finish installing the glass within 8 minutes after the
start of adhesive application.
• Since the adhesive is urethane, it has poor compatibility
with silicone sealer. For this reason, adhesion failure may
occur if their locations are not taken into consideration. If
the distance between them is less than 1 m, apply one of
them 24 hours after the other was applied. When the dis-
tance is more than 1 m, work on the vehicle in a sufficiently
ventilated place though this case poses no danger normal-
ly.
• Lift the safety window glass using suction cups or the like to
keep the application surface clean and install it in the body as
shown in the illustration. Push the fitting area lightly to engage
the fasteners fitted on the glass and body properly.
CAUTION
• If you should touch the application surface with bare hands
or lubricant should adhere to it, apply the adhesive again.
• Quickly remove adhesive that oozed out of the joints before it

dries and clean the glass with unleaded gasoline.
63-79
SIDE WINDOW GLASS <SLIDING WINDOW>
1 Joint cover 6 Packing
2 Side window trim 7 Glass
3 Clip 8 Run channel
4 Lock 9 Center seal
5 Connector 10 Side window sash
Assembly sequence

Entire backside circumference of side window sash Butyl rubber tape As required
63-80
63
Removal procedure
Removal: Side window sash
• Remove the joint cover, side window trim and clip from inside
the vehicle.
• Separate the adhesive surface between the side window sash

and body with a utility knife or piano wire (0.3 to 0.5 mm in diam-
eter).
CAUTION
• Separate them completely. A residual adhesive makes it
hard to remove the side window sash.
• Push off the side window sash to the outside with the glasses
moved to the center of the sash.
Removal: Glass
• Remove the glasses while lifting the upper frame of the sash.

Preparation: Installation of side window sash
• Remove the adhesive stuck to the body side pillar and clean it.
• Mend the paint coating if it is scratched or rusted.
63-81
SIDE WINDOW GLASS <SLIDING WINDOW>
Installation: Side window sash
• Remove butyl rubber tape completely from the body and side
window sash.
• Wipe off dirt, dust, grease and all other foreign matter from the
adhesive surface of the body with the side window sash using a
clean piece of gauze or cloth moistened with isopropyl alcohol.
• Attach butyl rubber tape to the entire backside circumference of
side window sash.
CAUTION
• Make sure the tape joint is at the bottom.
• Press-fit the side window sash to the body. Fit the clips at the po-
sitions shown in the illustration.
• Install the window trim in place and fit the joint cover at the joint.
CAUTION
• Locate the window trim joint at the position shown in the il-
lustration to prevent overlap with the clip.
• Install the joint cover with its longer flange inside.
63-82
63
M E M O
63-83
SIDE WINDOW GLASS <FIXED WINDOW>
1 Joint cover 5 Glass
2 Side window trim 6 Weatherstrip
3 Clip 7 Side window sash
4 Weatherstrip
Assembly sequence

Entire backside circumference of side window sash Butyl rubber tape As required
63-84
63
Removal procedure
Removal: Side window sash
• Remove the joint cover, side window trim and clip from inside
the vehicle.
• Separate the adhesive surface between the side window sash

and body with a utility knife or piano wire (0.3 to 0.5 mm in diam-
eter).
CAUTION
• Separate them completely. A residual adhesive makes it
hard to remove the side window sash.
• Push off the side window sash to the outside.

Preparation: Installation of side window sash
• Remove the adhesive stuck to the body side pillar and clean it.
• Mend the paint coating if it is scratched or rusted.
Installation: Glass
• Clean the edge of the glass with unleaded gasoline.
• Install the weatherstrip in the glass.
• Apply soapy water to the weatherstrip.
• Install the side window sash with the glass indication mark inside
the vehicle and under the side window sash.
63-85
SIDE WINDOW GLASS <FIXED WINDOW>
• Batten the side window sash and tap it lightly to install the glass
with the dimension shown in the illustration.
Installation: Side window sash

• Remove butyl rubber tape completely from the body and side
window sash.
• Wipe off dirt, dust, grease and all other foreign matter from the
adhesive surface of the body with the side window sash using a
clean piece of gauze or cloth moistened with isopropyl alcohol.
• Attach butyl rubber tape to the entire backside circumference of
side window sash.
CAUTION
• Make sure the tape joint is at the bottom.
• Press-fit the side window sash to the body. Fit the clips at the po-
sitions shown in the illustration.
• Install the window trim in place and fit the joint cover at the joint.
CAUTION
• Locate the window trim joint at the position shown in the il-
lustration to prevent overlap with the clip.
• Install the joint cover with its longer flange inside.
63-86
63
• Install the weatherstrip with side window sash.
63-87
FRONT BUMPER
1 Molding 7 Front bumper
2 Cap 8 Bumper bracket
3 Front grille 9 Splash shield <Without fog lamp>
4 Grommet
5 Head lamp bezel
*a: Front combination lamp (See Gr54.)
6 Head lamp bracket
*b: Head lamp (See Gr54.)
Assembly sequence

Bolt (installation of head lamp bracket, front bumper and
9 to 14 {0.9 to 1.4} –
bumper bracket)
Removal procedure
Removal: Molding
• Remove the clip and Velcro 1 with a screwdriver or the like. Take
care not to damage the clip.
• Remove Velcro 2. While pulling out the tab toward the vehicle
center, remove the molding.
CAUTION
• When removing the clip, take care not to scratch the body.
• If the molding is pulled by force, the tab may be broken.
63-88
REAR BUMPER 63
Removal sequence
1 Bracket *b:
a: Cross member
2 Rear bumper
3 Grommet
* Rear side panel

Bolt (installation of rear bumper and bracket) 9 to 14 {0.9 to 1.4} –
63-89
GARNISH
Removal sequence
1 Rear garnish
2 Trim clip
3 Weatherstrip
• Stick the weatherstrip (cut it to the appropriate length) on the
body at the positions shown in the illustration.
63-90
63
M E M O
63-91
INSTRUMENT PANEL
Lower Panel
1 Cigarette lighter 6 Driver side lower panel
2 Ashtray 7 Fuse box lid
3 Center lower panel 8 Lower side panel
4 Lower panel bracket
5 Idling speed adjustment knob
*a: Instrument panel (See later section.)
Assembly sequence
63-92
63
Area around Meter Cluster
1 Switch or plug 9 Box
2 Plug 10 Bracket
3 Switch or plug 11 Air conditioner control panel
4 Center upper panel 12 Bracket
5 Meter cluster (See Gr54.) 13 Heater controls (See Gr55.)
6 Radio bracket
7
8
Box
Radio or audio system (See Gr54.)
*a: Instrument panel (See later section.)
• The parts indicated with vary according to the specifications.
Assembly sequence
63-93
INSTRUMENT PANEL
Removal procedure
Removal: Switch or plug
Removal: Plug
63-94
63
Removal: Switch or plug
63-95
INSTRUMENT PANEL
Instrument Panel
63-96
63
Disassemble sequence
1 Instrument panel bracket 5 Air outlet grille
2 Oil tank lid 6 Center frame support
3 Glove compartment 7 Instrument panel support bracket
4 Instrument panel 8 Instrument panel frame
Assembly sequence

Bolt (installation of instrument panel) 5.3 ± 1 {0.54 ± 0.1} –
Bolt (installation of center frame support)
4.71 ± 1 {0.48 ± 0.1} –
Bolt (installation of instrument panel support bracket)
Bolt (installation of instrument panel frame) 11.2 ± 2 {1.14 ± 0.2} –
63-97
HEAD LINING <FRONT>
Removal sequence
1 Inside mirror
2 Sun visor
3 Air outlet grille (single and double)
4 Clock
5 Molding clip
6 End cap
7 Head lining molding
8 Front head lining
9 Head lining support rail
Removal procedure
Removal: Air outlet grille (single)
• Using a flat-blade screwdriver, remove the air outlet grille.
Removal: Head lining molding

• Lowering the head lining molding will bring the molding clip into
view. Cut it off using scissors or a utility knife.
CAUTION
• When cutting off the molding clip, be careful not to damage
the head lining.
63-98
63
M E M O
63-99
HEAD LINING <CENTER>
Removal sequence
1 Rack
2 Room lamp
3 Speaker
4 Air outlet grille
<With air conditioner>
5 Molding clip
6 End cap
8 Cooler duct cover
9 Head lining
10 Clip
11 Cooler duct <With air conditioner>
Trim <Without air conditioner>
12 Cooler duct sheet
<With air conditioner>
Work before removal

Preparation
• Remove the room lamp and speaker.
Removal procedure
Removal: Air outlet grille
• Using a flat-blade screwdriver, remove the air outlet grille.
63-100
63
CAUTION
the head lining.
Removal: Cooler duct cover
Removal: Head lining

• Remove the head lining from the upper groove in the cooler duct
to take it down from the roof.
Removal: Cooler duct and cooler duct sheet

• Remove the screws and open the cooler duct.
• Remove the clips and then remove the cooler duct sheet from
the body.
Removal: Trim
• Remove the screws and then remove the trim from the body.
63-101
HEAD LINING <REAR>
Removal sequence
1 Air outlet grille
2 Molding clip
3 End cap
5 Christmas tree clip
6 Louver
7 Frame
8 Rear head lining
9 Head lining support rail
Removal procedure
CAUTION
the head lining.
63-102
63
M E M O
63-103
OUTSIDE REAR VIEW MIRROR <DRIVER SIDE>
1 Mirror
2 Stay
Assembly sequence
verse.

Screw (installation of mirror) 4.9 to 5.88 {0.5 to 0.6} –
Screw (installation of stay) 4 to 6 {0.4 to 0.6} –
Installation: Stay
• Align the alignment marks as shown in the illustration and install
the stay.
63-104
OUTSIDE REAR VIEW MIRROR <PASSENGER SIDE> 63
1 Mirror
2 Under mirror
3 Stay
*a: Front panel
Assembly sequence
verse.

Screw (installation of mirror) 4.9 to 5.88 {0.5 to 0.6} –
Screw (installation of stay) 4 to 6 {0.4 to 0.6} Sealant

Notch in front panel
Orotex 725FW As required
Screw thread
Installation: Stay
• Align the alignment marks as shown in the illustration and install
the stay.
63-105
FRONT WIPER AND WASHER
Removal sequence
1 Wiper blade 7 Wiper link
2 Blade rubber 8 Washer nozzle
3 Wiper arm 9 Grommet
4 Seal rubber 10 Cable strap
5 Wiper motor (See Gr54.) 11 Tube
6 Motor bracket 12 Washer tank motor (See Gr54.)
CAUTION
• Remove the instrument panel before disassembling the wiper motor, motor bracket, wiper link, grommet,
cable straps and tube. (See “INSTRUMENT PANEL”.)
Service standards
Driver side 7.3 ± 0.5 N {740 ± 50 gf} – Replace
3 Wiper arm pressing force
Passenger side 6.2 ± 0.5 N {630 ± 50 gf} – Replace
63-106
63
Nut (installation of wiper arm) 23.8 ± 4.8 {2.4 ± 0.5} –
Bolt (installation of wiper link)
Bolt (installation of motor bracket) 4.7 ± 0.9 {0.5 ± 0.1} –
Bolt (installation of wiper motor)
Nut (installation of motor bracket) 11.2 ± 2.2 {1.1 ± 0.2} –

Entire circumference of seal rubber mounting surface
Cemedine 366 Deluxe As required
Entire circumference of washer nozzle mounting surface
Removal procedure
Removal: Washer nozzle
• Grip the washer nozzle with pliers.
• While bending the tabs, pull the washer nozzle to remove it.
Take care not to damage the exterior body panel.
• Remove the tube.
CAUTION
• Take care not to damage the washer nozzle.
Inspection: Wiper arm pressing force
• If the measurement deviates from the standard value, replace
the wiper arm.
Inspection: Washer nozzle

• Inspect the washer nozzle to make sure that it is not clogged.
• If the nozzle hole is clogged, clean it with a steel wire (0.9 mm in
diameter or less).
63-107
FRONT WIPER AND WASHER
Installation: Washer nozzle
• Connect the tube to install the washer nozzle.
Installation: Wiper arm and wiper blade

• Install the wiper arm and wiper blade so that the distance from
the weatherstrip falls within the ranges of dimensions shown in
the illustration.

Inspection: Washer fluid target point
[Inspection]
• Make sure that washer fluid target points are 400 mm above the
weatherstrip.
[Adjustment]
• If washer fluid target points are not in the appropriate locations,
adjust the angle of nozzle hole in the washer nozzle with a steel
wire.
CAUTION
• Take care not to damage the nozzle hole in the washer noz-
zle.
63-108
63
M E M O
63-109
REAR WIPER AND WASHER
Removal sequence
1 Cover 7 Washer nozzle
2 Wiper blade 8 Grommet
3 Blade rubber 9 Cable strap
4 Wiper arm 10 Tube
5 Pivot cap 11 Washer tank motor (See Gr54.)
6 Wiper motor (See Gr54.)
CAUTION
• The grommet, cable straps, tube and washer tank motor cannot be accessed without removing the trunk
trim. To disassemble the rear wiper and washer, remove the trunk trim first.
63-110
63
Service standards
4 Wiper arm pressing force 4.2 ± 0.4 N {430 ± 40 gf} – Replace

Nut (installation of wiper arm) 9 ± 2 {0.9 ± 0.2} –
Bolt (installation of wiper motor) 6.0 ± 1.5 {0.6 ± 0.15} –

Entire circumference of pivot cap mounting surface
Cemedine 366 Deluxe As required
Entire circumference of washer nozzle mounting surface
Removal procedure
Removal: Washer nozzle
• Grip the washer nozzle with pliers.
• While bending the tabs, pull the washer nozzle to remove it.
Take care not to damage the exterior body panel.
• Remove the tube.
CAUTION
• Take care not to damage the washer nozzle.
Inspection: Wiper arm pressing force
• If the measurement deviates from the standard value, replace
the wiper arm.
Inspection: Washer nozzle

• Inspect the washer nozzle to make sure that it is not clogged.
• If the nozzle hole is clogged, clean it with a steel wire (0.9 mm in
diameter or less).
63-111
REAR WIPER AND WASHER
Installation: Washer nozzle
• Connect the tube to install the washer nozzle.
Installation: Wiper arm and wiper blade

• Install the wiper arm and wiper blade so that the distance from
the weatherstrip falls within the ranges of dimensions shown in
the illustration.

Inspection: Washer fluid target point
[Inspection]
• Check that the washer fluid target point is approx. 550 mm
above and 70 mm left from the center of the wiper arm mount.
[Adjustment]
• If washer fluid target points are not in the appropriate locations,
adjust the angle of nozzle hole in the washer nozzle with a steel
wire.
CAUTION
• Take care not to damage the nozzle hole in the washer noz-
zle.
63-112
SEAT BELT 63
Removal sequence
1 Shoulder anchor cover
2 Emergency locking retractor
3 Buckle
CAUTION
• Do not disassemble the emergency locking retractor.

Bolt (installation of emergency locking retractor and seat belt)
34 to 54 {3.5 to 5.5} –
Bolt (installation of buckle)
63-113
(EURO 3)
chassis
FEBRUARY 2013
550 (H)
Pub.No.00ELB0011, FEBRUARY 2013

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Pub.No.

00ELB0011, FEBRUARY 2013

©2013 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

1. ENGINE volume (Pub.No.00ELB0010)

Group No. Group subject

2. CHASSIS volume (Pub.No.00ELB0011)

3. ELECTRICAL volume (Pub.No.00ELB0012)

VEHICLE MODEL CODING SYSTEM ................................................ 00-2

EQUIPMENT TYPE CODES LIST ...................................................... 00-3

POWER TRAIN TABLE ...................................................................... 00-4

HOW TO READ THIS MANUAL ......................................................... 00-6

JACKING UP THE VEHICLE............................................................ 00-26

TABLE OF STANDARD TIGHTENING TORQUES

1 Basic vehicle type B Front engine bus with frame

Power version number

Load carrying capacity of truck class (tonnage)

Vehicle type (B: Bus)

Vehicle type (B: Bus)

Tooth profile (H: Hypoid gear)

On-vehicle Inspection and Adjustment

DANGER Precautions that should be taken in handling potentially dangerous substances

Suggestions or supplementary information for more efficient use of equipment or

Terms and Units

• Left and right

Example: 390 N·m {40 kgf·m}

Unit SI unit {metric unit} Conversion factor

1.6 Major harness division

1.9 Code number: #001 to #999

• Vehicle identification number (VIN) <Type B>

(1) (2) (3) (4) (5) (6) (7)

(1) Geographic area

• An engine name plate indicates the following item.

• Perform service operations on a level surface. Before starting,

• Take extreme care when removing/installing heavy items such

• Never work in shoes that have oily soles.

• Prepare replacement parts ready for installation.

• To facilitate correct reassembly of parts, make alignment marks

• Wear safety goggles when using a grinder or welder. Wear

3. Handling of Sensors, Relays and Electronic Control Units

• When separating connectors, grasp the connectors themselves

• Before washing the vehicle, cover electrical parts to keep them

4. Handling Precautions for Electric Circuits

4.1 Inspection of harnesses

(1.2) Non-waterproof connectors

(2) Inspections with connectors separated

• When using a multimeter to check continuity, do not allow the

4.2 Inspection of connectors

• Check whether wires have been separated from their terminals

• Check that male and female terminals fit together tightly.

(2) Checking for loose terminals

4.3 Inspections when a fuse blows

• The main causes of short circuits are as follows:

4.4 Inspection of chassis ground

• Never disconnect the battery cables with the engine running.

• Never perform inspections using a high-voltage multimeter.

• Keep alternators dry.

• Never operate an alternator with the B and L terminals short-cir-

• Connectors and other parts to be checked are those included or

• Current flows backward as shown below.

1.1 Systems and diagnosis code displaying methods

1.2 Types of diagnosis codes

(2) Past diagnosis code

2. Access and Clearing of Stored Diagnosis Code