S1-YFCE18B - 1 (Chassis Vol 1 Euro 2)

(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧤ᤨ㧞㧟ಽ
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P, SG8J series,
equipped with J05E-TI, J08E-TI, P11C-TI engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner’s Manual.
All information and specifications in this manual are based upon the latest product information available at the time of print-
ing.
Hino Motors reserves the right to make changes at any time without prior notice.
This manual is divided into 12 sections with a thumb index for each section at the edge of the pages.
Please note that the publications below have also been prepared as relevant service manuals for the components and sys-
tems in this vehicles.
Manual Name Pub. No.

Chassis Workshop Manual S1-YFCE18B 2/2
J05E-TI Engine Workshop Manual S5-YJ05E12A
J08E-TI Engine Workshop Manual S5-YJ08E29B
P11C-TI Engine Workshop Manual S5-YP11E07B
(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧤ᤨ㧞㧟ಽ
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-YFCE18B 1/2

CHAPTER
MODELS FC9J, FD8J, GD8J, FG8J, GH8J, FL8J, FM8J, FM2P, SG8J
GENERAL INTRODUCTION GN02-001
CLUTCH MAIN UNIT CL02-001 (CS350) CL02-002 (CS380) CL02-003 (CS430)
CLUTCH CONTROL CL03-001
TR02-004 TR02-005
TR02-001 TR02-002 TR02-003 TR02-006
TRANSMISSION MAIN UNIT (EATON (EATON
(LX06S) (LJ06S) (MF06S) (ZF9S109)
FS6109) FS8209)
TR05-001 TR05-002 TR05-003

(TRANSMIS- (TRANSMIS- (TRANSMIS- TR05-004
P.T.O. (POWER TAKE-OFF)
SION SERIES: SION SERIES: SION SERIES: (EATON)
LX06S) LJ06S) MF06S)
TRANSMISSION/TRANSFER CONTROL TR06-001
PP02-001 PP02-002 PP02-003 PP02-004 PP02-005

PROPELLER SHAFT
(LD0932) (LF0932) (MC1040) (HD1050) (HE1160)
DF02-001 DF02-002 DF02-003 DF02-004 DF02-005

DIFFERENTIAL CARRIER
(SH13) (SH14) (SH16) (SH17) (THD17)
BR01-001
BR01-002
BRAKE EQUIPMENT (MODELS: WITH AIR OVER
(MODELS: WITH FULL AIR BRAKE)
HYDRAURIC BRAKE)
BR02-001
BR02-002
SERVICE BRAKE (MODELS: WITH AIR OVER
HYDRAURIC BRAKE)
BR03-002 BR03-003
BR03-001
ABS & ASR (WABCO, FOR AIR OVER (WABCO, FOR FULL
(DENSO)
HYDRAURIC BRAKE) AIR BRAKE)
ES START BR04-001 BR04-002

(EASY & SMOOTH START SYSTEM) (MODELS: WITH DENSO ABS) (MODELS: WITH WABCO ABS)
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INDEX: CHASSIS GROUP 1/1
GENERAL INTRODUCTION
CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
WORKSHOP CLUTCH CONTROL
MANUAL TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
TRANSMISSION / TRANSFER CONTROL
PROPELLER SHAFT EQUIPMENT
PROPELLER SHAFT
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
BRAKE EQUIPMENT
SERVICE BRAKE
ABS & ASR
ES START (EASY & SMOOTH START SYSTEM)

All rights reserved. This manual may not be
reproduced or copied in whole in part, with-
out the written consent of Hino Motors, Ltd.
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GENERAL INTRODUCTION GN02–1
GN02
GN02-001
GENERAL INTRODUCTION.....................GN02-2
WARNING .......................................................GN02-2
HOW TO USE THIS MANUAL.........................GN02-3
PRECAUTIONS FOR WORK ..........................GN02-8
TIGHTENING OF BOLTS
AND NUTS FOR ENGINE .............................GN02-13
TIGHTENING OF BOLTS
AND NUTS FOR CHASSIS ...........................GN02-15
TIGHTENING OF FLARE NUTS
AND HOSES..................................................GN02-17
SEALANT ON THE TAPERED SCREW
FOR PIPING ..................................................GN02-18
NYLON TUBE ................................................GN02-19
ASSEMBLY OF JOINT/GASKET
FOR PIPING ..................................................GN02-22
HANDLING OF LIQUID GASKET..................GN02-24
TROUBLESHOOTING
USING THE TROUBLE LIST.........................GN02-25
TROUBLESHOOTING
USING A DIAGNOSIS MONITOR .................GN02-26
DIAGNOSIS USING THE PC
(PERSONAL COMPUTER)
DIAGNOSIS TOOL WITH INTERFACE.........GN02-30
CHASSIS SERIAL NUMBER,
VEHICLE IDENTIFICATION NUMBER
AND ENGINE SERIAL NUMBER ..................GN02-33
RECOMMENDED LUBRICANTS ..................GN02-34
GN02–2 GENERAL INTRODUCTION
WARNING
EN00Z0002C100001
In order to ensure safety in work and avoid possible damage to vehicle, strictly observe the following precautions:
Audience of this manual is a qualified service engineer who has acquired expertise. In case an unqualified service engi-
neer or a service engineer without appropriate training has performed maintenance, or in case maintenance is performed
without using appropriate tools and units or in accordance with the method described in this manual, the vehicle under
maintenance could be damaged as well as do harm to the service engineer and the people in the maintenance site.
• Appropriate maintenance and repairs are a must for assurance of safety of the service engineer as well as the safety
and reliability of the vehicle. Replace parts of the vehicle with HINO genuine parts. Avoid using degraded parts.
• This manual contains the procedures to follow in performing maintenance and repairs. When performing mainte-
nance and repairs in accordance with the procedures, use special tools designed to meet specific needs in a proper
way.
• Never use a non-recommended work method or tool; this could impair the safety of the service engineer as well as
the safety and reliability of your vehicle.
• This manual contains various items classified into DANGERS, WARNINGS, CAUTIONS and NOTICES in order to
avoid accidents during maintenance and repairs or damage to the vehicle resulting in impairment of its safety and
reliability.
Note that these instructions described as DANGERS, WARNINGS, CAUTIONS and NOTICES are not the minimum
requirements to observe in order to avoid possible dangers.
HOW TO USE THIS MANUAL

EN00Z0002C100002
1. REPAIR WORK
(1) The repair work is roughly classified into the three processes: "diagnosis", "mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work" and "final inspection".
(2) This manual describes the first process "diagnosis" and the second process "mounting/dismounting, replacement,
assembly/disassembly and inspection/adjustment work". Description on the third process "final inspection" is omitted.
(3) While this manual does not describe the following element work, the work is to be performed in practical cases:
a. Jack work and lift work
b. Cleaning of removed parts as required
c. Visual inspection
2. TROUBLESHOOTING IN THIS MANUAL

(1) This manual describes the following steps 2 and 3.
Thoroughly listen to the conditions and environment for the trou-

(1) Interview "Step 1"
ble and confirm the fact.
Perform diagnostic inspection, checkup of the symptom, function

(2) Pre-inspection
"Step 2" inspection and basic inspection to confirm the trouble. If the trou-
(3) Replication method
ble hardly recurs, use the replication method.
Classify the inspection results obtained in step 2 to systematically

(4) Troubleshooting by diagnosis code
"Step 3" perform inspection accordance with the troubleshooting proce-
(5) Troubleshooting by trouble
dure by diagnosis code or trouble.
Check for the trouble after the trouble is removed. In case the
(6) Checkup test "Step 4" trouble is hardly replicated, conduct a checkup test under the con-
ditions and environment for the trouble.
(2) Pre-inspection
• Execute the following steps to perform pre-inspection.

Diagnostic inspection → diagnosis code erasure → trouble check (If the trouble does not recur,
use the replication method.) → Diagnosis code re-check
• Assume the faulty system before the replication test. Connect a tester and determine a proba-
ble cause of trouble together with checkup of the trouble. For a probable cause of trouble, refer
to the troubleshooting chart.
Pre-inspection
• In case the trouble is momentary or in case an error code is displayed but no special trouble
takes place, execute related troubleshooting procedures while using the replication method.
• Trouble checkup
In case the trouble recurs, follow steps 2, 3 and 4 in this order.
Otherwise, use the replication method, that is, reproduce the external conditions, and inspect
each wire harness and connector parts.
3. DESCRIPTION IN THIS MANUAL

(1) Component Locator
SHTS00Z000200001
✩: This is the ID number of an item to be prepared for creating electronic data and is not necessary for repair work.
(2) Work item
SHTS00Z000200002
4. DEFINITION OF TERMS
This manual defines the terms used herein as follows:
(1) Direction
a. Chassis
• To-and-fro direction
The direction of forward travel of the vehicle while mounted on the vehicle is forward direction; the direction of back-
ward travel of the vehicle while mounted on the vehicle is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the vehicle is clockwise direction; the counterclockwise direction as
seen from the rear of the vehicle is counterclockwise direction. (In case of engine, the clockwise direction as seen
from the flywheel side is clockwise direction; the counterclockwise direction as seen from the flywheel side is counter-
clockwise direction.)
• Upward/Downward direction
The upward direction while mounted on the vehicle is upward, and downward direction while mounted on the vehicle
is downward.
• Right/Left direction
The right direction as seen from the rear of the vehicle while mounted on the vehicle is right direction; the left direc-
tion as seen from the rear of the vehicle while mounted on the vehicle is left direction. (In case of engine, the right
direction as seen from the flywheel side is right direction; the left direction as seen from the flywheel side is left direc-
tion.)
b. Standalone unit
• To-and-fro direction
The direction of input of power is forward direction; the direction of output of power is backward direction.
• Direction of rotation
The clockwise direction as seen from the rear of the unit is clockwise direction; the counterclockwise direction as
seen from the rear of the unit is counterclockwise direction.
• Upward/Downward direction
The upward direction while the unit is mounted on the vehicle (chassis) is upward, and downward direction while the
unit is mounted on the vehicle (chassis) is downward.
• Right/Left direction
The right direction as seen from the rear of the unit is right direction; the left direction as seen from the rear of the unit
is left direction.
(2) Standard value (Assembly standard):
Indicates a basic dimension or including the tolerance and the clearance generated by the clearance of a combina-
tion of two parts
(3) Limit (Service limit):
Indicates a numeric value which requires correction or replacement.
5. DEFINITION OF SAFETY TERMS
Indicates an extremely hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a potential hazardous situation if proper procedures are not followed and
could result in death or serious injury.
Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.
Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.
Provides additional information to help you to perform the repair efficiently.

6. UNIT
(1) This manual uses the SI unit system. The SI unit is an international unit which is based on one unit per quantity unlike
the conventional unit system which differs from country to country, in order to facilitate technology exchange.
(2) This manual writes the SI unit and a conventional unit side by side, the conventional unit enclosed in parentheses { }.
Conven- Conversion value*1 Conven- Conversion value*1

SI unit tional (1[Conventional unit] SI unit tional (1[Conventional unit]
unit = X [SI unit]) unit = X [SI unit])
Spring 1 kgf/mm=
Force N kgf 1 kgf=9.80665 N N/mm kgf/mm
constant 9.80665 N/mm
1 kgf⋅cm=
Torque*2 N⋅m kgf⋅cm Volume L cc 1 cc=1 mL
0.0980665 N⋅m
1kgf/cm2=
2
kgf/cm 98.0665 kPa= Efficiency W PS 1 PS=0.735499 kW
Pressure Pa 0.0980665 Mpa
Quantity
mmHg 1mmHg=0.133322 kPa W⋅H cal 1 kcal=1.13279 W⋅h
of heat
r/min. 1 rpm=1 r/min. Fuel con-
Rotation 1 g/PS⋅h=
rpm sumption g/W⋅h g/PS⋅h
speed min.-1 1 rpm=1 min.-1 ratio
1.3596 g/kW⋅h
*1: X is a value obtained by converting 1 [conventional unit] to an SI unit and is used as a conversion factor of the
conventional unit and SI unit.
*2: The torque conversion value may depend on the unit. Follow the specific value described for each unit.
PRECAUTIONS FOR WORK

EN00Z0002C100003
GENERAL PRECAUTIONS
To assure safety in work and prevent possible danger, observe the following:
1. CLOTHES AND APPEARANCE

(1) Use safety glasses.
(2) To prevent injury, remove a watch, necktie, ring, bracelet and necklace.
(3) Bind long hair behind.
(4) Wear a cap and safety boots.
2. SAFETY WORK
(1) To prevent burns, never touch a radiator, muffler, exhaust pipe, and tail pipe just after the engine is turned off.
(2) While the engine is rotating, keep your clothes and tools off the rotating sections, in particular the cooling fan and V-
belt.
(3) Remove the starter key except when starting the engine.
(4) Provide good ventilation to avoid excessive CO when starting the engine.
(5) The fuel/battery gas is flammable. Never make a spark or light a cigarette.
(6) Take utmost care when working on the battery. It contains corrosive sulfuric acid.
(7) Large electric current flows through the battery cable and starter cable. Be careful not to cause a short, which can
result in personal injury and/or property damage.
(8) Leaving a tool or waste in the engine room causes the tool or waste to touch the rotating section of the engine and
pop out, which could result in an injury.
3. TOWING
• When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to
protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame
near the No.1 crossmember when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct con-
tact with the bumper.
(1) Towing procedures
a. Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle
shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle
lubricant and entry of dirt or foreign matter.
b. Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the
frame. The hook should be used only if the towed vehicle is not loaded.
c. The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-
tical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in
towing a vehicle trapped in a gutter.
d. Keep the gear shift lever in "Neutral".
e. Make sure that the starter switch is kept in the "ON" position.
f. Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum
will be available for the brake. This is dangerous, as the brake system does not function if the engine is not run-
ning.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually
hard to turn, making it impossible to control the vehicle.
g. Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
h. Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.
(2) If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed for
that purpose.
a. Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect
the transmission and differential gears from being damaged. The hub openings should be covered to prevent the
loss of axle lubricant or the entry of dirt or foreign matter.
The above-mentioned precautions should be observed for vehicles equipped with either automatic or manual
transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with
lubricant if necessary.
b. Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight
ahead position.
PRECAUTIONS ON MAINTENANCE
Observe following before maintenance:
1. PREPARATIONS FOR DISASSEMBLY

(1) Prepare general tools, special tools and instruments before work.
(2) Before disassembling complicated sections, make a fitting mark where functions are not affected to facilitate the
assembly work. Before repair of the electrical system, remove the cable from the minus terminal of the battery.
(3) Follow the inspection procedure in this manual before disassembly
2. INSPECTION DURING DISASSEMBLY

(1) Each time you remove a part, inspect the state of the assembly of the part, deformation, damage, wear and flaws.
3. ARRANGEMENT OF DISASSEMBLED PARTS

(1) Arrange the disassembled parts in order. Discriminate parts to be reused from replacement parts.
4. CLEANING OF DISASSEMBLED PARTS

(1) Thoroughly clean the parts to be reused.
5. INSPECTION AND MEASUREMENT

(1) Inspect and measure the parts to be reused as required.
6. ASSEMBLY
(1) Observe the specified values (tightening torque, adjustment value) to assemble conforming parts in a correct proce-
dure.
(2) Use genuine parts for replacement.
(3) Use new packing, gasket, O-ring and cotter pin.
(4) Use a seal gasket depending on the location of gasket. Apply specified oil or grease to a sliding section where indi-
cated. Apply specified grease to the lip of the oil seal.
7. ADJUSTMENT WORK CHECK

(1) Use a gauge and a tester to adjust to the specified maintenance value.
PRECAUTIONS FOR ELECTRICAL SYSTEM
1. REMOVING THE BATTERY CABLE

(1) Before electrical system work, remove the cable from the minus
terminal of the battery in order to avoid burning caused by short-
circuiting.
LOOSEN (2) To remove the battery cable, fully release the nut to avoid damage
to the battery terminal. Never twist the terminal.
SHTS00Z000200008
2. HANDLING OF ELECTRONIC PARTS

(1) Never give an impact to electronic parts of a computer or relay.
(2) Keep electronic parts away from high temperatures and humidity.
(3) Never splash water onto electronic parts in washing the vehicle.
SHTS00Z000200009
3. HANDLING OF WIRE HARNESS

(1) Perform marking on a clamp and a clip and secure then in original
position so that the wire harness will not interfere with the end and
acute angle section of the body and a bolt.
(2) To attach a part, take care not to bite the wire harness.
SHTS00Z000200010
4. HANDLING OF CONNECTOR
(1) To remove a connector, hold the connector (indicated by an arrow
in the figure) to pull it out. Never pull the harness.
(2) To remove a connector with lock, release the lock then pull it out.
(3) To connect a connector with lock, insert it until it clicks.
(4) To insert a test lead into the connector, insert it from behind the
connector.
(5) In case it is difficult to insert a test lead from behind the connector,
prepare a harness for inspection and perform inspection.
SHTS00Z000200011
PRECAUTIONS FOR ELECTRIC WELDING
1. Improperly performing electric welding on the cab or chassis causes a backflow of the welding electric cur-
rent thus damaging various electrical equipment and electrical components. Observe the following in elec-
tric welding:
(1) Turn off the starter switch.
(2) Check that all switches are off.
(3) Follow the battery cable removal procedure to remove the minus terminal of the battery.
(4) Disconnect the connector of the computers.
(5) Remove all fuses.
(6) Ground the electric welder in the proximity of the welding section.
a. Welding to the frame
Ground the welder at a plated bolt or frame in the proximity of the welding section.
To ground at the frame itself, peel off the coating on the frame.
Grounding at a chassis spring is inhibited because it causes damage to the spring.
b. Welding to cab
Open the front panel and ground at the mounting bolt of the cab hinge or cab itself.
(7) Other precautions
a. To avoid sputter in welding, cover the rubber holes, wire harnesses, pipes, chassis springs and tires before work.
b. Perform welding under appropriate welding conditions in order to reduce influence of heat to the surrounding as
well as to secure the quality of welding.
(8) Once the welding work is complete, attach the removed fuse and the minus terminal of the battery in this order to
reconstruct the original structure.
In case the coating on frame or cab has been removed, apply rustproof coating of the same color.
(9) After reconstruction, perform functional checkup to ensure normal operation.
FLOW OF WELDING CURRENT
1. WITHOUT TREATMENT OF ITEMS (1) THROUGH (5)
EQUIPMENT GROUND
ELECTRONIC
UNIT
WELDER
CHASSIS FRAME
CAB GROUNDING WIRE
BATTERY
THE WELDING CURRENT FLOWS IN TWO DIRECTIONS: (A) FROM CAB

TO ELECTRONIC UNIT TO BATTERY TO WELDER GROUND AND (B)
FROM CAB TO CAB GROUND TO WELDER GROUND. THIS DAMAGES THE
ELECTRIC UNIT.
2. WITH TREATMENT OF ITEMS (1) THROUGH (5)
EQUIPMENT GROUND
ELECTRONIC
UNIT
WELDER
REMOVE THE FUSE. TURN OFF THE
STARTER SWITCH.
CHASSIS FRAME
CAB GROUNDING WIRE
BATTERY REMOVE THE MINUS TERMINAL.
THE WELDING CURRENT FLOWS LOOPS BACK TO THE WELDER WITHOUT

PASSING THROUGH THE ELECTRONIC UNIT.
SHTS00Z000200012
TIGHTENING OF BOLTS AND NUTS FOR ENGINE

EN00Z0002C100004
1. TIGHTENING TORQUE OF GENERAL STANDARD

(1) Washer based bolt
Unit: N⋅m {kgf⋅cm, lbf⋅ft}
Screw diameter x pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}
M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}
M10 x 1.5 (Coarse thread) 55 {560, 40} 68.5 {700, 51}
M12 x 1.25 (Fine thread) 108 {1,100, 80} 136 {1,390, 101}
M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1,280, 93}
M14 x 1.5 (Fine thread) 171.5 {1,750, 127} 216 {2,210, 160}
M14 x 2 (Coarse thread) 154 {1,570, 114} 199 {2,030, 147}
Remarks Bolt with the numeral "7" on its head Bolt with the numeral "9" on its head
NOTICE
8T bolt conforms to the standard of 7T bolt.
(2) With washer
Screw diameter x pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6 {60, 4.3} 10 {100, 7.2} 13 {130, 9.4}
M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}
M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}
M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}
M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1,200, 87}
M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1,100, 80}
M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1,500, 108} 186 {1,900, 137}
M14 x 2 (Coarse thread) 74 {750, 54} 132 {1,350, 98} 172 {1,750, 127}
Bolt with the numeral "4"
Bolt with the numeral "7"
on its head
on its head Bolt with the numeral "9"
Remarks Projection bolt
Stud with chamfered free on its head
Stud with rounded free
end face
end face
NOTICE
8T bolt conforms to the standard of 7T bolt.
R FACE (4T) C FACE (7T)

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2. PRE-COATED BOLT
A pre-coated bolt is a bolt having a thread coated with seal-
ant.
(1) Cases where sealant must be applied again
a. Pre-coated bolt is removed
b. Pre-coated bolt has moved during tightening torque inspec-
tion
(Loosened or tightened)
HINT
Torque check is to be made using the lower limit value. In case the
bolt has moved, retighten it in the following procedure:
SHTS00Z000200014 (2) How to reuse pre-coated bolt
a. Clean the bolt and the tapped hole (clean the tapped hole
also when the bolt is to be replaced).
b. Blow air to dry up the bolt.
c. Apply a specified sealant to the thread of the bolt.
3. TENSION CONTROL WITH ANGULAR TORQUING METHOD

IN PLASTIC REGION OF MATERIAL
(1) Precautions
Part of an engine uses the Tension control with angular torquing
method in plastic region of material.
This is different from the conventional tightening method. Follow
the instructions in each chapter.
SHTS00Z000200015
(2) Target region

Cylinder head bolt, crankshaft main bearing cap bolt, connecting
rod bearing, cap bolt and so on.
! CAUTION
Before assembly, measure the entire length of the bolt and if the
use limit is exceeded, replace the bolt with new one.
Apply engine oil to the bolt seat face and bolt thread.
SHTS00Z000200016
(3) Tightening after tightening at the pre-set seating torque.

Further tighten by 90° or 135° (a turn by 90° and another by 45°)
or 180° (two turns by 90°).
SHTS00Z000200017
TIGHTENING OF BOLTS AND NUTS FOR CHASSIS

EN00Z0002C100005
1. TIGHTENING TORQUE OF GENERAL STANDARD BOLT/NUT

(1) Selection of tightening torque
a. To select the tightening torque of a bolt, find the corresponding strength category in the table below. Select the
corresponding value from the tightening torque table given later.
b. To select the tightening torque of a nut, use the above method based on the mating bolt.
(2) Identification of bolt strength
a. Identification on the part itself
HEXAGON BOLT
On the hexagon bolt, the strength category is generally indicated on the head of the bolt by way of depression,
embossment, hollow and upset in accordance with the symbol in the table below.
Strength category 6T 7T 8T 9T 10T 11T 12T
Symbol on the part 6 7 8 q*1 10 11 12
(*1): 9 is likely to be confused with 6 so that 9 is represented in q.
HEXAGON NUT
The following tables shows examples of symbols to identify the strength category of hexagon nut on the nut itself.
(3) Types of general standard bolt and nut
Standard seat face Flanged seat face A Flanged seat face B

(4) Table of tightening torque of general standard bolt and nut (Standard seat face is shown as a typical case)
Strength category
4T 7T 9T
Bolt diameter
4.5±1.8 {50±20, 3.6±1.4}
(Cab)
M6 9.0±1.8 {90±20, 6.5±1.4} 11.5±2.0 {117±23, 8.5±1.6}
5.5±1.1 {60±10, 4.4±0.7}
(Chassis)
14.0±3.5
{140±40, 10.1±2.8} (Cab)
22.0±4.0 29.0±5.5
M8 17.0±3.0
{220±40, 15.9±2.8}*2 {300±60, 21.7±4.3}*2
{170±30, 12.3±2.1}
(Chassis)
57.0±11.0
43.0±8.5
{580±110, 41.9±7.9}*2
{440±90, 31.8±6.5}*2 (Cab)
27.0±5.0 (Cab)
M10 51.5±10.0
{276±55, 20.0±3.9} 68.5±13.5
{530±100, 38.3±7.2}
{700±140, 51±10}
(Chassis)
(Chassis)
76.0±15.0 100.0±20.0
{776±150, 56±10}*2 (Cab) {1,020±200, 74±14}*2 (Cab)
48.0±9.5
M12 91.0±18.0 120.0±24.0
{490±98, 35.4±7.0}
{930±180, 67±13} {1,220±240, 88±17}
(Chassis) (Chassis)
77.0±15.0 120.0±24.0 160.0±32.0
M14
{786±157, 57±11} {1,220±240, 88±17} {1,630±326, 118±23}
120.0±24.0 190.0±38.0 250.0±50.0
M16
{1,220±244, 88±17} {1,940±390, 140±28} {2,550±510, 184±37}
165.0±33.0 260.0±52.0 345.0±69.0
M18
{1,680±336, 121±24} {2,650±530, 192±38} {3,520±704, 255±50}
235.0±47.0 370.0±74.0 490.0±98.0
M20
{2,400±480, 174±34} {3,770±750, 273±54} {5,000±1,000, 362±72}
320.0±64.0 505.0±100.0 670.0±130.0
M22
{3,270±654, 236±47} {5,150±1,030, 372±74} {6,840±1,370, 495±99}
405.0±81.0 640.0±125.0 845.0±165.0
M24
{4,130±826, 299±59} {6,530±1,310, 472±94} {8,620±1,720, 623±124}
! CAUTION
• In case of tightening the bolt/nut with the flanged seat face A, the tightening torque value except *2 in the
table is to be increased by 10% from the indicated tightening torque value.
• In case of tightening the bolt/nut with the flanged seat face B, the tightening torque value *2 in the table is to
be increased by 20% from the indicated tightening torque value.
Note that for M8 the tightening torque value is constant for the flanged seat face B also.
• The bolt/nut with flanged seat B which is marked *2 in the table is compatible with a standard seat face as a
pair. Its tightening torque is the same as that of the standard seat face.
TIGHTENING OF FLARE NUTS AND HOSES

EN00Z0002C100006
1. TIGHTENING TORQUE OF PIPE FLARE NUT

Pipe outer
diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15
Material
15±5 25±5 36±5 52±7 67±7 88±8
Steel pipe {150±50, {250±50, {370±50, {530±70, {680±70, {900±80,
10.8±3.6} 18.1±3.6} 26.8±3.6} 38.3±5.0} 49.2±5.0} 65.1±5.7}
2. TIGHTENING TORQUE OF HOSE

Hose outer diameter
Hose outer diameter Hose outer diameter
φ13, φ20, φ22 metal fitting for
φ10.5 metal fitting PF3/8 metal fitting
packing
21.5±1.5 {215±15, 15.5±1.0}
Air hose 41.5±2.5 {425±25, 30.7±1.8} —
Meter gauge only 10 {100, 7.2}
Packing
Brake hose — —
51.5±7.5 {525±75, 38.0±5.4}
3. TIGHTENING TORQUE OF FLARE JOINT FOR NYLON TUBE

Nominal diameter of
M12 M16 M20
screw
Tightening torque 14.7±2 {150±20, 10.8±1.4} 29.4±5 {300±50, 21.7±3.6} 51.9±5 {530±50, 38.3±3.6}
4. TIGHTENING TORQUE OF LOCK NUT FOR BRASS JOINT

Nominal diameter of
M12 M16 M20 M27
screw
15±2 66±6 97±9 209±19
Tightening torque
{150±20, 10.8±1.4} {670±60, 48.4±4.3} {990±90, 71.6±6.5} {2,130±190, 154±13}
SEALANT ON THE TAPERED SCREW

FOR PIPING
EN00Z0002C100007
To the tapered thread of the air pipe joint is applied the sealant "LOC-
TITE #575". Follow the procedure below to remove/attach the piping.
1. REMOVAL
(1) The sealant (LOCTITE #575) has a high sealing capability. The
return torque of taper joint is about 1.5 times as high as the initial
tightening torque. To remove the joint, use a longer wrench.
(2) For replacement of joint in a place with poor workability, remove
the auxiliaries with the joint attached then remove the joint.
SHTS00Z000200023
2. ATTACHING
(1) To apply sealant (LOCTITE #575), use waste and thinner to wipe
the dirt off the sealing section, directly apply the sealant by a
quarter turn (three ridges) starting from the second ridge from the
tip, then assemble in accordance with the tightening torque table
below.
Wipe dirt off the mating part (female screw) before tightening it.
! WARNING
In case the sealant has entered your eye or attached to your skin,
wash it away in running water.
SHTS00Z000200024
Tightening torque of tapered joint Unit: N⋅m {kgf⋅ft, lbf⋅ft}
Screw diameter
1/4 3/8 1/2
Material
49±10
Steel {500±100, 64±15 {650±150, 47±10}
36.2±7.2}
25±5 34±5 44±5
Aluminum, brass {250±50, {350±50, {450±50,
18.1±3.6} 25.3±3.6} 32.5±3.6}
(2) To replace vulcanized tape with sealant, remove the tape before-
hand, same as (1).
NOTICE
Take special care not to let dirt and foreign matters enter the pip-
ing.
(3) In the event of air leakage after sealant is applied and piping
attached, retightening cannot check the air leakage. Follow the
steps (1) and (2) to reassemble the piping.
NYLON TUBE
EN00Z0002C100008
1. TYPES OF JOINT
(1) Nylon tube joints have two types: one-touch connector joint and
sleeve nut joint.
! CAUTION
Function and quality of a nylon tube and each joint are guaranteed
as a set. Use HINO genuine parts. Otherwise a burst or break may
result.
Structure of joint and components
One-touch connector joint Sleeve nut joint
2. ONE-TOUCH CONNECTOR JOINT

(1) Remove the one-touch connector joint.
SHTS00Z000200027
a. Check that there is no dust or dirt in the proximity of the con-

nector end. If any, use air blow to remove dust or dirt before
removal.
SHTS00Z000200028
b. To remove the connector, pull out the nylon tube at a stroke in

the axial direction while holding down the retainer of the con-
nector. Use a dedicated special tool to hold down the retainer
of the connector.
Size of special tool
Tube outer diameter Part No. Name
φ6 S0942-11510
φ8 S0942-11520
φ10 S0942-11530 Release tool
φ12 S0942-11540
SHTS00Z000200029
φ15 S0942-11550
Set in above five
S0942-11560 Release tool set
sizes
c. To connect the connector joint, give a mark such as taping at

the tube insertion length and insert the tube to the position of
the mark.
! CAUTION
Fully insert the nylon tube to the position although shock is felt
two times as the nylon tube passes through the retainer hook and
O-ring.
Tube outer diameter Tube insertion length (mm {in.})

φ6 21.5-22.5 {0.847-0.885}
SHTS00Z000200030 φ8, φ10 22.0-23.0 {0.867-0.905}
φ12 22.5-23.5 {0.886-0.925}
φ15 24.0-25.0 {0.945-0.984}
d. After connection, pull the tube and check that the distance
from the connector end (retainer) to the taping at the insertion
length position is 5 mm {0.197 in.} or less.
3. SLEEVE NUT JOINT

(1) Connection of sleeve nut
a. To cut a nylon tube in a predetermined length, use a dedi-
cated special tool.
SST: Nylon Tube Cutter (S0946-01020)
! CAUTION
• Cut a tube only when there is extra length or when using a
new tube.
• When cutting a nylon tube, set the squareness of the tube
end with respect to the axis core within 90±5°.
SHTS00Z000200031
b. Thread the sleeve nut and sleeve in this order into the tube.
Then push in the insert at the tip.
! CAUTION
Take care of the assembling direction.
5 OR LESS
SHTS00Z000200032
c. For connection, push the insert until its end strikes the con-
nector/union while taking care not to let the sleeve nut, sleeve
INSERT and insert drop. In this state, fully tighten the sleeve nut with
hand. The position of sleeve nut is referred to as the "hand-
tightening position".
TUBE
CONNECTOR/UNION
d. Hold down the tube so that it will not move (come loose) and
tighten the sleeve nut in accordance with the torque in the
SLEEVE table below.
Tightening torque of sleeve nut Unit: N⋅m {kgf⋅cm, lbf⋅ft}
SLEEVE NUT Nominal diameter of screw x pitch Tightening torque
M12 x 1 (φ6) 23±5 {230±50, 16.6±3.6}
SHTS00Z000200033
M14 x 1.5 (φ8) 37±4 {380±40, 27.5±2.8}
M16 x 1.5 (φ10) 40±5 {410±50, 29.6±3.6}
M18 x 1.5 (φ12) 55±5 {560±50, 40.5±3.6}
(2) Assembly of sleeve nut (removing the tube from the joint and re-
attaching it in the same position)
MATCH MARK a. Give a match mark between the connector/union and the
sleeve nut before loosening the sleeve nut so as to memorize
the position.
b. For reassembly, tighten the sleeve nut up to the previous posi-
tion (match mark position). After that, retighten by 60°.
c. After reassembly, check for air leakage, if any, retighten until
the leakage stops.
d. If the leakage persists, replace the tube, sleeve and insert
with new ones. If this does not stop the leakage, replace the
SHTS00Z000200034 sleeve nut and connector/union as well.
4. HANDLING OF NYLON TUBE

(1) Types of nylon tube
Tube outer Operating tem-

Tube indication
diameter perature range
-40-90°C
DIN tube φ6, φ10, φ12
{-40-194°F}
! CAUTION
• Never repair a nylon tube under high temperatures exceeding
the operating temperature range, in particular when drying
the coating.
• For punching, welding and sanding, protect a nylon tube
from tools, cutting, heat source or spark or remove the nylon
tube.
• Never attach the clamp of the welder near the tube.
• Never splash acidic liquid such as battery liquid onto the
tube.
• Never exceed the minimum bending radius R of the nylon
tube listed in the table below. Avoid using a tube with trace of
bending line.
Minimum bending radius in use:

Tube outer diameter
R (mm {in.})
φ6 30 {1.181}
φ8 50 {1.969}
φ10 65 {2.559}
φ12 70 {2.756}
φ15 80 {3.150}
(2) Fixing the nylon tube

a. To fix the nylon tube to a vehicle, use a dedicated clamp and a
dedicated special tool or clamping tool available on the mar-
ket.
SST:
Clamp (S4783-71230)
Nylon Tube Tensioning Tool Assembly (S0962-01010)
Tool available on the market: Clamping tool (Tyton MK6)

Clamping torque (reference): 166.6 N {17 kgf, 37.5 lbf}
! CAUTION
SHTS00Z000200036
• Set the tool clamping force to "3" on the dial.
• If the nylon tube is fixed with nonconforming clamping force,
the nylon tube may be damaged.
ASSEMBLY OF JOINT/GASKET FOR PIPING

EN00Z0002C100009
1. TIGHTENING TORQUE OF JOINT

Metal seal system
Seal system Gasket seal system (Flare pipe system, nipple connector system)
(aluminum+rubber or copper)
Tightening screw size Type A Type B
M8 13 {130, 9.4}
M10 20 {200, 14} 11 {110, 8.0}
M12 25 {250, 18} 20 {200, 14}
M14 25 {250, 18} 31 {320, 23}
M16 29 {300, 22} 39 {400, 29}
M18 39 {400, 29} 59 {600, 43}
M20 *39 {400, 29} 64 {650, 47}
M24 69 {700, 51} 20 {200, 14}
M28 *127 {1,300, 94}
2. JOINT ASSEMBLY PROCEDURE AND POST-INSPECTION

(1) Before starting assembly, check that there is no dust or burr on each seat surface (mating part, pipe joint, gasket).
(2) Pipes are provided with the degree of freedom in assembly. The seat face is likely to be tilted. Temporarily tighten the
pipe then perform final tightening in order to avoid leakage.
(3) When the tightening is complete, apply a regular pressure to each pipe joint and check that there is no leakage.
(4) Observe the above tightening torque values.
NOTICE
When a soft washer of the aluminum plus rubber carbon press-fitting type is once mounted then loosened or
removed, replace it with a new one. This does not apply to normal retightening.
3. EXAMPLES OF JOINT SYSTEM FOR PIPING
Metal seal system

Gasket seal system
Type A (Flare pipe system) Type B (Nipple connector system)
HANDLING OF LIQUID GASKET

EN00Z0002C100010
1. APPLICATION OF LIQUID GASKET AND ASSEMBLY OF PARTS

(1) Thoroughly remove the old liquid gasket on each part and mating part and clean the parts by using waste to wipe off
oil, water and dust.
Overlap the coating at the beginning and end of coating.
(2) To assemble coated part, beware of any dislocation from the mating part. If any dislocation is found, coat the part
again.
(3) Finish assembly within 20 minutes of completion of liquid gasket application.
If 20 minutes is exceeded, remove the liquid gasket and apply it again.
(4) Wait at least 15 minutes after assembly of parts before starting the engine.
2. REMOVING PARTS
(1) To remove each part, never twist a single section but twist the part in alternate directions at the collar or clearance on
the flange. When removing gasket, take care not to let the refuse of gasket enter the engine.
3. OTHER
(1) When the liquid gasket comes in a tube, use the supplied winding tool. When the gasket comes in a cartridge, use a
spray gun.
Note that the cutting position of the nozzle of the tube provides necessary width of application.
1: Approx. 2 mm {0.079 in.} when cut at the first segment

2: Approx. 5 mm {0.197 in.} when cut at the second segment
TROUBLESHOOTING USING THE TROUBLE LIST

EN00Z0002F200001
SHTS00Z000200050
TROUBLESHOOTING USING A DIAGNOSIS MONITOR

EN00Z0002F200002
1. DIAGNOSIS MONITOR
(1) When connected to the diagnosis connector dedicated to each
system, the diagnosis monitor indicates a faulty section with
sound and light.
SST: Diagnosis Monitor (S0963-01370)
SHTS00Z000200051
2. CONNECTION OF DIAGNOSIS MONITOR

(1) Turn "ON" the starter switch.
(2) Connect a dedicated harness to the black (or white) connector out
of the central diagnosis connectors (total 2) at the lower right sec-
tion of the instrumental panel at the driver's seat, and connect the
diagnosis monitor to the connector having the tag of "each system
name".
SST: Dedicated Harness (S0963-02300)
SHTS00Z000200052
! CAUTION
The central diagnosis connectors are normally connected to the
(RIGHT-HAND DRIVE)
fixing dummy connectors. Remove the central diagnosis connec-
FIXING DUMMY tors from the dummy connectors before using them. When the
CONNECTOR central diagnosis connectors are not used, they should be
engaged into the fixing dummy connectors.
HINT
• Turning "ON" the starter switch with the diagnosis monitor
BLACK CONNECTOR connected causes the diagnosis monitor to keep sounding
without outputting diagnosis monitor codes. First turn "ON"
the starter switch, wait at least ten seconds, and connect the
WHITE CONNECTOR
diagnosis monitor.
SHTS00Z000200053
• The method for outputting diagnosis monitor codes differs
from system to system. Follow the instruction in the chapter
for each system.
SHTS00Z000200054
TAG AND SYSTEM NAME OF DEDICATED HARNESS
Tag name Name of system to be diagnosed
1 STD: ENG Common rail
3 STD: AIR BAG Not used
5 STD: ABS/ASR ABS
7 STD: ES START ES START
10 STD: VSC Not used
11 STD: TIRE Not used
2 OPT: RTD/4WD Not used
4 OPT: SHAKAN Not used
6 OPT: AIR SUS Not used
8 OPT: IDL STOP Not used
9 OPT: ATM Not used
12 OPT: PRO SHIFT Not used
DEDICATED HARNESS (S0963-02300) 2 1
4 3
10 6 5
8 7
12 11 9
SHTS00Z000200055
3. INDICATION OF DIAGNOSIS MONITOR CODE

(1) Diagnosis code can be checked on the diagnosis monitor and
check engine light. For example, diagnosis codes 32 and 21 are
indicated as described below. The indication method uses the
blinking interval of light. For the first code, "3" in the ten place illu-
minates for 0.5 seconds three times and twice after 1.5 seconds.
For the second code, the light illuminates twice and once for the
same period as the first code after an interval of 4.3 seconds; this
operation is repeated. In case there is no fault in the system, light
repeats blinking for 3 seconds.
HINT
Indication of a diagnosis code in the figure below is a typical
example. For details, refer to chapter on each system.
INDICATION OF DIAGNOSIS MONITOR CODE (EXAMPLE)
WHEN CODES 32 AND 21 ARE INDICATED:

0.5 SECONDS 0.5 SECONDS
LIGHT ON
LIGHT OFF
4.3 SECONDS
1.5 SECONDS CODE 21

CODE 32 THE OPERATION IS REPEATED
WHEN THE SYSTEM IS NORMAL
0.3 SECONDS
LIGHT ON
LIGHT OFF
SHTS00Z000200056
4. ERASURE OF PAST FAULTS

(1) Record the first output diagnosis monitor code.
(2) Remove the diagnosis monitor with the starter key in the "ON"
position.
! CAUTION
• If the starter key is placed in "LOCK" position, the past faults
are not erased. Keep the starter key "ON".
• Erase the malfunction code memory using the PC DIAGNO-
SIS TOOL (Hino DX).
(3) Wait at least 5 seconds. Connect the diagnosis monitor to output
SHTS00Z000200057 the current fault information.
5. HOW TO USE TROUBLESHOOTING BY DIAGNOSIS MONI-

TOR CODE
(1) The "diagnosis code table" and "Troubleshooting by code" are
shown for each system which outputs diagnosis codes. In case
the diagnosis code is identified, troubleshooting may be initiated
referring to the code list.
SHTS00Z000200058
DIAGNOSIS USING THE PC (PERSONAL COMPUTER) DIAGNOSIS

TOOL WITH INTERFACE
EN00Z0002F200003
1. DIAGNOSIS TOOL
• Trouble diagnosis can be performed using the PC diagnosis tool.
By connection to the diagnosis connector, the trouble location is
indicated.
SST:
Interface Box (Hino-Bowie) (S0912-11040)
Cable between vehicle & Hino-Bowie (S0904-21220)
Diagnosis software: HINO Diagnostic explorer (DX)
Reprogramming software: HINO Reprog Manager
SHTS00Z000200059 NOTICE
Only ECU reprogramming can be performed by authorized HINO
dealer.
2. CONNECT THE PC DIAGNOSIS TOOL

(1) Turn the starter switch to the "LOCK" position.
(2) Connect the diagnosis cable between diagnosis connector and
interface.
(3) Connect the interface to the PC.
(4) Turn the starter switch to the "ON" position.
(5) The opening menu will be displayed on the PC screen.
(LEFT-HAND DRIVE) (RIGHT-HAND DRIVE)
P P
INTER FACE
DIAGNOSIS DIAGNOSIS
CONNECTOR CONNECTOR
SHTS00Z000200060
3. CONNECTION OF SIGNAL CHECK HARNESS

(1) To prevent damage to ECU connector and improve workability,
connect a signal check harness. Perform measurement while
placing the test lead on the signal check connector of the signal
check harness.
a. Remove the connector from ECU.
! CAUTION
Take care not to snap off the lock lug of the connector.
b. Connect a signal check harness to the vehicle harness and
ECU.
SST: Signal Check Harness (for common rail type fuel injec-
tion system) (S0904-91080)
(2) Terminal number
ECU terminal numbers in the text correspond to connectors of
signal check harness as shown below.
SHTS00Z000200061
SHTS00Z000200062
.
(EXAMPLE)
CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER AND ENGINE
SERIAL NUMBER
ENGRAVED EN00Z0002C100011
POSITION
1. VEHICLE MODEL AND CHASSIS SERIAL NUMBER OR VEHI-
CLE IDENTIFICATION NUMBER
(1) Vehicle model and chassis serial number or vehicle identification
number are engraved near the front wheel of the right or left frame
SHTS00Z000200063 of the vehicle. When ordering parts, notify us of these numbers for
quick support.
(2) At the step inside the right door of the cab is attached an identifi-
(RIGHT-HAND DRIVE) cation plate stamped the vehicle model and chassis serial number
or vehicle identification number.
IDENTIFICATION
PLATE
SHTS00Z000200064
(LEFT-HAND DRIVE)
IDENTIFICATION
PLATE
SHTS00Z000200065
2. ENGINE MODEL AND ENGINE SERIAL NUMBER

(1) Engine model and engine serial number are engraved on the right
side of the cylinder block.
When ordering parts, notify us of these numbers for quick sup-
port.
ENGRAVED
POSITION
SHTS00Z000200066
RECOMMENDED LUBRICANTS
EN00Z0002C100012
No. LUBRICANTS POSITION VISCOSITY RECOMENDATIONS (SAE)

1 Engine oil Cylinder block
(JASO: DH-1, DH-2*1)
(API: CD*2, CE*2, CF, CH-4,
CI-4, CJ-4)
(ACEA: E-3, E-4, E-5*1, E-6)
*1: HINO recommends these

oil to the EURO4/EPA07 regu-
lation countries, and use
ultra-low sulfur fuel only.
*2: These oil grades do not

comply with the latest
exhaust emission (EURO4/
EPA07 etc.) regulations, and
HINO cannot recommend the
use of these oil grades.
2 Gear oil Transmission:
(API: GL-4) LX06S, LJ06S, MF06S
Gear oil Transmission:

[API: CD (Mineral oil)] EATON
FS6109, FS8209
Gear oil
(API: GL-4)
Eaton Approved Synthetic oil

Eaton Approved Semi-Syn- —
thetic oil
3 Hypoid gear oil Differential (Rear):
(API: GL-5) SH13, SH14, SH16, SH17,
THD17
4 Gear oil Steering

(API: GL-4)
No. LUBRICANTS POSITIONS

5 Power steering fluid (ATF DEXRON) Integral power steering gear
6 Brake fluid (DOT-3) or (DOT-4) Brake
7 Clutch fluid (DOT-3) or (DOT-4) Clutch
8 Wheel bearing grease Wheel hub
Lithium base wheel bearing grease NLGI No.2 LITH-
IUM-SOAP
9 Chassis grease Steering, suspension, etc.
Lithium base multipurpose grease No.2
2A%.AA%52HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧠ಽ
CLUTCH MAIN UNIT (CS350) CL02–1
CLUTCH MAIN UNIT (CS350)

CL02
CL02-001
CLUTCH ASSEMBLY (CS350) ................. CL02-2

DATA AND SPECIFICATIONS.........................CL02-2
DESCRIPTION .................................................CL02-3
TROUBLESHOOTING......................................CL02-4
SPECIAL TOOL ................................................CL02-5
COMPONENT LOCATOR ................................CL02-6
OVERHAUL ......................................................CL02-7
INSPECTION AND REPAIR ...........................CL02-13
CL02–2 CLUTCH MAIN UNIT (CS350)
CLUTCH ASSEMBLY (CS350)

DATA AND SPECIFICATIONS
EN0220402I200001
CLUTCH FACING Unit: mm {in.}
Sintered metal
Material Molded non-asbestos
(Ceramic metal)
Type Dry single plate with damper spring
Outside diameter 350 {13.780}
Inside diameter 220 {8.661}
Thickness 4.5 {0.1772} 4.41 {0.1736}
COMPRESSION SPRING Unit: mm {in.}
Clutch cover parts No. 3130
Free length 83.4 {3.283}
Coil outside diameter 30.5 {1.201}
Diameter of wire 5.5 {0.217}
Quantity 12
Setting load 1,243.5 N {126.8 kgf, 279.5 lbf}
Setting length 54.8 {2.157}

DESCRIPTION
EN0220402C100001
SHTS022040200001
1 Clutch disc hub 10 Torsion spring

2 Rivet 11 Release lever
3 Clutch facing 12 Pressure plate
4 Clutch plate 13 Spring seat
5 Damper spring 14 Compression spring
6 Clutch cover 15 Strap plate
7 Release lever pin 16 Friction washer
8 Release lever support 17 Strap plate bolt
9 Release lever support nut 18 Lock plate
TROUBLESHOOTING
EN0220402F300001
Symptom Possible cause Remedy/Prevention

Clutch dragging Clutch disc distorted or warped. Replace clutch disc.
Release lever incorrectly adjusted. Adjust release lever.
Transmission input shaft worn. Replace input shaft and check clutch
hub for excessive wear. If worn,
replace disc. Check flywheel housing
alignment.
Clutch slipping Release lever and release bearing Adjust clearance.
clearance incorrectly adjusted.
Clutch disc facing gummed with oil or Replace facing or disc assembly.
grease.
Release bearing worn. Replace bearing.
Clutch pedal free-play incorrectly Adjust free-play.
adjusted.
Compression spring weak. Replace compression spring.
Clutch facing worn. Replace facing or disc assembly.
Vehicle vibrates when starting. Improper engine idling. Adjust idling.
Clutch control incorrectly adjusted. Adjust clutch control.
grease.
Glazed flywheel friction surface. Unglazed flywheel surface with coarse
emery cloth, stroking parallel to
machining lines.
Clutch disc distorted or warped. Replace disc.
Improper clutch cover tightening. Tighten bolts.
Flywheel housing misalignment. Replace flywheel housing.
Noisy clutch Release bearing worn or dried. Replace release bearing.
Pilot bearing worn. Replace pilot bearing.
Clutch disc distorted or warped. Replace clutch disc.
Transmission input shaft or clutch disc Clean and lubricate or replace.
spline worn.
Insufficient lubrication of pedal and its Lubricate.
accessories.
Insufficient lubrication of release bear- Lubricate.
ing hub.
Transmission input shaft retainer Clean or replace if rusted.
rusted or soiled.
adjusted.
Clutch pedal can not be depressed. Clutch control incorrectly adjusted. Adjust clutch control.
Insufficient lubricant release bearing Lubricate.
hub.
Change in clutch pedal give. Air trapped in clutch fluid. Bleed air.
SPECIAL TOOL
EN0220402K100001
Prior to starting a clutch main unit overhaul, it is necessary to have these special tools.
Illustration Part number Tool name Remarks
CLUTCH PRESSURE PLATE

SH112-61070
FIXING BOLT
SL611-01024 PLAIN WASHER
CLUTCH PILOT BEARING

S0965-01970
PULLER
S0942-01442 SLIDING HAMMER
CLUTCH RELEASE LEVER

S0966-11030
HEIGHT GAUGE
S0966-21200 CLUTCH ALIGNING ARBOR

2A%.AA%52HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧞ಽ
COMPONENT LOCATOR
EN0220402D100001
SHTS022040200008
1 Pilot bearing 11 Release lever

2 Clutch facing 12 Bushing
3 Disc assembly 13 Release lever pin
4 Rivet 14 Torsion spring
5 Pressure plate 15 Cotter pin
6 Spring seat 16 Plain washer
7 Compression spring 17 Release lever support
8 Friction washer 18 Release lever support nut
9 Clutch cover 19 Lock plate
10 Strap plate bolt 20 Fitting bolt
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 37.5-48.5 {380-500, 28-36} C 9.8-14.7 {100-150, 7-10}
B 39.2-49.0 {400-500, 29-36}
OVERHAUL
EN0220402H200001
IMPORTANT POINT - DISMOUNTING
1. REMOVE THE CLUTCH COVER AND DISC.

(1) Install the four pressure plate fixing bolts and plain washers
through the clutch cover into the tapped holes in the pressure
plate.
SST:
Pressure Plate Fixing Bolt (SH112-61070)
Plain Washer (SL611-01024)
(2) Tighten the bolts in diagonal direction alternately and evenly to

the compress the compression springs and release pressure
SHTS022040200009
plate tension.
(3) Loosen the fitting bolts.
! CAUTION
When removing the clutch cover and clutch disc, be careful not to
drop them on your foot.
IMPORTANT POINTS - DISASSEMBLY
1. DISASSEMBLE THE CLUTCH COVER.

(1) Before removing the special tools and the strap plate bolt, com-
press the clutch cover to release the compression spring tension.
(2) Slowly release the press.
SHTS022040200010
NOTICE
Before disassembling, make aligning marks on the clutch cover
and pressure plate.
SHTS022040200011
2. DISASSEMBLE THE RELEASE LEVER ASSEMBLY.

(1) Remove the pin and the release lever.
SHTS022040200012
IMPORTANT POINTS - ASSEMBLY
1. REPLACE THE CLUTCH FACING.

(1) Drill off the rivets with a 5 mm {0.197 in.} diameter drill.
NOTICE
Do not remove the clutch facing with a tapping rod and a hammer
or a press.
(2) Remove the old facing.
(3) Place the new facing on the clutch plate and insert the rivets into
the holes so that the facing is held in position. (Secure the rivets
with adhesive tape to prevent loosing them.)
(4) Using a suitable riveter, rivet the new facing. In order to distribute
pressure evenly, rivet in diagonal direction alternately.
(5) Using a dial gauge, check the misalignment of the clutch disc after
riveting.
SHTS022040200013
2. REPLACE THE PILOT BEARING.

(1) Remove the pilot bearing.
SST:
Pilot Bearing Puller (S0965-01970)
Sliding Hammer (S0942-01442)
SHTS022040200014
(2) Using a suitable tapping rod, install the pilot bearing.

NOTICE
After installing the pilot bearing, ensure that it rotates smoothly.
SHTS022040200015
3. INSTALL THE RELEASE LEVER.

(1) Assemble the release lever, release lever support and torsion
spring, then install the release lever assembly on the pressure
plate.
NOTICE
• Do not coat any grease on the bushing.
• Coat lithium base grease to the sliding part between the
clutch release lever and the pressure plate.
SHTS022040200012
4. INSTALL THE CLUTCH COVER.

(1) Install the clutch cover in position according to the aligning marks.
Compress the clutch cover to relieve the compression spring ten-
sion.
SHTS022040200010
NOTICE
• When compressing the clutch cover, be sure to hook up the
torsion springs between clutch cover and release lever.
• When compressing the clutch cover, pull the release lever
support up through the holes in the clutch cover.
• Be sure to insert the compression spring upper seats in the
pressure cover.
SHTS022040200011
(2) Temporarily tighten the release lever support nuts.

NOTICE
Coat the spherical seat of the clutch cover and threaded section of
the release lever support with a small amount of anti-seizure
agent.
SHTS022040200016
(3) Install the four pressure plate fixing bolts with the plain washers
plate.
SST:
SHTS022040200017
(4) Install the strap plate bolt with the friction washer and lock washer.
SHTS022040200018
IMPORTANT POINTS - MOUNTING
1. INSTALL THE CLUTCH DISC ON THE FLYWHEEL.

(1) Insert an aligning arbor or splined input shaft through the clutch
disc hub and into the flywheel pilot bearing to position the clutch
disc.
SST: Clutch Aligning Arbor (S0966-21200)
Disc hub diameter A: 36 mm {1.417 in.}
SHTS022040200019
2. INSTALL THE CLUTCH COVER ASSEMBLY.

(1) Insert the clutch cover aligning pins into each place of the clutch
cover.
(2) Tighten the bolts evenly. Make several presses around the clutch
cover until it is snug.
(3) Remove the pressure plate fixing bolts and plain washer.
(4) Remove the clutch aligning arbor.
NOTICE
When installing a new clutch cover assembly, do not forget to
remove the four pressure plate fixing bolts from the clutch cover.
SHTS022040200020
3. ADJUST THE RELEASE LEVER HEIGHT WHEN INSTALLING

A NEW CLUTCH DISC.
(1) Adjust the clearance of the contact surface between the special
tool and the release lever by turning the release lever support nut.
Clearance: Zero
SST: Clutch Release Lever Height Gauge (S0966-11030)
SHTS022040200021
4. INSTALL THE LOCK PLATE.

NOTICE
Be sure to lock the support nut with the lock plate.
SHTS022040200022
INSPECTION AND REPAIR

EN0220402H300001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
Molded 2.0-2.6 0.1 Replace disc Measure

Non-asbestos {0.0788-0.1023} {0.0039} assembly or fac-
ing.
Rivet head
depth Sintered metal Flywheel 1.2 0.1 Replace disc Measure
(Celamicmetal) side "A" {0.0472} {0.0039} assembly or fac-
ing.
Flywheel 2.4
side "B" {0.0945}
Clutch disc misalignment 0-0.7 0.7 Replace. Measure

{0-0.0275} {0.0275}
Oily facings Loose rivets — — Replace disc Visual check

Broken or loose damper assembly,
springs if necessary.
Clearance between clutch 0.05-0.15 0.3 Replace the Measure

disc hub and transmission {0.0020-0.0059} {0.0118} clutch disc or
input shaft spline the transmis-
sion input shaft.
Pressure plate misalign- Less than 0.5 Regrind the fric- Measure
ment 0.1 {0.0039} {0.0197} tion surface or
replace.
Pressure plate thickness 24 {0.945} 23 {0.906} Replace. Measure
Pressure plate friction sur- — — Regrind the fric- Visual check

face scoring or roughness tion surface or
replace,
if necessary.
Compression spring free 83.4 {3.283} 79.2 Replace. Measure

length {3.118}
Compression spring — 5.0 {0.197} Replace. Measure

squareness
Compression spring set- 1,243.5 N 1,181.3 N Replace. Measure

ting load at the specified {126.8 kgf, 279.5 lbf} {120.5 kgf,
setting length at 54.8 {2.157} 266 lbf} at
54.8
{2.157}
Flywheel misalignment — 0.15 Regrind the fric- Measure

{0.059} tion surface or
replace.
Flywheel friction surface — — Regrind the fric- Visual check

scoring or roughness tion surface or
replace,
if necessary.
Pilot bearing improper rota- — — Replace, Visual check

tion if necessary.

CL02
CL02-002

DESCRIPTION .................................................CL02-3
SPECIAL TOOL ................................................CL02-5
OVERHAUL ......................................................CL02-7

EN0220502I200001
Sintered metal
(Ceramic metal)
Inside diameter 220 {8.661} —
Thickness 5.0 {0.197} 4.75 {0.187}
Quantity 12
Setting load 1,285.5 N {131 kgf, 288.8 lbf}
Setting length 59.6 {2.346}

DESCRIPTION
EN0220502C100001
SHTS022050200001
1 Clutch disc hub 10 Torsion spring

2 Rivet 11 Release lever
3 Clutch facing 12 Pressure plate
4 Clutch plate 13 Spring seat
5 Damper spring 14 Compression spring
7 Release lever pin 16 Friction washer
8 Release lever support 17 Strap plate bolt
9 Release lever support nut 18 Lock plate
TROUBLESHOOTING
EN0220502F300001

alignment.
grease.
adjusted.
grease.
machining lines.
spline worn.
accessories.
ing hub.
rusted or soiled.
adjusted.
hub.
SPECIAL TOOL
EN0220502K100001

SH112-61070
FIXING BOLT

S0965-01970
PULLER

S0966-11030
HEIGHT GAUGE

2A%.AA%52HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧞ಽ
COMPONENT LOCATOR
EN0220502D100001
SHTS022050200008
1 Pilot bearing 11 Release lever

2 Clutch facing 12 Bushing
5 Pressure plate 15 Cotter pin
6 Spring seat 16 Plain washer
7 Compression spring 17 Release lever support
8 Friction washer 18 Release lever support nut
9 Clutch cover 19 Lock plate
10 Strap plate bolt 20 Fitting bolt

A 64-84 {653-856, 48-61} C 9.8-14.7 {100-150, 7-10}
B 39.2-49.0 {400-500, 29-36}
OVERHAUL
EN0220502H200001

plate.
SST:

SHTS022050200009
plate tension.
! CAUTION

SHTS022050200010
NOTICE
and pressure plate.
SHTS022050200011

SHTS022050200012

NOTICE
or a press.
riveting.
SHTS022050200013

SST:
SHTS022050200014

NOTICE
SHTS022050200015

plate.
NOTICE
SHTS022050200012

sion.
SHTS022050200010
NOTICE
pressure cover.
SHTS022050200011

NOTICE
agent.
SHTS022050200016
plate.
SST:
SHTS022050200017
SHTS022050200018

disc.
SHTS022050200019

cover.
NOTICE
SHTS022050200020

A NEW CLUTCH DISC.
Clearance: Zero
SHTS022050200021

NOTICE
SHTS022050200022

EN0220502H300001
Unit: mm {in.}
Molded 2.2-2.8 0.1 Replace disc Measure

Non-asbestos {0.0866-0.1102} {0.0039} assembly or fac-
ing.
Rivet head
depth Sintered metal Flywheel 1.2 0.1 Replace disc Measure
(Celamicmetal) side "A" {0.0472} {0.0039} assembly or fac-
ing.
Flywheel 2.4
side "B" {0.0945}

{0-0.0275} {0.0275}
Oily facings Loose rivets — — Replace disc Visual check

Broken or loose damper assembly,
springs if necessary.
Clearance between clutch 0.05-0.15 0.3 Replace the Measure

disc hub and transmission {0.0020-0.0059} {0.0118} clutch disc or
input shaft spline the transmission
input shaft.
Pressure plate misalign- Less than 0.5 Regrind the fric- Measure
ment 0.1 {0.0039} {0.0197} tion surface or
replace.
Pressure plate friction sur- — — Regrind the fric- Visual check

face scoring or roughness tion surface or
replace,
if necessary.
Compression spring free 92.9 {3.657} 88.3 Replace. Measure

length {3.476}
Compression spring — 5.0 Replace. Measure

squareness {0.197}
Compression spring setting 1,285 N 1,181.3 N Replace. Measure

load at the specified setting {131 kgf, 288.8 lbf} {120.5 kgf,
length at 59.6 {2.346} 266 lbf} at
54.8
{2.157}
Flywheel misalignment 0-0.1 0.15 Regrind the fric- Measure

{0-0.0039} {0.059} tion surface or
replace.
Flywheel friction surface — — Regrind the fric- Visual check

scoring or roughness tion surface or
replace,
if necessary.
Pilot bearing improper rota- — — Replace, Visual check

tion if necessary.
2A%.AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧡ಽ

CL02
CL02-003

DESCRIPTION .................................................CL02-3
SPECIAL TOOL ................................................CL02-5
OVERHAUL ......................................................CL02-7

EN0220602I200001
Sintered metal
(Ceramic metal)
Inside diameter 250 {9.843} —
Thickness 5.0 {0.197} 4.95 {0.195}
Quantity 12
Setting load 1,496.5 N {152.6 kgf, 336.9 lbf}
Setting length 63 {2.346}

DESCRIPTION
EN0220602C100001
SHTS022060200001
1 Clutch disc hub 10 Release lever

3 Clutch facing 12 Release lever support
4 Clutch plate 13 Release lever support nut
5 Damper spring 14 Release lever pin
6 Pressure plate 15 Lock plate
8 Compression spring 17 Friction washer
9 Spring seat 18 Strap plate bolt
TROUBLESHOOTING
EN0220602F300001

alignment.
grease.
adjusted.
grease.
machining lines.
spline worn.
accessories.
ing hub.
rusted or soiled.
adjusted.
hub.
SPECIAL TOOL
EN0220602K100001

SH112-61080
FIXING BOLT

S0965-01020
PULLER

S0966-11020
HEIGHT GAUGE

COMPONENT LOCATOR
EN0220602D100001
SHTS022060200008
1 Clutch facing 10 Release lever support nut

3 Pressure plate 12 Release lever support
4 Spring seat 13 Torsion spring
5 Compression spring 14 Bushing
6 Clutch cover 15 Release lever
7 Friction washer 16 Cotter pin
8 Strap plate bolt 17 Rivet
9 Lock plate 18 Fitting bolt

A 64-84 {653-856, 48-61} C 9.8-14.7 {100-150, 8-10}
B 39.2-49.0 {400-500, 29-36}
OVERHAUL
EN0220602H200001

plate.
SST:

SHTS022060200009
plate tension.
! CAUTION

SHTS022060200010
NOTICE
and pressure plate.
SHTS022060200011

SHTS022060200012

NOTICE
or a press.
riveting.
SHTS022060200013

SST:
SHTS022060200014

NOTICE
SHTS022060200015

plate.
NOTICE
SHTS022060200012

sion.
SHTS022060200016
NOTICE
pressure cover.
SHTS022060200017

NOTICE
agent.
SHTS022060200018
plate.
SST:
SHTS022060200019
SHTS022060200020

disc.
SHTS022060200021

cover.
NOTICE
SHTS022060200022

A NEW CLUTCH DISC.
Clearance: Zero
SHTS022060200023

NOTICE
SHTS022060200024

EN0220602H300001
Unit: mm {in.}
Molded non-asbestos 2.2-2.8 0.1 Replace disc Measure

{0.0866- {0.0039} assembly or
0.1102} facing.
Rivet head
depth Sintered Flywheel 1.8 0.1 Replace disc Measure
metal side "A" {0.0708} {0.0039} assembly or
(Ceramic facing.
metal) Pressure 2.6
plate {0.1023}
side "B"

{0-0.512} {0.512}
Oily facings Loose rivets Broken or — — Replace disc Visual check

loose damper springs assembly,
if necessary.
Clearance between clutch disc hub 0.05-0.15 0.5 Replace the Measure
and transmission input shaft spline {0.0020- {0.0197} clutch disc or
0.0059} the transmis-
sion input
shaft.
Pressure plate Less than 0.5 Regrind the Measure

misalignment 0.1 {0.0039} {0.0197} friction surface
or replace.
Pressure plate friction surface — — Regrind the Visual check

scoring or roughness friction surface
or replace,
if necessary.
Compression spring free length 92.1 {3.626} 87.5 {3.445} Replace. Measure
Compression spring squareness — 5.0 {0.197} Replace. Measure
Compression spring setting load at 1,496.5 N 1,421.7 N Replace. Measure

the specified setting length {152.6 kgf, {145 kgf,
336.9 lbf} at 319.604 lbf}
63 {2.346} at 63 {2.346}
Flywheel misalignment — 0.2 {0.0079} Regrind the Measure

friction surface
or replace.
Flywheel friction surface scoring or — — Regrind the Visual check

roughness friction surface
or replace,
if necessary.
Pilot bearing improper rotation — — Replace, Visual check

if necessary.
2A%.AHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧤ಽ
CLUTCH CONTROL CL03–1
CLUTCH CONTROL
CL03
CL03-001
CLUTCH CONTROL UNIT........................ CL03-2

DESCRIPTION .................................................CL03-2
SPECIAL TOOL ................................................CL03-4
INSPECTION AND ADJUSTMENT ..................CL03-5
CLUTCH PEDAL AND RELEASE UNIT... CL03-9

OVERHAUL ....................................................CL03-16
CLUTCH MASTER CYLINDER .............. CL03-20

COMPONENT LOCATOR ..............................CL03-20
OVERHAUL ....................................................CL03-21
CLUTCH BOOSTER ............................... CL03-22

COMPONENT LOCATOR ..............................CL03-22
OVERHAUL ....................................................CL03-23
CL03–2 CLUTCH CONTROL
CLUTCH CONTROL UNIT

EN02Z0203I200001
CLUTCH BOOSTER Unit: mm {in.}
Engine series J08C-TI P11C
Power cylinder inside diameter 90 {3.543}
Hydraulic cylinder inside diameter 19.8 {0.780}
Relay valve piston outside diameter 14.3 {0.563} 12.7 {0.500}
Valve piston outside diameter 27.0 {1.063}
DESCRIPTION
EN02Z0203C100001
CLUTCH RELEASE UNIT
(REPRESENTATIVE TYPE)
SHTS02Z020300001
1 Release bearing 4 Release fork

2 Lubrication hose 5 Release fork shaft
3 Release bearing hub
MASTER CYLINDER
SHTS02Z020300002
1 Piston 4 Push rod

2 Reservoir tank 5 Return spring
3 Valve
CLUTCH BOOSTER
SHTS02Z020300003
1 Return spring 7 Retainer

2 Relay valve piston 8 Cylinder shell
3 Piston cup 9 Push rod
4 Poppet valve 10 Power piston
5 Hydraulic cylinder 11 Piston seal
6 Hydraulic piston
SPECIAL TOOL
EN02Z0203K100001
Prior to starting a clutch booster overhaul, it is necessary to have these special tools.
S0953-61020 STAND
S0965-31780 HOOK
S0965-72100 GUIDE
S0965-72090 GUIDE
S0965-72150 GUIDE ENGINE SERIES: J08C-TI
S0965-72160 GUIDE ENGINE SERIES: J08C-TI
S0965-71990 GUIDE ENGINE SERIES: P11C
S0965-72010 GUIDE ENGINE SERIES: P11C

INSPECTION AND ADJUSTMENT

EN02Z0203H300001
AIR BLEEDING
1. BLEED THE AIR FROM HYDRAULIC LINE.

NOTICE
• Do not mix the clutch fluid with different types or brands.
• Be careful not to spill clutch fluid from the reservoir tank or
from the air bleeder during air bleeding. Clutch fluid can
damage the paint finish on the body or floor.
• There are two methods of bleeding, gravity bleeding and
manual air bleeding.
2. GRAVITY BLEEDING
(1) Connect a funnel to a vinyl tube.
(2) Connect the other end of the vinyl tube to the bleeder screw.
(3) Hold the funnel about 1.5 m {4.92 ft} higher than the reservoir
tank.
(4) Loosen the bleeder screw and pour the clutch fluid into the funnel.
(5) Observe the flow of clutch fluid into the reservoir tank.
(6) When the air bubbles cease, close the bleeder screw.
(7) Check the fluid level. If necessary, add or remove clutch fluid in
order to match the "MAX" level.
1. Funnel filled with clutch fluid
2. Vinyl tube (inside diameter: 6 mm {0.24 in.})
3. Bleeder
4. Clutch booster
5. About 1.5 m {4.92 ft}
6. Clutch pedal
7. Master cylinder
SHTS02Z020300009
8. Reservoir tank
3. MANUAL BLEEDING
(1) Fill the reservoir with clutch fluid.
(2) Connect the bleeder tube to the clutch booster screw. Place the
other end of tube in a container half-filled with clutch fluid.
SHTS02Z020300010
(3) Slowly pump the clutch pedal several times. While pressing on the
pedal, loosen the bleeder screw. Repeat this procedure until there
are no more air bubbles in the fluid.
NOTICE
• Do not return the clutch pedal before closing the bleeder
screw.
• Keep the reservoir filled with clutch fluid.
• Re-bleeding will be necessary if the reservoir is emptied dur-
ing bleeding operation.
SHTS02Z020300011
(4) Check the fluid level. If necessary, add or remove clutch fluid in
RESERVOIR TANK
order to match the "MAX" level.
MAX.
NORMAL
MIN.
SHTS02Z020300012
4. AFTER BLEEDING, MAKE SURE THE PUSH ROD STROKE IS

AS SPECIFIED.
(1) Depress the clutch pedal fully and measure the push rod stroke. If
the stroke is less than standard, re-bleed the hydraulic system.
Transmission series Standard

LX06S,LJ06J,MF06S,
More than 19.5 mm {0.768 in.}
FS6109,FS8209
ZF9S109 More than 22.0 mm {0.866 in.}
SHTS02Z020300013
CHECK AND ADJUSTMENT
1. CHECK AND ADJUST THE CLUTCH PEDAL PLAY.

(1) Check the push rod play.
a. If necessary, adjust the push rod play.
1 STEP: PUSH ROD PLAY
2 STEP CLUTCH PEDAL PLAY
SHTS02Z020300014
b. Loosen the lock nut and turn the master cylinder push rod
until the push rod play is correct.
LOCK NUT
Standard:
PISTON Clearance between push rod and piston:
0.5 mm {0.0197 in}
Push rod play at pedal top: 2-4 mm {0.079-0.157 in.}
c. Tighten the lock nut.
PUSH ROD
SHTS02Z020300015
(2) Check the clutch pedal play.

a. Push the pedal until the beginning of clutch resistance is felt.
Engine series Assembly standard

J08C-TI 52-65 mm {2.048-2.559 in.}
P11C 62-78 mm {2.441-3.070 in.}
b. If necessary, adjust the clutch pedal play by adjusting the

clutch release bearing clearance.
c. Loosen the lock nut and turn the push rod counterclockwise
until the release bearing contacts the release lever.
SHTS02Z020300016
d. Turn the push rod clockwise about 2.5 turns.

(REPRESENTATIVE TYPE) Standard:
CLEARANCE
Clearance between release bearing and release lever:
2.0 mm {0.079 in.}
RELEASE
LEVER e. Tighten the lock nut.
RELEASE
BEARING
SHTS02Z020300017
2. CHECK THE CLUTCH PEDAL HEIGHT AND STROKE.

Assembly Standard:
Engine series J08C-TI P11C

169.2-179.2 mm 190.5 -200.5 mm
Pedal Height
{6.66-7.05 in.} {7.50-7.89 in.}
150-160 mm 180-190 mm
Pedal Stroke
{5.91-6.29 in.} {7.09-7.48 in.}
SHTS02Z020300018
3. CHECK THE LENGTH OF THE EXPOSED THREADED SEC-

TION OF THE PUSH ROD. IF ITS LENGTH IS LESS THAN THE
SERVICE LIMIT, IT IS TIME TO REPLACE THE CLUTCH FAC-
ING.
Transmission series Service limit

LX06S 18 mm {0.709 in.}
LJ06S 33 mm {1.299 in.}
MF06S, ZF9S109 20 mm {0.787 in.}
EATON FS6109/8209 11 mm {0.433 in.}
SHTS02Z020300019
CLUTCH PEDAL AND RELEASE UNIT

COMPONENT LOCATOR
EN02Z0203D100001
SHTS02Z020300020
1 Reservoir tank 10 Switch (For exhaust brake)

2 Master cylinder 11 Switch (For transmission P.T.O. control)
3 Return spring (If so equipped)
4 Cotter pin 12 Seal
5 Pin 13 Clip
6 Clutch pedal 14 Pedal shaft
7 Bushing 15 Pedal bracket
8 Bracket 16 Brake valve
9 Pedal pad

A 39-91 {398-927, 29-67} C 18-31 {184-316, 14-22}
B 9.5-18.5 {97-188, 7.1-13.5}
TRANSMISSION SERIES: LX06S
SHTS02Z020300021
1 Cotter pin 10 Set screw

2 Spring hanger 11 Release shaft
3 Pin 12 Key
4 Push rod 13 Release fork
5 Tension spring 14 Release bearing hub
6 Clutch booster 15 Release bearing
7 Bracket 16 Lubrication hose
8 Cover 17 Anti-rattle spring
9 Gasket

A 45.5-58.5 {465-597, 34-43} D 37.5-48.5 {383-495, 28-35}
B 37.5-48.5 {383-495, 28-35} E 37.5-48.5 {383-495, 28-35}
C 27.5-32.5 {281-331, 21-24} F 14.5-17.5 {148-178, 11-12}
TRANSMISSION SERIES: LJ06S
SHTS02Z020300022
1 Cotter pin 11 Release shaft bearing

2 Spring hanger 12 Lubrication fitting
3 Pin 13 Set screw
4 Push rod 14 Release shaft
5 Tension spring 15 Key
6 Clutch booster 16 Release fork
7 Bracket 17 Release bearing hub
8 Cover 18 Release bearing
9 Gasket 19 Lubrication hose
10 Clutch housing 20 Anti-rattle spring

A 45.5-58.5 {465-597, 34-43} E 37.5-48.5 {383-495, 28-35}
B 37.5-48.5 {383-495, 28-35} F 14.5-17.5 {148-178, 11-12}
C 37.5-48.5 {383-495, 28-35} G 246-322 {2,510-3,280, 182-237}
D 27.5-32.5 {280-330, 20-23}
TRANSMISSION SERIES: MF06S
SHTS02Z020300023
1 Cotter pin 11 Release shaft bearing

2 Spring hanger 12 Lubrication fitting
3 Pin 13 Set screw
4 Push rod 14 Release shaft
5 Tension spring 15 Key
6 Clutch booster 16 Release fork
7 Bracket 17 Release bearing hub
8 Cover 18 Release bearing
9 Gasket 19 Lubrication hose
10 Clutch housing 20 Anti-rattle spring

A 45.5-58.5 {465-597, 34-43} D 44.5-57.5 {454-586, 33-42}
B 64-84 {653-856, 47-61} E 344-460 {3,510-4,690, 254-339}
C 37.5-48.5 {383-495, 28-35} F 14.5-17.5 {148-178, 11-12}
TRANSMISSION SERIES: FS6109/8209

(MODELS FOR CHILE AND TAIWAN)
12
18 17
16
20 13 14
19
E 15
10
2
1
D Z
Z B
21
3
4 B
A
5 8
11
6
10
7 B
B B
9
C
SHTS02Z020300024
1 Release lever 12 Lubrication fitting

2 Key 13 Bushing
3 Pin 14 Release shaft
4 Clevis 15 Set screw
5 Cotter pin 16 Release fork
6 Spring hanger 17 Antirattle spring
8 Push rod 19 Lubrication hose
9 Clutch booster 20 Release bearing
10 Bracket 21 Clutch housing
11 Support

A 45.5-58.5 {465-597, 34-43} D 64-84 {653-857, 48-61}
B 37.5-48.5 {383-495, 28-35} E 48-62 {490-632, 35-45}
C 27.5-32.5 {280-330, 20-23}
(MODEL FOR THAILAND AND INDONESIA)
12
23
20
14
19 15
22 14
21 18
Y
E
17
16
F
10
2 14
1 12
D Z
Z
B 12 Y
3 13
4 B
A
5 8 12
6 10
7 11
B
B
C 9
SHTS02Z020300025
1 Release lever 13 Cover

2 Key 14 Bushing
3 Pin 15 Release shaft
4 Clevis 16 Wire
5 Cotter pin 17 Set screw
6 Spring hanger 18 Release fork
7 Tension spring 19 Antirattle spring
8 Push rod 20 Release bearing hub
9 Clutch booster 21 Lubrication hose
10 Bracket 22 Release bearing
11 Support 23 Clutch housing
12 Lubrication fitting

A 45.5-58.5 {465-597, 34-43} D 64-84 {653-857, 48-61}
B 37.5-48.5 {383-495, 28-35} E 70-78 {714-795, 52-57}
C 27.5-32.5 {280-330, 20-23} F 48-62 {490-632, 35-45}
TRANSMISSION SERIES: ZF9S109
SHTS02Z020300026
1 Cotter pin 11 Cover

2 Clevis 12 Gasket
3 Pin 13 Release fork
4 Push rod 14 Set screw
6 Clutch booster 16 Anti-rattle spring
7 Bracket 17 Lubrication hose
8 Spring hanger 18 Release bearing
9 Lubrication fitting 19 Key
10 Clutch housing 20 Release shaft

A 45.5-58.5 {465-597, 34-43} E 64-84 {653-857, 48-61}
B 37.5-48.5 {383-495, 28-35} F 14.5-17.5 {148-178, 11-12}
C 19-25 {193-255, 14-18} G 27.5-32.5 {280-330, 20-23}
D 167-223 {1,704-2,276, 124-164}
OVERHAUL
EN02Z0203H200001
IMPORTANT POINTS - DISMOUNTING
1. REMOVE THE PEDAL UNIT ASSEMBLY.

(1) Remove the 8 bolts and 2 nuts and dismount the pedal bracket
assembly from the vehicle.
NOTICE
Be careful not to damage the vehicle.
SHTS02Z020300027
2. REMOVE THE CLUTCH PEDAL.

(1) Remove the stroke sensor from the clutch pedal.
(2) Remove the clip, and tap the pedal shaft lightly to remove the
clutch pedal using a brass bar and a hammer.
SHTS02Z020300028
1. INSTALL THE CLUTCH PEDAL.

(1) Apply lithium grease to the inner side and outer periphery of the
bushing, and install the bushing to the inserting hole on the shaft
part of the clutch pedal.
(2) Install the clutch pedal to the installing axle for pedal shaft and
install the pedal shaft to the pedal bracket using a plastic hammer.
2. INSTALL THE PEDAL UNIT ASSEMBLY.
SHTS02Z020300028
3. INSTALL THE SWITCH FOR EXHAUST BRAKE AND TRANS-

MISSION P.T.O.
(1) Install the switch bushing into the switch bracket.
SHTS02Z020300029
(2) Push the switch into the switch bushing until the switch pounds
the buffer, then fix the switch by turning if clockwise.
NOTICE
Check that the switch body does not contact the buffer and also
that the switch rightly function.
SHTS02Z020300030
SHTS02Z020300031
1. REPLACE THE RELEASE BEARING.

(1) Using a suitable tool and a press, remove the bearing from the
release bearing hub.
SHTS02Z020300032
(2) Press the bearing into the hub.

NOTICE
• After installing the bearing, ensure that it rotates smoothly.
• The bearing is permanently lubricated and require no clean-
ing or lubrication.
• In order to prevent damage to the race surface, press fit
slowly by a press and do not apply impact loads.
SHTS02Z020300033
2. REPLACE THE RELEASE SHAFT BEARING.

(1) Using a suitable tool and a press, remove the bearings from the
clutch housing.
(2) Press the bearings into the housing.
SHTS02Z020300034
NOTICE
The bearing must be installed with red colored and engraved fac-
ing of the oil seal outward.
SHTS02Z020300035
3. APPLY BEARING GREASE OR HEAT RESISTANCE GREASE.

(1) Apply bearing grease to the following parts.
a. The release fork and the release bearing hub contact point.
b. The release bearing hub inner groove.
(2) Apply heat resistance grease to the transmission input shaft
spline.
NOTICE
Apply a small amount of grease to the spline.
SHTS02Z020300036

EN02Z0203H300002
Release bearing improper — — Replace release Visual check

rotation bearing,
if necessary.
Release fork and release — — Replace the Visual check

hub: parts,
Wear and damage if necessary.
Release shaft bearing: — — Replace the Visual check

Wear and damage parts,
if necessary.
CLUTCH MASTER CYLINDER

COMPONENT LOCATOR
EN02Z0203D100002
SHTS02Z020300039
1 Clevis 8 Body
2 Lock nut 9 O-ring
3 Push rod 10 Stopper bolt
4 Boot 11 Clamp
5 Retainer ring 12 Reservoir cap
6 Piston 13 Gasket
7 Return spring 14 Reservoir tank

A 11.5-16.9 {118-172, 8.5-12.4} B 2.4-4.4 {25-45, 1.9-3.2}
OVERHAUL
EN02Z0203H200002
1. REMOVE THE MASTER CYLINDER.

NOTICE
• Before removing the master cylinder, drain the clutch fluid
from the hydraulic line.
• Place a small drain pan under the master cylinder to catch
the hydraulic fluid. Do not let the clutch fluid remain on a
painted floor. Wash it off immediately.
IMPORTANT POINT - ASSEMBLY
1. INSTALL THE RETURN SPRING AND PISTON TO THE CYLIN-

DER.
NOTICE
Lubricate the cylinder bore and piston with clean clutch fluid.

EN02Z0203H300003
Piston seal and cup: — — Replace the pis- Visual check

Wear and damage ton assembly
Cylinder body bore: and/or cylinder
Scoring and corrosion body,
if necessary.
CLUTCH BOOSTER
COMPONENT LOCATOR
EN02Z0203D100003
SHTS02Z020300040
1 Poppet valve adapter 15 Soft washer

2 Gasket 16 Oil pipe connector
3 Conical spring 17 Pipe joint bolt
4 Poppet valve 18 Cup and washer retainer
5 Poppet valve body 19 Oil seal
6 O-ring 20 Push rod washer
7 Return spring 21 Retainer ring
8 Piston 22 Push rod
9 Piston cup 23 Piston seal
10 Push rod boot 24 Lock nut
11 Pin 25 Collar
12 Cylinder 26 Cylinder shell
13 Exhaust port 27 Hydraulic piston
14 Air bleeder

A 19.6-29.4 {200-300, 15-21} D 6.9-12.7 {70-130, 6-9}
B 3.9-5.9 {40-60, 2.9-4.3} E 27.5-32.5 {280-330, 20-23}(Engine series: J08C-TI)
C 14.7-19.6 {150-200,11-14} 44.5-57.6 {454-587, 33-42}(Engine series: P11C)
OVERHAUL
EN02Z0203H200003
1. REMOVE THE CLUTCH BOOSTER.

NOTICE
• Before removing the clutch booster, drain the clutch fluid
from the hydraulic line.
• Apply the parking brake and bleed the pressure from the air
brake system.
1. SET THE CLUTCH BOOSTER ON A STAND.

SST: Stand (S0953-61020)
NOTICE
Before disassembling the air booster, clean the outside of the
booster.
SHTS02Z020300041
2. DISASSEMBLE THE CONTROL VALVE.

(1) Remove the poppet valve adapter and gasket.
(2) Remove the conical spring and poppet valve.
(3) Remove the poppet valve body, return spring and piston.
SHTS02Z020300042
3. DISASSEMBLE THE CYLINDER.

(1) Remove the pin and piston.
(2) Remove the retainer ring.
(3) Remove the push rod washers, the cup and washer retainer, pis-
ton cup and the oil seal.
(4) Using the special tool, remove the O-ring.
SST: Hook (S0965-31780)
SHTS02Z020300043

• There is red colored and brown colored grease in the overhaul kit.
• The red colored grease should be used for the piston, the oil
seals, the O-rings, the piston cups on the end plate, hydraulic cyl-
inder and the relay valve.
• The brown colored grease should be used for the O-rings, the
gasket, the piston seal and the inside of the cylinder shell.
1. ASSEMBLE THE POWER PISTON.

(1) Apply the brown colored grease to the O-ring and install the O-
ring on the push rod.
SHTS02Z020300044
(2) After tightening the lock nut, secure the lock nut at three places
with a punch to prevent loosening.
SHTS02Z020300045
(3) Install the piston seal on the piston.
SHTS02Z020300046
(4) Apply the brown colored grease on the piston seal and the inside
of the cylinder shell.
SHTS02Z020300047
2. ASSEMBLE THE CYLINDER.

(1) Install the cup and washer retainer.
(2) Install the piston cup.
(3) Install the O-ring on the cup and washer retainer.
(4) Install the cup and washer retainer.
(5) Install the oil seal.
(6) Install the push rod washer.
(7) Install the retainer ring.
(8) Install the O-ring.
NOTICE
Coat the parts with red colored grease.
SHTS02Z020300048
3. INSTALL THE CYLINDER ASSEMBLY ON THE POWER PIS-

TON.
(1) Insert the control tube bushing and the seal on the control tube.
SHTS02Z020300049
4. ASSEMBLE THE HYDRAULIC CYLINDER.

(1) Using the special tools, install the piston cups on the piston.
SST:
Guide (S0965-72090)
Guide (S0965-72100)
SHTS02Z020300050
SHTS02Z020300051
(2) Apply the red colored grease on the piston cups, the piston and
the inside of the hydraulic cylinder.
SHTS02Z020300052
(3) Install the piston assembly in the hydraulic cylinder.

(4) Install the pin.
SHTS02Z020300053
5. ASSEMBLE THE PISTON.

(1) Install the piston cups and O-ring on the piston.
(2) Coat the cups with red colored grease.
SST:
Guide (Engine series: J08C-TI) (S0965-72150)
Guide (Engine series: P11C) (S0965-71990)
Guide (Engine series: J08C-TI) (S0965-72160)
Guide (Engine series: P11C) (S0965-72010)
NOTICE
• Take care not to damage the piston cups when installing
them on the piston.
SHTS02Z020300054
• Coat the O-ring and sliding surfaces with silicone grease as
shown in the figure.
6. INSTALL THE PISTON ASSEMBLY TO THE CYLINDER.
SHTS02Z020300055
7. INSTALL THE RETURN SPRING, O-RING, POPPET VALVE

BODY, POPPET VALVE AND CONICAL SPRING.
NOTICE
Coat the O-ring with brown colored grease.
SHTS02Z020300056
8. INSTALL THE ADAPTER.

(1) Coat the gasket with brown colored grease and install the gasket
on the adapter.
(2) Install the adapter on the poppet valve body and tighten it.
SHTS02Z020300057
IMPORTANT POINT - MOUNTING
1. INSTALL THE CLUTCH BOOSTER.

(1) Connect the air and hydraulic lines to the clutch booster.
(2) Install the tension spring.
SHTS02Z020300058

EN02Z0203H300004
Piston cup: — — Replace the Visual check

Cylinder body bore: if necessary.
Scoring and corrosion
Piston seal: — — Replace the Visual check

Power cylinder bore: if necessary.
Scoring and corrosion
2A64AA.:5A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧞ಽ
TRANSMISSION MAIN UNIT (LX06S) TR02–1
TRANSMISSION MAIN UNIT (LX06S)

TR02
TR02-001
TRANSMISSION ASSEMBLY .................. TR02-2

DATA AND SPECIFICATIONS........................ TR02-2
DESCRIPTION ................................................ TR02-3
TROUBLESHOOTING..................................... TR02-4
SPECIAL TOOL ............................................... TR02-6
PROPOSAL TOOL
(TRANSMISSION CASE ASSEMBLY) ............ TR02-7
GEAR SHIFT HOUSING ........................... TR02-8

COMPONENT LOCATOR ............................... TR02-8
OVERHAUL ................................................... TR02-12
CASE AND MAIN UNIT .......................... TR02-16

COMPONENT LOCATOR ............................. TR02-16
TRANSMISSION CASE ASSEMBLY ..... TR02-21

OVERHAUL ................................................... TR02-21
INSPECTION AND REPAIR .......................... TR02-43
INPUT SHAFT ASSEMBLY .................... TR02-44

OVERHAUL ................................................... TR02-44
OUTPUT SHAFT ASSEMBLY ................ TR02-49

OVERHAUL ................................................... TR02-49
COUNTER SHAFT ASSEMBLY ............. TR02-59

OVERHAUL ................................................... TR02-59
TR02–2 TRANSMISSION MAIN UNIT (LX06S)
TRANSMISSION ASSEMBLY
EN0332002I200001
Model FC FD for Taiwan

Six forward speeds, one reverse
Type 2, 3, 4, 5, 6th Synchromesh, 1st and Reverse,
Constant mesh
1st 8.190 6.098
2nd 5.073 3.858
3rd 2.982 2.340
Gear ratios: 4th 1.849 1.442
5th 1.343 1.000
6th 1.000 0.761
Reverse 7.619 5.672
Number of teeth input shaft 21 25
Counter drive gear 44 39
1st gear 11 11
2nd gear 19 19
3rd gear 26 26
Number of teeth counter shaft
4th gear 34 34
5th gear 39 39
6th gear — —
Reverse gear 11 11
1st gear 43 43
2nd gear 46 47
3rd gear 37 39
Number of teeth output shaft 4th gear 30 31
5th gear 25 25
6th gear — —
Reverse gear 40 40
Reverse idle gear 23/11 23/11
Power take-off opening On left side of gear case
Oil capacity, gear box Approx. 5.0 liters {1.10 Imp.gal/1.32 US gal.}
Oil capacity, gear box with power take-off Approx. 7.4 liters {1.63 Imp.gal/1.95 US gal.}
Lubricant, type Gear oil (API GL-4)
Viscosity, between-12 and 32°C {10 and 90°F} SAE90
Viscosity, above 32°C {90°F} SAE140
DESCRIPTION
EN0332002C100001
5 6 7 8 9 10 11 12
13 14 17
18 16 15
4
26 25 27 24 23 22 21 20 19
SHTS033200200001
1 Input shaft 15 Lock nut

2 Oil seal 16 Flange
3 Front bearing retainer 17 Output shaft
4 5th-6th shift sleeve 18 Speedometer driven gear
5 Shift shaft 19 Rear bearing retainer
6 Case cover 20 Cylindrical bearing
7 5th (or 6th) gear 21 Reverse shift sleeve
8 4th gear 22 1st-2nd shift sleeve
9 Inner shift lever 23 Counter shaft
10 3rd gear 24 3rd-4th shift sleeve
11 2nd gear 25 Counter drive gear
12 1st gear 26 Counter shaft front bearing
13 Reverse gear 27 Transmission case
14 Speedometer drive gear
TROUBLESHOOTING
EN0332002F300001

Gear slip-off (Control system) Joint worn and/or damaged Replace joint.
Bolts and nuts loose Tighten bolts and nuts.
Improper link rod adjustment Adjust link rod.
Gear slip-off (Gear shift housing) Lock ball and spring distorted and/or Repair or replace as required.
broken
Groove for shift shaft worn Replace shift fork.
Gear slip-off (Transmission gear) Synchronizer hub and sleeve worn Replace as required.
Synchronizer sleeve and gear clutch Replace as required.
teeth worn or damaged
Input shaft and/or output shaft bearing Replace bearing.
worn and/or broken
Retainer ring and/or thrust washer Replace as required.
worn and/or broken
Loosened transmission to engine Tighten bolts.
mounting bolts
Difficult gear engagement (Engine) Engine idling speed too high Adjust engine idling.
Difficult gear engagement (Clutch) Improper disengagement of clutch Adjust clutch.
Clutch disc sticking Repair or replace.
Clutch shifter sleeve bent Replace shifter sleeve.
Difficult gear engagement Input shaft and/or output shaft bearing Replace bearing.
(Transmission) worn and/or damaged
Engine crankshaft pilot bearing worn Replace bearing.
and/or damaged
Synchronizer cone and ring worn Replace as required.
Difficult gear engagement Looseness of control system and/or Tighten and adjust control system.
(Control system) improper adjustment
Improper motion of gear shift lever Adjust shift lever.
Shift and select rod worn Replace shift and select rod.
Rigid relay shaft nylon bushing and/or Replace as required.
sticking of shafts
Difficult gear engagement Improper lubrication of control lever Lubricate as required.
(Lubrication) Shortage of gear oil and/or low oil vis- Add oil or change oil as required.
cosity
Noise (Transmission) Grinding in transmission Check screws, bolts or other foreign
materials in transmission.
Loose transmission-to-engine mount- Tighten bolts.
ing bolts
Worn or damaged gear and bearing Replace as required.
Noise (Lubrication) Shortage of gear oil and/or low oil vis- Add oil or change oil as required.
cosity
Gear oil leaks (Transmission) Leaks at the front and rear bearing Repair and replace as required.
retainer seal and gasket, case cover
gasket, sand hole of case or shift shaft
expansion plug
Improper amount of gear oil and lack Check oil level and type.
of oil viscosity

Gears are difficult to engage or can- Control cable damaged, bent, deterio- Replace control cable.
not be engaged when engine is not rated or deformed due to heat
operating. Loose parts Inspect and tighten.
Damaged shift lever assembly Replace shift lever.
Damaged or bent parts on upper Replace.
transmission cover section (lever,
spring, etc.)
Faulty adjustment of control cable Adjust.
assembly and link rod
Excessive play in shift lever. Worn bushing in joint or shift lever Replace.
Loose mounting bolts and nuts Inspect and tighten.
SPECIAL TOOL
EN0332002K100001
Prior to starting a transmission overhaul, it is necessary to have these special tools.
S0983-94601 SOCKET WRENCH
S0965-02070 INPUT SHAFT PULLER
S0963-02220 SHAFT HANGER
S0969-91370 GUIDE
S0965-31710 HOOK
S0965-31720
S0965-31730 HOOK
S0965-31740
S0965-01881 PULLER
S0965-02080 PULLER
PROPOSAL TOOL (TRANSMISSION CASE ASSEMBLY)

EN0332002K100002
TRANSMISSION WORKSTAND
Unit : mm {in.}
TAPPED HOLE OR THROUGH HOLE FOR M10

(Make 12 holes equally spaced)
600
{23.622}
Approx. 500
{19.685}
300
150 {11.811}
{5.906} 410(410~411)
{16.142(16.142-16.181)}
SHTS033200200011
JIG FOR PREVENTING DETACHMENT
Unit : mm {in.} 22
{0.867}
75 {2.953}
t=0.8 {0.0315} or equivalent
(R43 {1.693})
40 {1.575}
90 {3.544}
55 {2.165}
SHTS033200200012
GEAR SHIFT HOUSING

COMPONENT LOCATOR
EN0332002D100001
MODEL: FC (WITH POWER SHIFT)
SHTS033200200013
1 Shift lever shaft 10 Air breather

2 Power shift assembly 11 Lockout plunger
3 Pipe joint 12 Compression spring
4 Neutral switch (If so equipped) 13 Steel ball
5 Outer select lever 14 E-ring
6 Spring pin 15 Inner shift lever
7 Plain washer 16 Select lever shaft
8 Oil seal 17 Gear control lever assembly
9 Shift lever shaft housing

A 34-38 {350-387,25-28} D 9.8-11.8 {100-120, 7.3-8.6}
B 20-30 {204-305, 15-22} E 75.5-91.2 {770-929, 56-67}
C 25-30 {255-305,19-22} F 43.5-54.5 {444-555, 30-40}
MODEL: FC (WITHOUT POWER SHIFT)
SHTS033200200014

2 Control rod support 11 Lockout plunger
3 Control rod end 12 Compression spring
4 Neutral switch (If so equipped) 13 Steel ball
8 Oil seal 17 Pipe joint bracket
9 Shift lever shaft housing 18 Transmission case assembly

A 34-38 {350-387,25-28} E 18.6-28.4 {190-289, 14-20}
B 18-26 {184-265, 14-19} F 24.5-37.3 {250-380, 19-27}
C 25-30 {255-305,19-22} G 43.5-54.5 {444-555, 33-40}
D 9.8-11.8 {100-120, 7.3-8.6}
MODEL: FD
SHTS033200200015

2 Power shift assembly 11 Lockout plunger
3 Pipe joint 12 Compression spring
4 Neutral switch 13 Steel ball
8 Oil seal 17 Plug
9 Shift lever shaft housing

A 34-38 {350-387,26-28} E 75.5-91.2 {770-929, 56-67}
B 20-30 {204-305, 15-22} F 43.5-54.5 {444-555, 33-40}
C 25-30 {255-305,19-22} G 40.2-46.1 {410-470, 30-33}
D 9.8-11.8 {100-120, 7.3-8.6}
SHTS033200200016
1 Shift lever shaft housing assembly 3 Clip holder

2 Bracket 4 Transmission case assembly

A 43.5-54.5 {444-555, 33-40} B 37.5-48.5 {383-494, 28-35}
OVERHAUL
EN0332002H200001
1. REMOVE THE SHIFT LEVER HOUSING.

(1) Take off the liquid gasket adhered to the contact surface using a
scraper.
NOTICE
Be careful not to damage the contact surface.
SHTS033200200017
2. REMOVE THE POWER SHIFT.

(1) Remove the power shift.
SHTS033200200018
3. REMOVE THE NEUTRAL SWITCH (IF SO EQUIPPED).

(1) Remove the neutral switch from the shift lever housing.
SHTS033200200019
4. REMOVE THE OUTER SELECT LEVER AND SELECT LEVER

SHAFT.
(1) Using a copper hammer and tapping rod, remove the spring pin.
(2) Remove the outer select lever and select lever shaft.
(3) Remove the oil seal from the shift lever housing.
SHTS033200200020
5. REMOVE THE SHIFT LEVER SHAFT AND INNER SHIFT

LEVER.
(1) Remove the shift lever shaft and inner shift lever from the shift
lever housing.
(2) Remove the oil seal from the shift lever housing.
SHTS033200200021
6. REMOVE THE LOCKOUT PLUNGER, LOCK BALL AND

RETAINER.
(1) Loosen the plug to remove the spring, lock ball retainer and lock-
out plunger.
NOTICE
The spring may fly out of the groove. So wear safety glasses while
working.
SHTS033200200022
1. INSTALL THE LOCKOUT PLUNGER, LOCKBALL AND

SPRING.
(1) Apply bearing grease to the lockout plunger.
(2) Insert the spring, lock ball to the installing hole for lockout plunger
in order, and insert the lockout plunger so that the lock ball does
not fly out and install the retainer.
(3) After applying adhesive to the plug, install the lockout plunger, the
spring and the plug.
SHTS033200200022
2. INSTALL THE SHIFT LEVER SHAFT AND INNER SHIFT

LEVER.
(1) Using a receiving block and a hammer, drive a new oil seal into
the shift lever housing.
NOTICE
Be careful not to damage the lip part of the oil seal.
(2) Apply bearing grease to the lip part of the oil seal and shaft part of
the shift lever shaft.
SHTS033200200023
(3) Match the shift lever shaft and inner shift lever as shown, and
push the shift lever shaft into the inner shift lever.
Model: With power shift
VIEW FROM PUSHING DIRECTION OF
INNER SHIFT LEVER SHAFT • They should be installed so that the nut seat surface for power
shift installing makes an angle of 90° with the inner shift lever.
A
INNER SHIFT LEVER

B
SHIFT LEVER
SHAFT SPLINE
NUT SEAT SURFACE
FOR POWER SHIFT
SHIFT LEVER INSTALLING
SHAFT
90q
INNER SHIFT
LEVER
SHTS033200200024
Model: Without power shift

• They should be installed so that the shift lever shaft and the inner
shift lever are matched.
INNER SHIFT LEVER SHAFT
A
INNER SHIFT LEVER

B
SHIFT LEVER
SHAFT SPLINE
SHIFT LEVER
SHAFT
INNER SHIFT
LEVER
0
SHTS033200200025
3. INSTALL THE SELECT LEVER SHAFT AND OUTER SELECT

LEVER.
(1) Using a receiving block and hammer, drive a new oil seal into the
shift lever housing.
NOTICE
Be careful not to damage the lip part of the oil seal.
(2) Apply bearing grease to the lip part of the oil seal and shaft part of
the select lever shaft.
SHTS033200200026
(3) Match the installing position of the select lever shaft and outer
select lever and fix the spring pin.
NOTICE
Be sure to match the position of the select lever shaft, outer select
lever and spring pin.
SHTS033200200027
4. INSTALL THE SHIFT LEVER HOUSING

(1) Remove oil, dust etc. on the contact surface of the shift lever
housing and transmission case.
(2) Coat the transmission case with liquid gasket (ThreeBond #1216
or equivalent) as shown in the figure.
NOTICE
• The race of the liquid gasket must be continuous.
• Coating width of the liquid gasket should be 3 mm {0.1181
in.}
SHTS033200200028
IMPORTANT POINT - INSPECTION

SHIFT STROKE
14 mm 14 mm
{0.551 in.} {0.551 in.} 1. INSPECT THE STROKE OF THE INNER SHIFT LEVER.
SELECT
OR MORE OR MORE (1) Fit the scale to the inner shift lever and measure the shift stroke
STROKE
and select stroke of the inner shift lever.
14 mm
{0.551 in.} STANDARD
OR MORE
SHIFT STROKE 14 mm {0.551 in.} or more
14 mm SELECT STROKE 14 mm {0.551 in.} or more
{0.551 in.}
OR MORE
SHTS033200200029
CASE AND MAIN UNIT

COMPONENT LOCATOR
EN0332002D100002
SHTS033200200030
1 Seal ring 12 Synchronizer hub 23 1st gear sub-assembly

2 Oil muffler 13 Synchronizer sleeve 24 Constant hub
3 Retainer ring 14 Needle roller bearing 25 Reverse gear
4 Cylindrical bearing 15 5th (or 6th) gear 26 Oil seal
5 Input shaft sub-assembly 16 Bushing 27 Dust reflector
6 Spacer 17 4th gear 28 Flange
7 Synchronizer cone 18 Roller bearing 29 O-ring
8 Synchronizer ring 19 Synchronizer ring sub-assem- 30 Lock nut
bly
9 Synchronizer key 20 3rd gear sub-assembly 31 Constant sleeve
10 Synchronizer head 21 Output shaft
11 Compression spring 22 2nd gear sub-assembly

A 587-783 {5,986-7,984, 433-577}
2A64AA.:5A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧡㧠ಽ
SHTS033200200031
1 Concentric pin 18 Release shaft bearing

2 Spacer 19 Expansion plug
3 Reverse shift head 20 O-ring (If so equipped)
4 Reverse shift shaft 21 Lockout plunger
5 Reverse shift fork 22 Control lever stopper
6 1st-reverse shift head 23 5th-6th shift fork
7 1st-reverse shift shaft 24 5th-6th shift shaft
8 1st-reverse shift fork 25 5th-6th shift head
9 Transmission case cover assembly 26 3rd-4th shift shaft
10 Idler gear cover 27 3rd-4th shift fork
11 Front bearing retainer 28 Drain plug
12 Gasket 29 Gasket
13 Oil seal 30 Steel ball
14 Outer rotor 31 Compression spring
15 Inner rotor 32 Plug
16 Oil pump cover 33 Front bearing retainer assembly
17 Oil pump drive shaft 34 Filler plug

A 54-68 {550-700, 40-50} E 26-30 {266-305, 20-22}
B 44.5-53.5 {454-545, 33-39} F 6-10 {62-101, 4.5-7.3}
C 44.5-53.5 {454-545, 33-39} G 23.5-28.5 {240-290, 18-21}
D 23-29 {235-295, 17-21}
SHTS033200200032
1 Cylindrical roller bearing 10 Compression spring

2 Retainer ring 11 Lock ball
3 Counter drive gear 12 Reverse idler gear
4 Counter 5th gear 13 Needle roller bearing
5 Counter shaft 14 Reverse idler shaft
6 Key 15 Lock plate
7 Retainer ring 16 Power take-off cover
8 Back up light switch 17 Inlet oil pump pipe sub-assembly
9 Plug 18 Oil strainer

A Without power shift: 19.5-30.5 {199-311, 15-22} C 19-25 {194-254, 15-18}
With power shift: 54-68 {551-693, 40-50} D 49-63 {500-642, 37-46}
B 63.5-92.5 {648-943, 47-68} E 26-30 {266-305, 20-22}
MODEL: FC
SHTS033200200033
1 O-ring 6 Gasket
2 Speedometer gear bushing 7 Rear bearing retainer assembly
3 Oil seal 8 Set screw
4 Speedometer driven gear 9 Speed sensor
5 Speedometer drive gear

A 8.5-10.5 {87-107, 6.3-7.7} C 14.7-29.3 {150-298, 11-21}
B 54-68 {550-700, 40-50}
MODEL: FD
SHTS033200200034
1 O-ring 4 Speedometer drive gear

2 Speedometer gear bushing 5 Gasket
3 Set screw 6 Rear bearing retainer assembly

A 54-68 {550-700, 40-50} C 8.5-10.5 {87-107, 6.3-7.7}
B 54-68 {550-700, 40-50}
TRANSMISSION CASE ASSEMBLY

OVERHAUL
EN0332002H200002

! CAUTION
Do not work on the transmission while it is still hot. This can
result in personal injury.
1. BLOCK THE WHEELS.
2. DRAIN THE TRANSMISSION OIL.
3. DISCONNECT THE PROPELLER SHAFT.
4. DISCONNECT THE ELECTRIC HARNESS AND OTHER

ATTACHMENTS.
5. DISCONNECT THE PARKING BRAKE CABLE.
6. DISCONNECT THE TRANSMISSION CONTROL.
7. REMOVE THE CLUTCH CONTROL.
8. REMOVE THE TRANSMISSION CASE COVER FITTING

BOLTS.
HINT
Disassembly and reassembly of the transmission is carried out
basically by standing the transmission vertically. So, remove the
bolts fixing the transmission case from the clutch housing side for
better workability.
SHTS033200200035
9. INSTALL THE TRANSMISSION ASSEMBLY INTO A TRANS-

MISSION WORKSTAND.
(1) Wire the transmission assembly rearward and lift it using a hoist.
NOTICE
As the transmission case is made of aluminum, be careful not to
shock it.
(2) Fix the transmission assembly to a workstand on the level ground
with bolts and nuts.
SHTS033200200036
1. REMOVE THE TRANSMISSION WORKSTAND.

(1) Install the transmission case cover fitting bolts.
NOTICE
Temporarily after tightening all bolts in equal, tighten them regu-
larly.
2. INSTALL THE CLUTCH CONTROL.
3. CONNECT THE TRANSMISSION CONTROL.
4. CONNECT THE PARKING BRAKE CABLE.
5. CONNECT THE ELECTRIC HARNESS AND OTHER ATTACH-

MENTS
6. CONNECT THE PROPELLER SHAFT.
7. FILL THE TRANSMISSION WITH GEAR OIL UP TO THE

FILLER PLUG HOLE.
SHTS033200200035
1. REMOVE THE PARKING BRAKE AND FLANGE COUPLING.
2. REMOVE THE OIL STRAINER.
SHTS033200200037
3. REMOVE THE STEEL BALL.

(1) Remove the plug on the transmission case upper surface.
STEEL BALL
(2) Remove the spring and steel ball using a magnetic finger.
SHTS033200200038
4. REMOVE THE REAR BEARING RETAINER ASSEMBLY.
SHTS033200200039
5. DISASSEMBLE THE REAR BEARING RETAINER ASSEMBLY.

(1) Remove the speedometer gear bushing.
Model: FC
.
a. Remove the set screw of speedometer gear bushing and remove

the driven gear and bushing.
b. Remove the O-ring and oil seal from the speedometer gear bush-
ing.
NOTICE
Remember the position of aligning marks when removing the
speedometer gear bushing.
SHTS033200200040
Model: FD
.
a. Remove the set screw and remove the speedometer gear bush-
ing.
b. Remove the O-ring from the speedometer gear bushing.
NOTICE
Remember the position of aligning marks when removing the
speedometer gear bushing.
(2) Remove the oil seal.

a. Using a flat blade screwdriver, remove the oil seal from the rear
bearing retainer.
NOTICE
Be careful not to damage the rear bearing retainer.
SHTS033200200041
6. REMOVE THE SPEEDOMETER DRIVE GEAR.
SHTS033200200042
7. REMOVE THE TRANSMISSION CASE ASSEMBLY.

(1) Using a snap ring expander, remove the retainer ring from the
counter shaft.
! CAUTION
The retainer ring may fly out of the groove. Wear safety glasses
while working.
rear bearing on the counter shaft side.
NOTICE
SHTS033200200043 while working.
rear bearing on the output shaft side.
! CAUTION
while working.
SHTS033200200044
(4) Install the special tool to the groove of the rear bearing outer
periphery on the counter shaft side.
SST:
Hook (S0965-31730)
Puller (S0965-02080)
(5) Pull out the rear bearing by tightening the bolt of the special tool
puller part.
(6) Remove the spacer.
SHTS033200200045
(7) Install the special tool to the groove of the rear bearing outer
periphery on the output shaft side.
SST:
Hook (S0965-31720)
Puller (S0965-01881)
(8) Pull out the rear bearing by tightening the bolt of the special tool
puller part.
(9) Remove the spacer.
SHTS033200200046
(10) Remove the 4 bolts connected to the clutch housing from the
transmission case side.
(11) Insert a chisel between lip parts of right and left side connected
on the transmission case, and tap the chisel using a hammer to
separate clutch housing and transmission case.
SHTS033200200047
(12) Lift the transmission case assembly straight to remove it.

(13) Take off the liquid gasket adhered to the contact surface using a
scraper.
NOTICE
SHTS033200200048
8. REMOVE THE OIL PIPE.
SHTS033200200049
9. REMOVE THE CONTROL LEVER STOPPER, LOCKOUT

PLUNGER AND INTER LOCK PIN.
(1) Loosen the 4 bolts to remove the control lever stopper.
NOTICE
The inner 2 bolts of the control lever stopper fitting bolts are
reamer bolt, so keep the inner 2 bolts separately.
SHTS033200200050
(2) Remove the 3 lockout plungers from the control lever stopper.
LOCKOUT PLUNGERS
SHTS033200200051
(3) Using a magnetic finger, remove the 2 interlock pins from the shift
shaft.
INTERLOCK PIN
SHTS033200200052
10. REMOVE THE OUTPUT SHAFT ASSEMBLY, COUNTER

SHAFT ASSEMBLY AND SHIFT SHAFT ASSEMBLY.
(1) Install the jig for preventing detachment into the 5th-6th synchro-
nizer unit to prevent the 5th-6th synchronizer cone and ring from
detaching.
HINT
In case of not using the jig for preventing detachment, support
parts for the prevention of detachment by one of the worker.
JIG FOR PREVENTING
DETACHMENT
SHTS033200200053
(2) Using the special tool, fix the output shaft assembly, counter shaft
assembly and shift shaft assembly.
SST: Shaft hanger (S0963-02220)
HINT
The retainer ring and the lock nut removed previously should be
reused.
(3) Using a hoist, lift up the output shaft assembly, counter shaft
assembly and shift shaft assembly together.
NOTICE
• Lift them up little by little.
SHTS033200200054 • Be careful not to make shift shaft be caught.
• Be careful not to damage the gear and bearing etc. when lift-
ing up.
(4) Remove the special tool and separate the output shaft assembly,
counter shaft assembly and shift shaft assembly.
SHTS033200200055
11. REMOVE THE COUNTER SHAFT FRONT BEARING INNER

RACE.
(1) While holding the tapered portion of the oil pump drive pin by
wrench, rotate (or vibrate) the oil pump drive pin by using impact
wrench, and then pull it out.
SHTS033200200056
(2) Using the special tool, pull out the front bearing inner race from
the counter shaft.
SST:
Hook (S0965-31740)
Puller (S0965-02080)
SHTS033200200057
12. DISASSEMBLE THE SHIFT SHAFT ASSEMBLY.

(1) Remove the shift fork and shift head.
a. Using a 5.0 mm {0.197 in.} diameter tapping rod and a hammer,
drive out the inner pin and outer pin from the shift fork, shift head
and spacer.
b. Remove the spacer, shift fork and shift head from the shift shaft.
SHTS033200200058
13. REMOVE THE FRONT BEARING RETAINER ASSEMBLY.
SHTS033200200059
14. DISASSEMBLE THE FRONT BEARING RETAINER ASSEM-

BLY.
(1) Remove the oil seal.
a. Using a flat blade screwdriver, remove the oil seal from the front
bearing retainer.
NOTICE
Be careful not to damage the front bearing retainer.
SHTS033200200060
15. REMOVE THE INPUT SHAFT ASSEMBLY.

(1) Using the special tool, pull out the input shaft assembly from the
clutch housing.
SST:
Sliding hammer (S0942-01442)
Input shaft puller (S0965-02070)
SHTS033200200061
16. REMOVE THE FRONT BEARING OUTER RACE ON THE

COUNTER SHAFT SIDE.
(1) Using a receiving block and a hammer, tap the front bearing outer
race equally to drive it out.
17. REMOVE THE OIL FILTER ASSEMBLY.
SHTS033200200062
18. DISASSEMBLE THE TRANSMISSION CASE ASSEMBLY.

(1) Remove the idler cover.
a. Loosen the bolts to remove the idler cover.
b. Take off the liquid gasket adhered to the contact surface using a
scraper.
NOTICE
SHTS033200200063
(2) Remove the reverse idler gear.

a. Loosen the bolt to remove the lock plate.
SHTS033200200064
b. Using the special tool, pull out the reverse idler shaft.
SST: Sliding hammer (S0942-01442)
SHTS033200200065
c. Remove the O-ring from the reverse idler shaft.

d. Remove the needle roller bearing.
SHTS033200200066
1. ASSEMBLE THE FRONT BEARING RETAINER ASSEMBLY.

(1) Assemble the relief valve.
a. Install the steel ball and compression spring in order to the front
bearing retainer.
b. Install a new soft washer and the plug.
SHTS033200200067
(2) Install the oil seal.

a. Apply chassis grease to a new oil seal lip part.
b. Using a receiving block and a hammer, drive the oil seal into the
front bearing retainer.
NOTICE
• Be careful not to damage the lip part.
• Do not deform the oil seal.
SHTS033200200068
2. ASSEMBLE THE REAR BEARING RETAINER ASSEMBLY.

(1) Install the oil seal (Model: FC) and O-ring.
Model: FC
.
a. Apply chassis grease to a new O-ring and a new oil seal and
install them to the speedometer gear bushing.
NOTICE
• Be sure that the oil seal is installed in the proper direction.
• Be careful not to damage the O-ring and the oil seal.
Model: FD
.
SHTS033200200069 a. Apply chassis grease to a new O-ring and install it to the speed-
ometer gear bushing.
NOTICE
Be careful not to damage the O-ring.
(2) Apply chassis grease to the shaft part of the speedometer driven
gear and insert it into the speedometer gear bushing (Model: FC).
SHTS033200200070
(3) Install the speedometer gear bushing.

a. Align the mark line engraved on the speedometer gear bush-
ing with the mark line engraved on the rear bearing retainer
and insert it (Model: FC).
Number. of the Number. of the Number. of the

drive gear teeth driven gear teeth mark lines
6 19 Three lines
NOTICE
To prevent the drive gear and driven gear from damaging, align
SHTS033200200071 the mark lines.
(4) Fix the speedometer gear bushing with the set screw.
SHTS033200200072
3. INSTALL THE OIL SEAL.

(1) Apply chassis grease to the lip part of a new oil seal.
(2) Using a receiving block or a hammer, drive the oil seal into the
rear bearing retainer.
NOTICE
• Be careful not to damage the lip part of the oil seal.
• Do not deform the oil seal.
SHTS033200200073
4. ASSEMBLE THE SHIFT SHAFT ASSEMBLY.

(1) Assemble the shift fork and shift head.
a. Match the spacer, shift fork and shift head with shift shaft install-
ing position.
NOTICE
Be sure that the shift fork and shift head are installed in proper
position and direction.
SHTS033200200074
b. Using a hammer, drive a new inner pin and a new outer pin into
the shift fork, shift head and spacer.
SHTS033200200075
NOTICE
SHIFT SHAFT • Mount the inner pin and outer pin with their cut edges facing
opposite side to each other. Be sure that the cut edges of
INNER PIN inner pin and outer pin are vertical to the shift shaft when
CUT EDGE CUT EDGE knocking them into the shift fork and shift head.
OUTER PIN
MOUNT PINS WITH • Knock home the inner pin and outer pin down to the knock-
THEIR CUT EDGES
FACING OPPOSITE SIDE. ing seat of the shift fork, shift head and spacer.
OUTER PIN INNER PIN
SHTS033200200076
5. INSTALL THE COUNTER SHAFT FRONT BEARING INNER

RACE.
RECEIVING (1) Using a receiving block and a hammer, press the front bearing
BLOCK inner race into the counter shaft.
SHTS033200200077
(2) Using a press, press the oil pump drive pin into the counter shaft.
SHTS033200200078
6. ASSEMBLE THE TRANSMISSION CASE ASSEMBLY.

(1) Install the reverse idler gear.
a. Apply gear oil to the needle roller bearing.
b. Assemble the reverse idler gear and needle roller bearing.
c. Apply bearing grease to the O-ring and install the O-ring to the
groove of the reverse idler shaft.
d. Match the reverse idler gear with the transmission case installing
position.
SHTS033200200079
e. Using a copper hammer, drive the reverse idler shaft into the
transmission case assembly.
SHTS033200200080
f. Match the lock plate with reverse idler shaft and install it with the
bolt.
SHTS033200200081
(2) Measure the reverse idler gear end play.

Assembly Standard: 0.15-0.60 mm {0.0060-0.0236 in.}
Service Limit: 0.65 mm {0.0256 in.}
SHTS033200200082
(3) Install the idler cover.

a. Remove oil, dust etc. on the contact surface of the idler cover and
transmission case.
LIQUID GASKET 3 mm {0.1181 in.}
b. Coat the idler cover with liquid gasket (ThreeBond #1216 or
equivalent) as shown in the figure.
NOTICE
• The trace of the liquid gasket must be continuous.
in.}.
SHTS033200200083
c. Install the idler cover to the transmission case with bolts.

NOTICE
larly.
SHTS033200200084
7. INSTALL THE FRONT BEARING OUTER RACE OF THE

COUNTER SHAFT SIDE.
(1) Apply gear oil to the front bearing outer race.
SHTS033200200085
(2) Using a receiving block and a hammer, drive the front bearing
outer race into the clutch housing.
SHTS033200200086
(3) Using a depth gauge, measure the dimension from the clutch
housing front end surface to the front bearing outer race. If the
dimension exceeds the standard value, adjust it to the standard
value within the range.
SHTS033200200087
8. INSTALL THE INPUT SHAFT ASSEMBLY.

(1) Using a copper hammer, drive the input shaft assembly into the
clutch housing.
SHTS033200200088
9. INSTALL THE FRONT BEARING RETAINER ASSEMBLY.

(1) Apply gear oil to a new O-ring (3 pieces) and install the O-rings to
the clutch housing.
SHTS033200200089
(2) After applying gear oil to the input shaft, cover the input shaft
spline part with cloth etc. to prevent oil seal of the front bearing
retainer from damaging.
SHTS033200200090
(3) Using the special tool, make the seal ring of the oil muffler get to
fit to the groove part.
SST: Seal ring guide (S0969-91370)
NOTICE
Make sure that the seal ring of the input shaft assembly does not
protrude from the oil muffler.
SHTS033200200091
(4) Install the front bearing retainer assembly to the clutch housing
with bolts through a new gasket.
NOTICE
• Be sure that there is no curled-up of oil seal lip or no pinch-
ing of seal ring when mounting the front bearing retainer.
• Temporarily after tightening all bolts in equal, tighten them
regularly.
• Be care not to damage the gasket.
SHTS033200200092
10. INSTALL THE OUTPUT SHAFT ASSEMBLY, COUNTER SHAFT

ASSEMBLY AND SHIFT SHAFT ASSEMBLY.
(1) Apply gear oil to the sliding surface of the shift shaft.
(2) Using the special tool, fix the output shaft assembly, counter shaft
assembly and shift shaft assembly.
SST: Shaft hanger (S0963-02220)
HINT
• After assembling the shift shaft assembly to the output shaft
assembly and fixing them with special tool, assemble the
counter shaft assembly for better workability.
• Place the shift shaft assembly as shown in the figure.
SHTS033200200093
TRANSMISSION
FRONT SIDE
SHTS033200200094
(3) Install the jig for preventing detachment into the 5th-6th synchro-
JIG FOR PREVENTING DETACHMENT nizer unit to prevent the 5th-6th synchronizer cone and ring from
detaching.
HINT
In case of not using the jig for preventing detachment, support
parts for the prevention of detachment by one of the worker.
SHTS033200200095
(4) Using a hoist, lift up the output shaft assembly, counter shaft
assembly and shift shaft assembly together and install them to the
clutch housing.
NOTICE
• Be sure to insert the shaft protruded from the input shaft into
the hole of the output shaft point part.
• Be sure to insert the oil pump drive pin of counter shaft point
part into the hole of the oil pump.
• Be careful not to damage the gear and bearing etc. when
installing them.
SHTS033200200096 (5) Make sure that the gears of the output shaft and counter shaft
rotate smoothly by rotating the input shaft.
11. INSTALL THE STOPPER, LOCKOUT PLUNGER AND INTER

LOCK PIN.
(1) Apply chassis grease to the lockout plunger and inter lock pin.
(2) Install the inter lock pin to the shift shaft.
INTER LOCK PIN
SHTS033200200097
(3) Install the lockout plunger to the stopper.
LOCKOUT PLUNGER
SHTS033200200098
(4) Install the stopper with bolts.

NOTICE
• Be careful that lockout plunger does not fall out.
• Reamer bolt should be used as the inner 2 bolts of the con-
trol lever stopper fitting bolts.
SHTS033200200099
12. INSTALL THE OIL PIPE.

LIQUID GASKET 3 mm {0.1181 in.}
13. INSTALL THE TRANSMISSION CASE ASSEMBLY.
(1) Remove oil, dust etc. on the contact surface of the clutch housing
and transmission case.
(2) Apply liquid gasket (ThreeBond #1216 or equivalent) to the clutch
housing as shown in the figure.
NOTICE
in.}.
SHTS033200200100
(3) Install the transmission case assembly from right above.
SHTS033200200101
(4) Fix the transmission case assembly with 4 bolts.

NOTICE
larly.
SHTS033200200102
(5) Apply gear oil to the rear bearings of the output shaft and counter
shaft.
(6) Using a snap ring expander, install the retainer ring to the rear
bearing of the output shaft side and counter shaft side.
! CAUTION
while working.
SHTS033200200103
(7) Install the spacer to the counter shaft.

NOTICE
The spacer should be installed with its chamfered side facing
downward.
(8) Using a receiving block and a hammer, drive the rear bearing of
counter shaft side into the transmission case.
SHTS033200200104
(9) Install the spacer to the output shaft.

NOTICE
The spacer should be installed with its flange side facing down-
ward.
(10) Using a receiving block and a hammer, drive the rear bearing of
output shaft side into the transmission case.
(11) Make sure that the gears of the output shaft and counter shaft
rotate smoothly by rotating the input shaft.
SHTS033200200105
(12) Using a snap ring expander, install a new retainer ring to the
counter shaft.
NOTICE
• The retainer ring may fly out of the groove. So wear safety
glasses while working.
• Make sure that the retainer ring fits in the groove surely.
SHTS033200200106
(13) Using a thickness gauge, measure the clearance (play in axial

direction) between the rear bearing and the retainer ring. If the
clearance exceeds standard value, select a suitable retainer ring
and install it again.
Assembly Standard: 0.1 mm {0.0039 in.} or less
A kind of retainer ring
Thickness Color code
2.4 mm {0.0945 in.} None
2.5 mm {0.0984 in.} White

SHTS033200200107
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Brown
14. INSPECT THE SHIFT HEAD.

(1) Using a thickness gauge, measure the clearance between each
shift head, and make sure it does not exceed the standard value.
SHTS033200200108
(2) Make sure that a inspection jig inserts in the concave part of the
shift head smoothly.
CONCAVE PART
(3) Make sure that two shift shafts (shift heads) do not move at a
time.
NOTICE
If two shift shafts (shift heads) move at a time, it fails to install the
lockout plunger.
SHTS033200200109
15. INSTALL THE SPEEDOMETER DRIVE GEAR.
SHTS033200200110
16. INSTALL THE REAR BEARING RETAINER.

(1) Install the rear bearing retainer assembly to the transmission case
with bolts through a new gasket.
NOTICE
• Temporarily after tightening all bolts in equal, tighten them
regularly.
• Be care not to damage the gasket.
17. INSTALL THE LOCK BALL.
SHTS033200200111
18. INSTALL THE OIL STRAINER.
19. INSTALL THE PARKING BRAKE AND FLANGE COUPLING.
SHTS033200200112

EN0332002H300001
Unit: mm {in.}
Clearance between 0.02-0.45 1.5 {0.0591} Replace. Measure

shift fork and sleeve {0.0008-0.0177}
Interlock pin, interlock — — Replace, Visual check

plunger, compression if necessary.
spring and steel ball:
Wear and damage
Shift head, shift fork — — Replace, Visual check

and shift shaft: if necessary.
Wear and damage
Inner rotor and outer — — Replace the parts as Visual check

rotor in oil pump: a set, if necessary.
Wear and damage
Front bearing retainer: — — Replace, Visual check

Ball and spring in relief — — Replace, Visual check

valve: if necessary.
Wear and damage
Bearing: — — Replace, Visual check

Wear, damage and if necessary.
rotation condition
Reverse idler gear and — — Replace, Visual check

reverse idler shaft: if necessary.
Wear and damage
Needle roller bearing: — — Replace, Visual check

INPUT SHAFT ASSEMBLY

OVERHAUL
EN0332002H200003
1. REMOVE THE OIL MUFFLER.

(1) Remove the seal ring from the oil muffler.
SHTS033200200118
(2) Install the special tool to the groove of the oil muffler outer periph-
ery.
SST:
Puller (S0965-01881)
Hook (S0965-31710)
(3) Pull out the oil muffler by tightening the bolt of the special tool
puller part.
SHTS033200200119
2. REMOVE THE PILOT ROLLER BEARING.

(1) Using a flat blade screwdriver, remove the retainer ring on the
input shaft groove.
! CAUTION
while working.
(2) Remove the spacer and pilot roller bearing.
SHTS033200200120
3. REMOVE THE FRONT BEARING.

input shaft.
! CAUTION
while working.
(2) Using a snap ring expander, remove the retaine1
r ring from the front bearing.
! CAUTION
SHTS033200200121 while working.
(3) Install the special tool to the groove of the front bearing outer
periphery.
SST:
Hook (S0965-31720)
Puller (S0965-01881)
(4) Pull out the front bearing by tightening the bolt of the special tool
puller part.
SHTS033200200122
1. INSTALL THE FRONT BEARING.

(1) Apply gear oil to the front bearing.
SHTS033200200123
(2) Using a receiving block and a press, press the front bearing into
the input shaft.
NOTICE
A receiving block should be attached to the bearing inner race.
(3) Using a snap ring expander, install the retainer ring to the front
bearing.
! CAUTION
while working.
NOTICE
SHTS033200200124
Make sure that the retainer ring fits in the groove surely.
(4) Using a snap ring expander, install a new retainer ring to the input
shaft.
! CAUTION
while working.
NOTICE
SHTS033200200125

direction) between the front bearing and the retainer ring. If the
2.4 mm {0.0945 in.} None
2.5 mm {0.0984 in.} White

SHTS033200200126
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Brown
2. INSTALL THE PILOT ROLLER BEARING.

(1) Apply gear oil to the input shaft inner surface and pilot roller bear-
ing.
(2) Install the spacer, pilot roller bearing, spacer into the input shaft
inner surface in order.
SHTS033200200127
(3) Using a flat blade screwdriver, install a new retainer ring to the
input shaft.
! CAUTION
while working.
NOTICE
SHTS033200200128
3. INSTALL THE OIL MUFFLER.

(1) Heat the oil muffler in hot water or oil to 90°C-120°C {194°F-
248°F}.
NOTICE
• In case of using oil, do not heat the oil muffler in excess of
120°C {248°F}.
• Hot water or oil and parts are high temperature, so never
touch hot water or oil and parts with your bare hands.
• In case of using hot water, remove moisture before installa-
tion.
SHTS033200200129
(2) Install the oil muffler to the input shaft.
SHTS033200200130
(3) Install a new seal ring to the oil muffler.

NOTICE
• The oil muffler should be installed after its cooling down
completely.
• Because the seal ring is easy to be deformed, extend it at
minimum when mounting it.
• Make sure that the seal ring does not protrude from the oil
muffler when installing seal ring.
SHTS033200200131
(4) Using the special tool, make the seal ring of the oil muffler get to
fit to the groove part.
SST: Seal ring guide (S0969-91370)
(5) Apply gear oil to the sliding surface of the oil muffler.
SHTS033200200132
2A64AA.:5A/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧡㧡ಽ

EN0332002H300002
Input shaft: — — Replace, Visual check


Wear, damage and if necessary.
rotate condition
Oil muffler (Seal ring — — Replace, Visual check

groove): if necessary.
Wear and damage
OUTPUT SHAFT ASSEMBLY

OVERHAUL
EN0332002H200004
1. REMOVE THE 5TH-6TH SYNCHRONIZER UNIT.
SHTS033200200135
(1) Put the output shaft front end part upward and remove the
retainer ring from the output shaft using a snap ring expander.
! CAUTION
while working.
SHTS033200200136
2. REMOVE THE 1ST GEAR ASSEMBLY, 1ST-2ND SYNCHRO-

NIZER UNIT AND 2ND GEAR ASSEMBLY.
(1) Use the front side of 2nd gear as the support for pressing. Press
the rear end of the output shaft to pull out the gears.
NOTICE
• When pressing the output shaft, put a wood block on the
lower part of the shaft.
• Because the output shaft is heavy, support it securely.
SHTS033200200137
3. REMOVE THE 4TH GEAR ASSEMBLY, 3RD-4TH SYNCHRO-

NIZER UNIT AND 3RD GEAR ASSEMBLY.
(1) Using a snap ring expander, remove the retainer ring from the out-
put shaft.
! CAUTION
while working.
SHTS033200200138
(2) Use the front side of 2nd gear as the support for pressing. Press
the rear end of the output shaft to pull out the gears.
NOTICE
SHTS033200200139
4. DISASSEMBLE THE SYNCHRONIZER UNIT. (1ST-2ND, 3RD-

4TH, 5TH-6TH; 3 pieces)
(1) Using a snap ring expander, remove the retainer ring from the out-
put shaft.
! CAUTION
while working.
SHTS033200200140
(2) Remove the synchronizer key, synchronizer head and compres-

sion spring from the synchronizer hub.
! CAUTION
while working.
SHTS033200200141
5. DISASSEMBLE THE GEAR [4TH GEAR, 5TH (OR 6TH) GEAR;

2 pieces]
(1) Using a snap ring expander, remove 4th and 5th (or 6th) gear.
! CAUTION
while working.
SHTS033200200142
(2) Remove the synchronizer cone from 4th and 5th (or 6th) gear.
SHTS033200200143
1. ASSEMBLE THE SYNCHRONIZER UNIT. (1ST-2ND, 3RD-4TH,

5TH-6TH; 3 pieces)
(1) Only for 1st and 2nd synchronizer unit, remove the retainer ring of
1st side.
! CAUTION
while working.
SHTS033200200144
(2) Install the synchronizer sleeve.

(3) Install the retainer ring to the 1st side of 1st-2nd synchronizer unit.
! CAUTION
while working.
SHTS033200200145
2. ASSEMBLE THE GEAR ASSEMBLY. [4TH GEAR, 5TH (OR

6TH) GEAR; 2 pieces]
(1) Install the synchronizer cone to the 4th and 5th (or 6th) gear.
SHTS033200200146
groove of the synchronizer installing surface of 4th and 5th (or
6th) gear.
! CAUTION
while working.
NOTICE
SHTS033200200147
3. INSTALL THE 1ST-2ND SYNCHRONIZER UNIT.

(1) Install the inner cone, double cone, synchronizer ring to the output
shaft in order.
SHTS033200200148
(2) Using a heater, (piston heater etc.) heat the synchronizer unit in
hot water or oil to 90°C-120°C {194°F-248°F}.
! CAUTION
Hot water or oil and parts are high temperature, so never touch
hot water or oil and parts with your bare hands.
NOTICE
• In case of using oil, do not heat the synchronizer unit in
excess of 120°C {248°F}.
tion.
SHTS033200200149
(3) Install the synchronizer unit to the output shaft.
SHTS033200200150
4. INSTALL THE 1ST GEAR ASSEMBLY.

(1) Install the synchronizer bushing of the 2nd gear to the output
shaft.
! CAUTION
NOTICE
SHTS033200200151 tion.
(2) Install the synchronizer bushing of the 1st gear to the output shaft.
SHTS033200200152
(3) Apply sulfide molybdenum grease to the both ends surface of the
1st gear boss part and install the 1st gear assembly.
SHTS033200200153
5. INSTALL THE REVERSE GEAR.

(1) Using a heater, (piston heater etc.) heat the bushing of reverse
gear in hot water or oil to 90°C-120°C {194°F-248°F}.
! CAUTION
NOTICE
SHTS033200200154 tion.
(2) Install the bushing of the reverse gear to the output shaft.
SHTS033200200155
(3) Apply sulfide molybdenum grease to the both ends surface of the
reverse gear boss part and install the reverse gear.
SHTS033200200156
6. INSTALL THE 3RD GEAR ASSEMBLY.

(1) Install the jig for preventing detachment to the output shaft.
NOTICE
The jig should be used to prevent assembled gear and bearing
from falling off.
SHTS033200200157
7. INSTALL THE 3RD-4TH SYNCHRONIZER UNIT.

(1) Install the inner cone, double cone and synchronizer ring to the
output shaft in order.
SHTS033200200158
(2) Heat the synchronizer unit in hot water or oil to 90°C-120°C

{194°F-248°F}.
! CAUTION
NOTICE
tion.
SHTS033200200159
(3) Install the synchronizer unit to the output shaft.

(4) Install the synchronizer ring.
SHTS033200200160
8. INSTALL THE 4TH GEAR ASSEMBLY.

(1) Heat the bushing of 4th gear in hot water or oil to 90°C-120°C
{194°F-248°F}.
! CAUTION
NOTICE
SHTS033200200161 tion.
(2) Apply gear oil to the needle roller bearing of the 4th gear and
insert it into the 4th gear inner side.
(3) Install the 4th gear assembly and bushing to the output shaft.
SHTS033200200162
(4) Using a snap ring expander, install a new retainer ring to the out-
put shaft.
! CAUTION
The retainer ring may fly out of the groove. So wear safety glasses
while working.
NOTICE
SHTS033200200163

direction) between the gear bushing and the retainer ring. If the
2.35 mm {0.0925 in.} None
2.45 mm {0.0965 in.} White

SHTS033200200164
2.55 mm {0.1004 in.} Green
2.65 mm {0.1043 in.} Brown

9. INSTALL THE 5TH-6TH SYNCHRONIZER UNIT.

(1) Using a snap ring expander, install a new retainer ring to the out-
put shaft.
! CAUTION
while working.
NOTICE
SHTS033200200165

direction) between the synchronizer hub and the retainer ring. If
the clearance exceeds standard value, select a suitable retainer
ring and install it again.
1.9 mm {0.0784 in.} None
2.0 mm {0.0787 in.} White
SHTS033200200166

EN0332002H300003
Unit: mm {in.}
Synchronizer ring: — — Replace, Visual check

Deformity, crack and if necessary.
excessive damage
Gear excessive: — — Replace, Visual check

Wear, chips and cracks if necessary.
Clearance between 2nd, 3rd and 4th 0.2 {0.0079} Replace the syn- Measure
synchronizer ring and gear chronizer ring and/
synchronizer cone and 1.0-1.8 {0.0394- or gear sub-assem-
gear sub-assembly 0.0708} bly.
5th and input gear

1.2-2.0 {0.0473-
0.0787}
Oil seal lip: — — Replace, Visual check

Cylindrical bearing, — — Replace, Visual check

and ball bearing: if necessary.
Improper rotation
Needle roller bearing in — — Replace, Visual check

deformed shape if necessary.
Output shaft: — — Replace, Visual check

COUNTER SHAFT ASSEMBLY

OVERHAUL
EN0332002H200005
1. REMOVE THE FRONT BEARING INNER RACE.

(1) While holding the tapered portion of the oil pump drive pin by
wrench, rotate (or vibrate) the oil pump drive pin by using impact
wrench, and then pull it out.
SHTS033200200174
(2) Using the special tool, pull out the front bearing inner race from
the counter shaft.
SST:
Hook (S0965-31740)
Puller (S0965-02080)
SHTS033200200175
2. DISASSEMBLE THE COUNTER SHAFT ASSEMBLY.

counter shaft.
! CAUTION
while working.
SHTS033200200176
(2) Use the counter shaft 5th gear as the support for pressing. Press
the counter shaft to pull out the counter drive gear and counter 5th
gear.
NOTICE
SHTS033200200177
1. ASSEMBLE THE COUNTER SHAFT ASSEMBLY.

(1) Select the proper size key according to the size of the key groove
and install it.
Thickness (T) Shape
14.018-14.029 mm T
{0.5519-0.5523 in.}
14.070-14.085 mm T
{0.5540-0.5545 in.}
SHTS033200200178
(2) Press the counter shaft into the gears making certain that counter
shaft key and idler gear key groove are aligned.
(3) Press the counter shaft into the gears making certain that counter
shaft key and counter drive gear key groove are aligned.
SHTS033200200181
counter shaft.
! CAUTION
while working.
NOTICE
SHTS033200200182

direction) between the counter drive gear and the retainer ring. If
the clearance exceeds standard value, select a suitable retainer
ring and install it again.
A kind of retainer ring:
2.45 mm {0.0965 in.} White
2.55 mm {0.1004 in.} Red

SHTS033200200183
2.65 mm {0.1043 in.} Yellow
2.75 mm {0.1083 in.} Blue

(6) Press the oil pump drive pin into the counter shaft.
SHTS033200200184

EN0332002H300004
All gears: — — Replace, Visual check

Cracks and defects if necessary.
Idle gear, shaft and — — Replace, Visual check

needle roller bearing: if necessary.
Wear and damage
Counter shaft: — — Replace, Visual check

Wear, chips and cracks if necessary.
Counter shaft key and — — Replace the counter Visual check

key groove: Damage shaft and/or key,
and looseness if necessary.
2A64AA.,5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧤᦬㧟㧝ᣣ‫ᦐᧁޓ‬ᣣ‫ޓ‬ඦᓟ㧠ᤨ㧟㧞ಽ
TRANSMISSION MAIN UNIT (LJ06S) TR02–1
TRANSMISSION MAIN UNIT (LJ06S)

TR02
TR02-002
TRANSMISSION ASSEMBLY................... TR02-2

DATA AND SPECIFICATIONS ......................... TR02-2
DESCRIPTION ................................................ TR02-3
TROUBLESHOOTING ..................................... TR02-4
SPECIAL TOOL ............................................... TR02-6
DISMOUNTING AND MOUNTING .................. TR02-7

COMPONENT LOCATOR................................ TR02-9
OVERHAUL ................................................... TR02-12
INPUT SHAFT, OUTPUT SHAFT, GEARS

AND RELATED PARTS........................... TR02-18
COMPONENT LOCATOR.............................. TR02-18
OVERHAUL ................................................... TR02-20
COUNTER SHAFT, REVERSE IDLER SHAFT

AND GEARS ........................................... TR02-31
COMPONENT LOCATOR.............................. TR02-31
OVERHAUL ................................................... TR02-32
TR02–2 TRANSMISSION MAIN UNIT (LJ06S)
EN0332202I200001
Model FD, FG GD
Type 2, 3, 4, 5, 6th, Synchromesh,
1st and Reverse, Constant mesh
1st 6.893 6.746
2nd 4.274 4.190
3rd 2.607 2.451
Gear ratios: 4th 1.564 1.474
5th 1.000 1.000
6th 0.770 0.823
Reverse 6.453 6.453
Number of teeth input shaft 25
Counter drive gear 44 44
1st gear 12 12
2nd gear 21 21
3rd gear 27 28
Number of teeth counter shaft
4th gear 36 37
5th gear — —
6th gear 48 47
Reverse gear 12 12
1st gear 47 46
2nd gear 51 50
3rd gear 40 39
Number of teeth output shaft 4th gear 32 31
5th gear — —
6th gear 21 22
Reverse gear 44 44
Reverse idler gear 23
Oil capacity, gear box Approx. 8.0 liters {1.76 Imp.gal, 2.11 US gal.}
Oil capacity, gear box with power take-off Approx. 8.5 liters {1.87 Imp.gal, 2.25 US gal.}
Lubricant, type Gear oil (API GL-4)
DESCRIPTION
EN0332202C100001
SHTS033220200001
1 Input shaft 17 Reverse shift fork

2 Oil seal 18 Reverse gear
3 Front bearing retainer 19 Speedometer drive gear
4 5th - 6th synchronizer unit 20 Nut
5 Shift shaft 21 Flange
6 5th - 6th shift fork 22 Output shaft
7 Case cover 23 Speedometer driven gear
8 6th gear 24 Rear bearing retainer
9 4th gear 25 Cylindrical roller bearing
10 Steel ball 26 Reverse shift sleeve
11 Inner shift lever 27 1st - 2nd synchronizer unit
12 3rd - 4th shift fork 28 Counter shaft
13 3rd gear 29 3rd - 4th synchronizer unit
14 2nd gear 30 Counter 6th gear
15 1st - 2nd shift fork 31 Counter drive gear
16 1st gear 32 Transmission case
TROUBLESHOOTING
EN0332202F300001

Gear slip-off (Gear shift housing) Lock ball and spring distorted and/or Replace as required.
broken
worn and/or broken
worn and/or broken
mounting bolts
and/or damaged
sticking of shafts
(Lubrication) Shortage gear oil and/or low oil viscos- Add oil or change oil as required.
ity
Noise (Transmission) Grinding in transmission Check for screws, bolts or other for-
eign materials in transmission.
ing bolts
cosity
expansion plug
of oil viscosity

spring, etc.)
The play of the lever is excessive. A joint is seriously worn. Replace the joint.
Looseness of tightening bolt and nut Inspect and tighten each the bolts and
the nuts.
SPECIAL TOOL
EN0332202K100001
S0965-01900 PULLER
S0965-31180
HOOK
S0965-31200
S0965-01881 PULLER
S0965-01101 PULLER
DISMOUNTING AND MOUNTING

EN0332202H100001

! CAUTION

ATTACHMENTS.
5. DISCONNECT THE TRANSMISSION CONTROL CABLES

WITH THE CABLE BRACKET.
7. REMOVE THE TRANSMISSION.

(1) Remove the lower bolts around the clutch housing.
(2) Place a transmission jack under the transmission.
(3) Remove the remaining bolts around the clutch housing.
(4) Pull the transmission backwards. Lower the transmission jack and
pull the transmission out from under the vehicle.
SHTS033220200009
1. APPLY HEAT-RESISTANT GREASE TO THE INPUT SHAFT

SPLINE.
SHTS033220200010
2. INSTALL THE TRANSMISSION.

! CAUTION
In using the transmission jack, exercise good care to prevent the
transmission dropping from the jack because the transmission is
heavy and unstable.
(1) Jack up the transmission until the input shaft spline and the clutch
disc spline align.
(2) Slip the transmission in and attach the clutch housing to the fly-
wheel housing.
(3) Install the upper bolts around the clutch housing.
SHTS033220200009 (4) Lower the transmission jack and pull the jack out from under the
vehicle.
(5) Install the remaining bolts around the clutch housing.
4. CONNECT THE TRANSMISSION CONTROL CABLES WITH

THE CABLE BRACKET.

MENTS.

FILLER PLUG HOLE.
8. CHECK THE CLUTCH PEDAL PLAY.

Refer to chapter CLUTCH CONTROL.
9. CHECK THE GEAR SHIFT IN EACH POSITION.

Refer to chapter TRANSMISSION/TRANSFER CONTROL.
GEAR SHIFT HOUSING

COMPONENT LOCATOR
EN0332202D100001
WITHOUT POWER SHIFT
1
3
4
2
5
A 6
11 2
7
8
B
9
9
10
12
9
13 5
8
14
15
SHTS033220200011
1 Shift lever shaft 9 Compression spring

2 Oil seal 10 Plug
3 Stud 11 Neutral switch
4 Outer select lever 12 Steel ball
5 Pin 13 Retainer
6 Plain washer 14 Inner shift lever
7 Shift lever shaft housing 15 Select lever shaft
8 Lockout plunger

A 34-38 {350-390, 25-27} B 25-30 {255-306, 19-22}
WITH POWER SHIFT
SHTS033220200012
1 Power shift unit assembly 11 Plain washer

2 Nut 12 Shift lever shaft housing
3 Spring washer 13 Lockout plunger
4 Shift lever shaft 14 Compression spring
5 Oil seal 15 Plug
6 Pipe joint 16 Neutral switch
7 Stud 17 Steel ball
8 Bolt 18 Retainer
9 Outer select lever 19 Inner shift lever
10 Pin 20 Select lever shaft

A 75.5-91.2 {770-930, 56-67} D 40.2-46.1 {410-470, 30-33}
B 34-38 {350-390, 25-27} E 20-30 {204-305, 15-22}
C 25-30 {255-306, 19-22}
SHTS033220200013
1 Expansion plug 16 1st - 2nd shift head

2 3rd - 4th shift shaft 17 1st - 2nd shift shaft
3 Interlock plunger 18 1st - 2nd shift fork
4 3rd - 4th shift fork 19 Compression spring
5 Pins 20 Steel ball
6 Interlock pin 21 Cotter pin
7 5th - 6th shift shaft 22 Slotted nut
8 5th - 6th shift fork 23 Plain washer
9 5th - 6th shift head 24 Inversion lever
10 Transmission case cover 25 Inversion pin
11 Back - up light switch 26 Bolt
12 Air breather 27 Clip holder
13 Reverse shift head 28 Bracket
14 Reverse shift fork 29 Expansion plug
15 Reverse shift shaft

A 37.5-48.5 {385-490, 28-35} B 26-30 {265-300, 19-22}
OVERHAUL
EN0332202H200001
IMPORTANT POINT - DISASSEMBLY
1. REMOVE THE GEAR SHIFT SHAFT, SHIFT FORK AND SHIFT

HEAD.
(1) Set each shaft in the neutral position.
(2) Tap the shift head and shift fork fitting pins lightly with a 5 mm
{0.197 in.} diameter tapping rod.
SHTS033220200014
(3) Drive out the shift shafts and its expansion plugs one at a time.
When removing the shift shaft, remove the shift fork and the shift
head.
NOTICE
Take care not to damage the sliding bore.
! CAUTION
The steel ball may fly out of the hole when removing the shift
shaft. Wear safety glasses during removal.
SHTS033220200015
1. INSTALL THE STEEL BALL, COMPRESSION SPRING, SHIFT

SHAFT, SHIFT FORK AND SHIFT HEAD.
(1) Install the inversion lever and the pin.
(2) Place the ball and spring in the hole.
(3) Depress the ball and spring with a suitable tool.
! CAUTION
The steel ball may fly out of the hole when installing the shift
shaft. Wear safety glasses during installation.
(4) Coat the shift shaft with gear oil.
(5) Align the shift fork and head and put the shift shaft through, and
then slide the shift shaft over the ball.
(6) Place the shift shaft in neutral position.
NOTICE
• Pay special attention to the position and direction of the shift
fork and shift head.
• For 1st–2nd and 3rd–4th shift shafts, insert the interlock pin.
Coat the interlock pin with bearing grease.
SHTS033220200016
2. SECURE THE SHIFT HEAD AND FORK WITH CONCENTRIC

PINS.
(1) Drive the concentric pins into the fork and the head. Make sure
that the slits of the concentric pins are on opposite sides as
shown.
SHTS033220200017
INNER PIN
SLITS
SLITS
OUTER PIN
INSTALL
OUTER PIN INNER PIN

SHTS033220200018

(1) Drive a new oil seal into the shift lever shaft housing with the
installation tool.
SHTS033220200019
(2) Drive a new oil seal into the shift lever shaft with the installation
tool.
(3) Coat the sealing surface between the seal lips with bearing
grease.
NOTICE
• Always use a new oil seal.
• Take care not to damage the seal lip.
• Be sure the oil seal is inserted in the proper direction.
SHTS033220200020
4. INSTALL THE EXPANSION PLUG.

(1) Apply adhesive all around to the expansion plug.
SHTS033220200021
5. INSTALL THE LOCKOUT PLUNGER, THE STEEL BALL AND

THE COMPRESSION SPRING.
(1) Coat the lockout plunger with bearing grease.
(2) Put the compression spring and the steel ball, then install the
lockout plunger as shown in the figure.
NOTICE
When installing the lockout plunger, be careful not to spring out
the steel ball.
SHTS033220200022
(3) After applying lock agent (LOCTITE#575) to the plug, put the
compression spring and install the plug.
SHTS033220200023
6. INSTALL THE SHIFT LEVER SHAFT AND INNER SHIFT

LEVER.
(1) Match the shift lever shaft and inner shift lever as shown, and
VIEW FROM PUSHING DIRECTION OF push the shift lever shaft into the inner shift lever.
NOTICE
A
• (With power shift model) They should be installed so that the
nut seat surface for power shift installing makes an angle of
90° with inner shift lever.
INNER SHIFT LEVER

B
SHIFT LEVER
SHAFT SPLINE
NUT SEAT SURFACE
FOR POWER SHIFT
SHIFT LEVER INSTALLING
SHAFT
90q
INNER SHIFT
LEVER
SHTS033220200024
• (Without power shift model) They should be installed so that

the shift lever shaft installing makes an angle of counter-
clockwise 7° with the inner shift lever.
A
INNER SHIFT LEVER

B
SHIFT LEVER
SHAFT SPLINE
SHIFT LEVER
SHAFT
INNER SHIFT
LEVER
SHTS033220200025
7. INSTALL THE SELECT LEVER SHAFT AND OUTER SELECT

LEVER.
(1) Align the hole of the outer select lever with the hole of the select
lever shaft to fix them with spring pin.
NOTICE
When installing the select lever shaft, be sure to align the holes of
select lever shaft and outer select lever with the spring pin.
SHTS033220200026
8. INSTALL THE NEUTRAL SWITCH

(1) Apply lock agent (LOCTITE#575) to the neutral switch and install
it to the shift lever housing.
SHTS033220200027
9. INSTALL THE TRANSMISSION CASE COVER.

(1) Coat the face of the transmission case with liquid gasket.
NOTICE
• The liquid gasket must be ThreeBond #1215 or equivalent.
SHTS033220200028
10. INSTALL THE SHIFT LEVER SHAFT HOUSING.

(1) Coat the face of the transmission case cover with liquid gasket.
NOTICE
SHTS033220200029

EN0332202H300001
Unit: mm {in.}
Clearance between 0.2-0.45 1.0 {0.039} Replace. Measure

shift fork and sleeve {0.0079-0.0177}

spring and steel ball
wear and damage

and shift shaft wear if necessary.
and damage
Oil seal lip wear and — — Replace, Visual check

damage if necessary.
Shift lever shaft and — — Replace, Visual check

inner shift lever wear if necessary.
and damage
Compression spring — — Replace, Visual check

and lockout plunger if necessary.
and steel ball wear and
damage

AND RELATED PARTS
COMPONENT LOCATOR
EN0332202D100002
SHTS033220200036
1 Retainer ring 24 1st gear sub-assembly

2 Cylindrical roller bearing 25 Constant hub
3 Input shaft 26 Constant sleeve
4 Spacer 27 Reverse gear
5 Roller bearing 28 Thrust washer
6 Synchronizer cone 29 Oil seal
7 Synchronizer ring 30 Dust deflector
8 Synchronizer hub 31 Universal joint flange
9 Compression spring 32 O-ring
10 Synchronizer head 33 Nut
11 Synchronizer key 34 Front bearing retainer
12 Synchronizer sleeve 35 Gasket
13 6th gear 36 Soft washer
14 Needle roller bearing 37 Drain plug
15 Bushing 38 Filler plug
16 4th gear 39 Transmission case
17 Synchronizer double cone 40 Straight pin
18 Synchronizer inner cone 41 Speedometer driven gear bushing
19 Pin 42 Speedometer drive gear
20 Synchronizer bushing 43 Speedometer driven gear
21 3rd gear sub-assembly 44 Rear bearing retainer
22 Output shaft 45 Power take-off cover
23 2nd gear sub-assembly 46 Speed sensor

A 54-68 {550-700, 40-50} D 587-783 {6,000-8,000, 434-578}
B 79-117 {806-1,193, 59-86} E 8.5-10.5 {87-107, 6.3-7.7}
C 63.5-84.5 {650-870, 47-62} F 14.7-29.3 {150-300, 11-23}
OVERHAUL
EN0332202H200002
IMPORTANT POINTS - DISASSENMBLY
1. REMOVE THE OUTPUT SHAFT LOCK NUT.

(1) The lock nut has been caulked, so before loosening it, lift the
caulked part completely out of the shaft groove.
SHTS033220200037
(2) Using the special tool or the commercial tool, remove the lock nut.
NOTICE
Before loosening the lock nut, engage two gears so that the out-
put shaft can not be turned around.
SST: Socket Wrench (S0983-95005)
SHTS033220200038
2. REMOVE THE INPUT SHAFT.

(1) Using the special tools, pull out input shaft with the accompanying
bearings.
SST:
Input Shaft Puller (S0965-02070)
SHTS033220200039
3. REMOVE THE OUTPUT SHAFT REAR BEARING.

! CAUTION
The retainer ring is spring steel and may fly out of the groove dur-
ing removal. Wear safety glasses during removal.
(2) Using the special tools, remove the output shaft rear bearing.
SST:
Hook (S0965-31200)
Puller (S0965-01881)
NOTICE
SHTS033220200040 Insert the hook's click into the groove for the retainer ring, then
secure the puller to the hook with bolts. Secure the puller so that
it does not turn, then rotate the bolt to pull the bearing out.
4. REMOVE THE OUTPUT SHAFT ASSEMBLY FROM THE

TRANSMISSION CASE.
(1) Attach a jig to the end of the output shaft.
! CAUTION
If the output shaft assembly is removed from the transmission
without a jig, the reverse gear will drop from the shaft, which can
result in the personal injury.
(2) Attach a suitable hook or other lifting device around the 3rd-4th
speed synchronizer sleeve and carefully lift the output shaft
assembly from the transmission case.
SHTS033220200041
(3) When removing the output shaft assembly, remove the synchro-
nizer ring and the cone of the input shaft gear.
SHTS033220200042
5. REMOVE THE BUSHINGS FROM THE OUTPUT SHAFT.

(1) Support the 2nd gear and press the output shaft rear end through
the bushings, 1st gear, synchronizer unit, 2nd gear and needle
roller bearings.
NOTICE
When removing the output shaft, do not allow the shaft to drop on
a hard surface.
! CAUTION
Never put your feet under the shaft during removal. The shaft
could drop suddenly, which can result in personal injury.
SHTS033220200043
(2) Support the 3rd gear and press the output shaft rear end through
the bushing, the 4th gear, the synchronizer unit and the needle
roller bearings.
NOTICE
a hard surface.
! CAUTION
SHTS033220200044
6. DISASSEMBLE THE INPUT SHAFT.

(1) Remove retainer ring.
(2) Using a press, remove the cylindrical roller bearing.
! CAUTION
• The retainer ring is spring steel and may fly out of the groove
during removal. Wear safety glasses during removal.
• Never put your feet under the shaft during removal. The shaft
SHTS033220200045
1. ASSEMBLE THE SYNCHRONIZER UNIT.

(1) Install the compression spring.
! CAUTION
The compression spring is spring steel and may fly out of the hole
during assembly. Wear safety glasses during assembly.
SHTS033220200046
(2) Install the synchronizer key and head.
SHTS033220200047
2. INSTALL THE 2ND GEAR, SYNCHRONIZER UNIT, 1ST GEAR,

1ST GEAR BUSHING AND REVERSE GEAR BUSHING.
(1) Install the 2nd gear.
(2) Heat the 2nd synchronizer bushing for about 5 minutes in oil
heated to 120°C to 130°C {248°F to 266°F}.
Then install the synchronizer bushing on the shaft.
NOTICE
Do not heat the synchronizer bushing in excess of 150°C {302°F}.
! CAUTION
Never touch hot oil and heated synchronizer bushing with your
SHTS033220200048
bare hand. This can result in personal injury.
(3) Install the synchronizer bushing, synchronizer inner cone, syn-

chronizer double cone, synchronizer ring and pins.
SHTS033220200049
(4) Heat the 2nd synchronizer unit for about 5 minutes in oil heated to
120°C to 130°C {248°F to 266°F}.
Then install the synchronizer unit on the shaft.
NOTICE
Do not heat the synchronizer unit in excess of 150°C {302°F}.
! CAUTION
Never touch hot oil and heated synchronizer unit with your bare
hand. This can result in personal injury.
SHTS033220200050
(5) Heat the 1st gear bushing for about 5 minutes in oil heated to
120°C to 130°C {248°F to 266°F}.
Then install the bushing on the shaft.
NOTICE
Do not heat the bushing in excess of 150°C {302°F}.
! CAUTION
Never touch hot oil and heated bushing with your bare hand. This
can result in personal injury.
SHTS033220200051
(6) Heat the reverse gear bushing for about 5 minutes in oil heated to
120°C to 130°C {248°F to 266°F}.
Then install the bushing on the shaft.
NOTICE
Do not heat the bushing in excess of 150°C {302°F}.
! CAUTION
SHTS033220200052
(7) Hold the thrust washer with a jig.
! CAUTION
If the output shaft assembly is installed to the transmission with-
out a jig, the reverse gear will drop from the shaft, which can pos-
sibly result in personal injury.
SHTS033220200053
3. INSTALL THE 3RD GEAR, SYNCHRONIZER UNIT, 4TH GEAR

AND BUSHING ON THE SHAFT.
(1) Install the 3rd gear.
(2) Heat the 3rd synchronizer bushing for about 5 minutes in oil
Then install the synchronizer bushing on the shaft.
NOTICE
Do not heat the synchronizer bushing in excess of 150°C {302°F}.
! CAUTION
Never touch hot oil and heated synchronizer bushing with your
SHTS033220200048
bare hand. This can result in personal injury.

chronizer double cone, synchronizer ring and pin.
SHTS033220200054
(4) Heat the 3rd-4th synchronizer unit for about 5 minutes in oil
Then install the synchronizer unit on the shaft.
NOTICE
Do not heat the synchronizer unit in excess of 150°C {302°F}.
! CAUTION
Never touch hot oil and heated synchronizer unit with your bare
hand. This can result in personal injury.
SHTS033220200050
(5) Install the 4th gear and needle roller bearing.

(6) Install the 4th gear bushing.
Heat the bushing to approximately 120°C to 130°C {248°F to
266°F} in a heater and place on output shaft against the end stop.
! CAUTION
SHTS033220200055
4. INSTALL THE GEARS, BUSHINGS, NEEDLE ROLLER BEAR-

ING, SYNCHRONIZER UNITS AND OTHER PARTS ON THE
OUTPUT SHAFT.
(1) Select a retainer ring that will provide a tight fit.
Clearance: Less than 0.1 mm {0.0039 in.}
NOTICE
• Always use a new retainer ring.
• Make sure that the retainer ring seats in the groove.
SHTS033220200056
Retainer rings are available in the following sizes: Position "A"
2.4 mm {0.0945 in.} None
2.5 mm {0.0984 in.} Blue
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Yellow
2.8 mm {0.1102 in.} Red

SHTS033220200057
Retainer rings are available in the following sizes: Position "B"
2.45 mm {0.0965 in.} None
2.55 mm {0.1004 in.} Blue
! CAUTION
ing installation. Wear safety glasses during installation.
5. ASSEMBLE THE INPUT SHAFT.

(1) Using a press, install the cylindrical roller bearing to the input
shaft.
NOTICE
• When installing the bearing side ring, place the larger cham-
fering side to the gear.
• Do not put any pressure on the outer race.
SHTS033220200058
(2) Select a retainer ring, that will provide a tight fit.

NOTICE
Retainer rings are available in the following sizes
2.4 mm {0.0945 in.} None
SHTS033220200059 2.5 mm {0.0984 in.} Blue
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Yellow
! CAUTION
6. INSTALL THE ROLLER BEARING IN THE COUNTERBORE OF

THE INPUT SHAFT.
(1) Apply gear oil to the bearings.
(2) Place spacers at both ends of the bearings.
NOTICE
Always use roller bearings of uniform diameter (16 pieces per set).
There are 3 types of roller bearings in different diameters. There
are distinguished by the colors red, blue, and white.
! CAUTION
SHTS033220200060
7. REPLACE THE OIL SEAL OF THE FRONT AND REAR BEAR-

ING RETAINER.
(1) Using a screwdriver, remove the oil seal from the bearing retainer.
(2) Using a press and a suitable installing tool, press the oil seal into
the bearing retainer.
NOTICE
• Coat gear oil to oil seal surface.
• Be sure the oil seal is installed in the proper direction.
(3) Coat bearing grease to the sealing surface between the seal lips.
SHTS033220200061
8. INSTALL THE SPEEDOMETER DRIVEN GEAR BUSHING.

(1) Install the O-ring and oil seal to the bushing.
O-RING
NOTICE
• Coat the O-ring, oil seal and driven gear with bearing grease.
• Make sure that the oil seal is installed in the correct direction
when replacing it.
(2) Match the mark line on the bushing with the mark line on the rear
bearing retainer.
OIL SEAL
SHTS033220200062
(3) Align the speedometer driven gear bushing hole with the hole of
the rear bearing retainer.
The mark should be

Number of the drive Number of the
matched to the
gear teeth driven gear teeth
mark on retainer
7 18 One line
SHTS033220200063
9. INSTALL THE OUTPUT SHAFT ASSEMBLY IN THE TRANS-

MISSION CASE.
(1) Using ropes or some other lifting device, carefully lower the output
shaft assembly into the case. When installing the output shaft,
install the synchronizer ring and cone of the input shaft gear.
(2) Place the output shaft assembly in position.
NOTICE
Attach a jig to the end of output shaft.
! CAUTION
If the output shaft assembly is installed to the transmission with-
SHTS033220200042 out a jig, the reverse gear will drop from the shaft, which can pos-
sibly result in the personal injury.
10. INSTALL THE INPUT SHAFT INTO THE TRANSMISSION

CASE.
(1) Mesh the synchronizer cone to the input shaft.
(2) Align the synchronizer hub slot with synchronizer ring.
SHTS033220200064
11. INSTALL THE FRONT BEARING RETAINER.

(1) Coat both sides of the gasket with liquid gasket.
(2) Apply liquid gasket or sealing tape to the bolt "A".
NOTICE
• When installing the bearing retainer, the gasket must be
installed in such a way that the gasket notch matches the oil
drain hole on the case so as not to block the hole.
A • The liquid gasket must be ThreeBond #HP-17 or equivalent.
SHTS033220200065

NOTICE
• The liquid gasket must be ThreeBond #HP-17 or equivalent.
(2) Apply liquid gasket or sealing tape to the bolt.
SHTS033220200066
13. INSTALL THE OUTPUT SHAFT LOCK NUT.

(1) Before tightening the lock nut engage two gears so that the shaft
can not be turned around.
(2) Install the lock nut to the output shaft and tighten it.
NOTICE
Do not damage the O-ring.
SHTS033220200067
14. MEASURE THE GEAR BACKLASH, END PLAY AND RADIAL

PLAY.
(1) Block the counter shaft with a pry bar when measuring.
<BACKLASH "A"> Unit: mm {in.}
Assembly Standard Service Limit
Reverse gear 0.08-0.16 {0.0032-0.0062}
1st gear 0.08-0.18 {0.0032-0.0070}
2nd gear
0.08-0.16 {0.0032-0.0062}
3rd gear 0.4 {0.0157}
4th gear
6th gear 0.04-0.12 {0.0016-0.0047}
Input shaft gear
<END PLAY "B"> Unit: mm {in.}
Reverse gear 0.20-0.35 {0.0079-0.0137}
SHTS033220200068
1st gear
2nd gear 0.5 {0.0197}

0.15-0.30 {0.0060-0.0118}
3rd gear
4th gear
6th gear 0.15-0.50 {0.0060-0.0196}
<RADIAL PLAY "C"> Unit: mm {in.}
Assembly Standard
Reverse gear
0.033-0.111 {0.0013-0.0043}
1st gear
2nd gear 0.022-0.071 {0.0009-0.0027}
3rd gear 0.020-0.068 {0.0008-0.0026}
4th gear 0.021-0.095 {0.0009-0.0037}
6th gear 0.021-0.062 {0.0009-0.0024}
15. CAULK THE OUTSIDE RIM OF THE OUTPUT SHAFT LOCK

NUT.
(1) Using a hammer and a chisel, caulk the outside rim of the lock nut
into the groove on the output shaft.
A: More than 1.5 mm {0.0591 in.}
NOTICE
• The caulking should fit the groove thoroughly.
• The caulking should be done without rift.
SHTS033220200069

EN0332202H300002
Unit: mm {in.}
Inspection Item Standard Limit Remedy Inspection Procedure
Synchronizer ring, defor- — — Replace, Visual check

mity, crack and excessive if necessary.
damage
Gear excessive wear, — — Replace, Visual check

chips and cracks if necessary.
Clearance between syn- 2nd, 3rd and 4th 0.2 Replace the syn- Measure
chronizer ring and syn- gear {0.0079} chronizer ring and/
chronizer cone or gear 1.0-1.8 or gear sub assem-
sub assembly {0.0394-0.0708} bly.
6th and Input

gear
1.2-2.0
{0.0473-0.0787}
Oil seal lip wear and dam- — — Replace, Visual check

age if necessary.
Cylindrical roller bearing — — Replace, Visual check

and ball bearing improper if necessary.
rotation

COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS

COMPONENT LOCATOR
EN0332202D100003
SHTS033220200075
1 Seal cover 9 Spacer

2 Cylindrical roller bearing 10 Reverse idler gear
3 Retainer ring 11 Needle roller bearing
4 Counter drive gear 12 Reverse idler shaft
5 Counter 6th gear 13 O-ring
6 Counter shaft 14 Lock plate
7 Woodruff key 15 Bolt
8 Thrust washer

A 19-25 {190-260, 14-18}
OVERHAUL
EN0332202H200003
1. REMOVE THE IDLER SHAFT AND IDLER GEAR.

(1) Using a special tool, pull out the reverse idler shaft while holding
the reverse idler gear thrust washers and bearing inside the case.
SST: Sliding Hammer (S0942-01442)
SHTS033220200076
2. REMOVE THE COUNTER SHAFT REAR BEARING.

(1) Remove the retainer rings from the counter shaft and the cylindri-
cal roller bearing.
! CAUTION
The retainer ring is spring steel and may fly out of groove during
removal. Wear safety glasses during removal.
SHTS033220200077
(2) Install the special tools on the rear cylindrical roller bearing and
remove it.
SST:
Hook (S0965-31180)
Puller (S0965-01900)
NOTICE
Insert the hook's click into the groove for the retainer ring then
SHTS033220200078
3. REMOVE THE COUNTER SHAFT FROM THE TRANSMISSION

CASE.
(1) Tie a rope or hook around the counter shaft and carefully pry the
counter shaft assembly rearward until the front end of the shaft is
cleared out of the front cylindrical roller bearing.
(2) Carefully lift the counter shaft assembly from the case.
SHTS033220200079
4. REMOVE THE CYLINDRICAL ROLLER BEARING INNER

RACE.
(1) Using a special tool on the inner race, pull out the front cylindrical
roller bearing inner race from the counter shaft.
SST: Puller (S0965-01101)
SHTS033220200080
5. REMOVE THE COUNTER SHAFT GEARS.

! CAUTION
SHTS033220200081
(2) Support the counter shaft drive gear as close as possible to the
gear hub and press the counter shaft front end until it is free of the
drive gear.
(3) Support the counter 6th gear under the gear teeth and press the
counter shaft out of the gear.
NOTICE
When removing the counter shaft gears, do not allow the shaft to
drop to on a hard surface.
! CAUTION
SHTS033220200082 could drop suddenly, which can result in personal injury.
1. INSTALL THE COUNTER DRIVE GEAR AND COUNTER 6TH

GEAR.
(1) Select the proper size key according to the size of the key groove.
Thickness "T" Shape
10.015-10.024 mm
{0.3943-0.3946 in.}
SHTS033220200085 10.080-10.090 mm
{0.3969-0.3972 in.}
(2) Press the counter shaft into the gears making certain that the key
and keyway are aligned.
NOTICE
Ensure that the gears are installed in the proper direction.
SHTS033220200086
(3) Select a retainer ring that will provide a tight fit and install it on the
shaft.
NOTICE
• Make sure that the retainer ring seats in place.
2.4 mm {0.0945 in.} Brown

SHTS033220200087
2.5 mm {0.0984 in.} Blue
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Yellow
2.8 mm {0.1102 in.} Red
! CAUTION
2. INSTALL THE COUNTER SHAFT IN THE TRANSMISSION

CASE.
NOTICE
SHTS033220200079
shaft.
NOTICE
Retainer rings are available in the following sizes.
2.4 mm {0.0945 in.} Green

SHTS033220200088
2.5 mm {0.0984 in.} Brown
2.6 mm {0.1024 in.} Sky-blue
2.7 mm {0.1063 in.} Black
! CAUTION
3. DISTANCE BETWEEN THE GEAR CASE OUTER SURFACE

AND THE FRONT BEARING OUTER RACE.
4. PRESS IN THE SEAL COVER AND MAKE IT FLUSH WITH THE

CASE FRONT.
SHTS033220200089
5. INSTALL THE REVERSE IDLER GEAR.

NOTICE
• Apply a light coat of gear oil to the needle roller bearing,
spacer and thrust washers before assembling them.
• Be sure the gear is installed in the proper direction.
• Make sure that O-ring is in the shaft groove.
SHTS033220200090
6. MEASURE THE REVERSE IDLER GEAR END PLAY.

SHTS033220200091
7. MEASURE THE BACKLASH BETWEEN THE REVERSE IDLER

GEAR AND THE COUNTER SHAFT REVERSE GEAR.
8. MEASURE THE REVERSE IDLER GEAR RADIAL PLAY.

SHTS033220200092

EN0332202H300003
All gears for cracks and — — Replace, Visual check

defects if necessary.
Idler gear, shaft and nee- — — Replace, Visual check

dle roller bearing wear and if necessary.
damage
Counter shaft wear, chips — — Replace, Visual check

and cracks if necessary.
Counter shaft key way — — Replace the Visual check

damage and looseness counter shaft
and/or key,
If necessary.
2A64AA/(5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧠ಽ
TRANSMISSION MAIN UNIT (MF06S) TR02–1
TRANSMISSION MAIN UNIT (MF06S)

TR 02
TR02-003
TRANSMISSION ASSEMBLY................... TR02-2

DESCRIPTION ................................................ TR02-3
SPECIAL TOOL ............................................... TR02-6

OVERHAUL ................................................... TR02-11
INPUT SHAFT, OUTPUT SHAFT,

GEARS AND RELATED PARTS............. TR02-15
OVERHAUL ................................................... TR02-17
COUNTER SHAFT,
REVERSE IDLER SHAFT AND GEARS TR02-27
OVERHAUL ................................................... TR02-28
TR02–2 TRANSMISSION MAIN UNIT (MF06S)
EN0332302I200001
FG, FL, Hong Kong

Model Singapore GH Indonesia FM2P
and Taiwan GH
Type 2, 3, 4, 5, 6th, Synchromesh,
1st and Reverse, Constant mesh
1st 8.189 7.395 8.189
2nd 5.340 4.758 5.086
3rd 3.076 3.076 3.076
Gear ratios: 4th 1.936 1.936 1.936
5th 1.341 1.341 1.341
6th 1.000 1.000 1.000
Reverse 7.142 7.142 7.142
Number of teeth input shaft 22
Counter drive gear 47 47 47
1st gear 12 13 12
2nd gear 20 22 21
Number of teeth counter 3rd gear 25 25 25
shaft 4th gear 32 32 32
5th gear 43 43 43
6th gear — — —
Reverse gear 21 21 21
1st gear 46 45 46
2nd gear 50 49 50
3rd gear 36 36 36
Number of teeth output
4th gear 29 29 29
shaft
5th gear 27 27 27
6th gear — — —
Reverse gear 46 46 46
Reverse idler gear 29/19
Oil capacity, gear box Approx. 11.5 liters {2.53 Imp.gal, 3.04 US gal.}
Oil capacity, gear box with power take-off Approx. 11.8 liters {2.6 Imp.gal, 3.1 US gal.}
Lubricant, type Gear oil (API GL-4, MIL-L-2105)
DESCRIPTION
EN0332302C100001
SHTS033230200001
1 Input shaft 18 Speedometer drive gear

2 Front bearing retainer 19 Lock nut
3 Oil seal 20 Flange
4 5th - 6th synchronizer unit 21 Output shaft
5 Shift shaft 22 Speedometer driven gear
6 5th gear 23 Rear bearing retainer
7 5th - 6th shift fork 24 Cylindrical roller bearing
8 4th gear 25 Reverse shift sleeve
9 3rd - 4th shift fork 26 1st - 2nd synchronizer unit
10 Inner shift lever 27 Counter shaft
11 3rd gear 28 Counter 3rd gear
12 Steel ball 29 3rd - 4th synchronizer unit
13 2nd gear 30 Counter 4th gear
14 1st - 2nd shift fork 31 Counter 5th gear
15 1st gear 32 Counter drive gear
16 Reverse gear 33 Transmission case
17 Reverse shift fork
TROUBLESHOOTING
EN0332302F300001

Gear slip-off (Gear shift housing) Lock ball and spring distorted and/or Replace or replace as required.
broken
worn and/or broken
worn and/or broken
mounting bolts
and/or damaged
sticking of shafts
(Lubrication) Shortage gear oil and/or low oil viscos- Add oil or change oil as required.
ity
Noise (Transmission) Grinding in transmission Check for screws, bolts or other for-
eign materials in transmission.
ing bolts
cosity
expansion plug
of oil viscosity

spring, etc.)
The play of the lever is excessive. A joint is seriously worn. Replace the joint.
Looseness of tightening bolt and nut Inspect and tighten each the bolts and
the nuts.
SPECIAL TOOL
EN0332302K100001
S0965-01900 PULLER
S0965-31190
HOOK
S0965-31210
S0965-01881 PULLER
S0965-01101 PULLER
S0965-91250 ADAPTER

EN0332302H100001

! CAUTION

ATTACHMENTS.


SHTS033230200010

SPLINE.
SHTS033230200011

! CAUTION
In using the transmission jack, exercise good care to prevent the
transmission dropping from the jack because the transmission is
heavy and unstable.
disc spline align.
wheel housing.
SHTS033230200010 (4) Lower the transmission jack and pull the jack out from under the
vehicle.

THE CABLE BRACKET.

MENTS.

FILLER PLUG HOLE.
8. CHECK THE CLUTCH PEDAL PLAY.

Refer to chapter "CLUTCH CONTROL".
9. CHECK THE GEAR SHIFT IN EACH POSITION.

Refer to the chapter "TRANSMISSION/TRANSFER CONTROL".
GEAR SHIFT HOUSING

COMPONENT LOCATOR
EN0332302D100001
SHTS033230200012
1 Oil seal 7 Inner shift lever

2 Outer select lever 8 Select lever shaft
3 Select lever pin 9 Shift lever shaft housing
4 Neutral switch 10 Shift lever shaft
5 Lock pin 11 Power shift unit (If so equipped)
6 Expansion plug

A 37.5-48.5 {383-494, 28-35} D 9.8-11.8 {100-120, 7.3-8.6}
B 101-147 {1,030-1,498, 75-108} E 34-38 {347-387, 26-28}
C 64-86 {653-876, 48-63}
SHTS033230200013
1 Expansion plug 12 Back-up light switch

2 3rd - 4th shift shaft 13 Air breather
3 Interlock plunger 14 Reverse shift head
4 3rd - 4th shift fork 15 Reverse shift fork
5 Concentric pins 16 Reverse shift shaft
6 Collar 17 1st - 2nd shift head
7 Interlock pin 18 1st - 2nd shift shaft
8 5th - 6th shift shaft 19 1st - 2nd shift fork
9 5th - 6th shift fork 20 Compression spring
10 5th - 6th shift head 21 Steel ball
11 Transmission case cover 22 Link rod support lower bracket

A 93-117 {950-1,200, 69-86} C 26-30 {266-305, 20-22}
B 37.5-48.5 {383-494, 28-35}
OVERHAUL
EN0332302H200001
1. REMOVE THE GEAR SHIFT SHAFT, SHIFT FORK, SHIFT

HEAD AND COLLAR.
(1) Set each shaft in the neutral position.
(2) Tap the shift head and shift fork fitting pins lightly with a 3.5mm
{0.138 in.} diameter tapping rod.
SHTS033230200014
(3) Drive out the shift shafts and its expansion plugs one at a time.
When removing the shift shaft, remove the shift fork and the shift
head.
NOTICE
Take care not to damage the sliding bore.
! CAUTION
The steel ball may fly out of the hole when removing the shift
shaft. Wear safety glasses during removal.
SHTS033230200015
1. INSTALL THE STEEL BALL, COMPRESSION SPRING, SHIFT

SHAFT, SHIFT FORK AND SHIFT HEAD.
(1) Place the ball and spring in the hole.
(2) Depress the ball and spring with a suitable tool.
! CAUTION
The steel ball may fly out of the hole when installing the shift
shaft. Wear safety glasses during installation.
(3) Coat the shift shaft with gear oil.
(4) Align the shift fork and head and put the shift shaft through, and
then slide the shift shaft over the ball.
(5) Place the shift shaft in neutral position.
NOTICE
• Pay special attention to the position and direction of the shift
fork and shift head.
• For 1st-2nd and 3rd-4th shift shafts, insert the interlock pin.
Coat the interlock pin with bearing grease.
SHTS033230200016
2. SECURE THE SHIFT HEAD AND FORK WITH CONCENTRIC

PINS.
(1) Drive the concentric pins into the fork and the head. Make sure
that the slits of the concentric pins are on opposite sides as
shown.
SHTS033230200017
INNER PIN
SLITS
SLITS
OUTER PIN
INSTALL
OUTER PIN INNER PIN

SHTS033230200018

(1) Drive the new oil seal into the shift lever shaft housing with the
installation tool.
(2) Coat the sealing surface between the seal lips with bearing
grease.
NOTICE
SHTS033230200019
4. INSTALL THE EXPANSION PLUG.

(1) Apply adhesive all around to the expansion plug.
SHTS033230200020
5. INSERT THE SHIFT LEVER PIN INTO THE OUTER SELECT

LEVER.
NOTICE
Pay attention to the position of the shift and the direction of the
shift lever pin.
SHTS033230200021
6. INSTALL THE TRANSMISSION CASE COVER.

(1) Coat the face of the transmission case with liquid gasket.
NOTICE
SHTS033230200022
7. INSTALL THE SHIFT LEVER SHAFT HOUSING.

(1) Coat the face of the transmission case cover with liquid gasket.
NOTICE
SHTS033230200023

EN0332302H300001
Unit: mm {in.}
Clearance between shift 0.20-0.45 1.0 {0.0394} Replace. Measure

fork and sleeve {0.0079-0.0177}

spring and steel ball
wear and damage

and shift shaft wear and if necessary.
damage
Oil seal lip wear and — — Replace, Visual check

damage if necessary.
Shift lever shaft and — — Replace, Visual check

inner shift lever wear if necessary.
and damage

AND RELATED PARTS
COMPONENT LOCATOR
EN0332302D100002
SHTS033230200029
1 Retainer ring 24 1st gear sub-assembly

2 Cylindrical roller bearing 25 Reverse gear
3 Input shaft 26 Constant hub
4 Spacer 27 Constant sleeve
5 Roller bearing 28 Oil seal
6 Synchronizer cone 29 Dust deflector
7 Synchronizer ring 30 Universal joint flange
8 Synchronizer hub 31 O-ring
9 Compression spring 32 Lock nut
10 Synchronizer head 33 Front bearing retainer
11 Synchronizer key 34 Gasket
12 Synchronizer sleeve 35 Transmission case
13 5th gear 36 Speedometer driven gear bushing
14 Needle roller bearing 37 Speedometer driven gear
15 Bushing 38 Key
16 4th gear sub-assembly 39 Speedometer drive gear
17 3rd gear sub-assembly 40 Rear bearing retainer
18 Output shaft 41 Power take-off cover
19 Pin 42 Soft washer
20 2nd gear sub-assembly 43 Drain plug
21 Synchronizer bushing 44 Filler plug
22 Synchronizer inner cone 45 Transmission speedometer gear and gear ratio
plate
23 Synchronizer double cone 46 Speed sensor

A 587-783 {6,000-8,000, 434-578} E 79-117 {800-1,200, 58-86}
B 73-93 {750-950, 55-68} F 19-25 {190-260, 14-18}
C 19.5-24.5 {200-250, 15-18} G 14.7-29.3 {150-300, 11-23}
D 64-86 {650-870, 47-62}
OVERHAUL
EN0332302H200002
1. REMOVE THE OUTPUT SHAFT LOCK NUT.

(1) The lock nut has been caulked, so before loosening it, lift the
caulked part completely out of the shaft groove.
SHTS033230200030
(2) Using the special tool or the commercial tool, remove the lock nut.
NOTICE
Before loosening the lock nut, engage two gears so that the out-
put shaft can not be turned around.
SHTS033230200031
2. REMOVE THE INPUT SHAFT.

(1) Using the special tools, pull out input shaft with the accompanying
bearings.
SST:
Input Shaft Puller (S0965-02070)
SHTS033230200032
3. REMOVE THE OUTPUT SHAFT REAR BEARING.

! CAUTION
(2) Using the special tools, remove the output shaft rear bearing.
SST:
Hook (S0965-31210)
Puller (S0965-01881)
NOTICE
SHTS033230200033 Insert the hook's click into the groove for the retainer ring, then
4. REMOVE THE OUTPUT SHAFT ASSEMBLY FROM THE

TRANSMISSION CASE.
(1) Attach a jig to the end of the output shaft.
! CAUTION
If the output shaft assembly is removed from the transmission
without a jig, the reverse gear will drop from the shaft, which can
possibly result in the personal injury.
SHTS033230200034
(2) Attach a suitable hook or other lifting device around the 3rd-4th
speed synchronizer sleeve and carefully lift the output shaft
assembly from the transmission case.
(3) When removing the output shaft assembly, remove the synchro-
nizer ring and the cone of the input shaft gear.
SHTS033230200035
5. REMOVE THE BUSHINGS FROM THE OUTPUT SHAFT.

(1) Support the 2nd gear and press the output shaft front end through
the bushings, 1st gear, synchronizer unit, 2nd gear and needle
roller bearings.
NOTICE
a hard surface.
! CAUTION
Stay out from under the shaft during removal. The shaft could
drop suddenly, which can result in personal injury.
SHTS033230200036
6. DISASSEMBLE THE INPUT SHAFT.

(1) Remove retainer ring.
(2) Using a press, remove the cylindrical roller bearing.
! CAUTION
• The retainer ring is spring steel and may fly out of the groove
during removal. Wear safety glasses during removal.
• Stay out from under the shaft during removal. The shaft
SHTS033230200037
1. ASSEMBLE THE SYNCHRONIZER UNIT.

(1) Install the compression spring.
! CAUTION
The compression spring is spring steel and may fly out of the hole
during assembly. Wear safety glasses during assembly.
SHTS033230200038
(2) Install the synchronizer key and head.
SHTS033230200039
2. INSTALL THE 2ND GEAR, SYNCHRONIZER UNIT, 1ST GEAR,

1ST GEAR BUSHING AND REVERSE GEAR BUSHING.
(1) Install the needle roller bearing and 2nd gear.
NOTICE
Coat the needle roller bearing with gear oil during installation to
provide initial lubrication.
chronizer double cone, synchronizer ring and pins on the 2nd
gear.
SHTS033230200040
(3) Heat the synchronizer unit and bushing for about 5 minutes in
water or oil heated to 80-100°C {176-212°F}.
(4) Install the synchronizer unit and other parts on the output shaft.
(5) Place the bushing on the output shaft against the end stop.
NOTICE
• Do not heat the synchronizer unit and bushing in excess of
120°C {248°F}.
• If the unit is heated in hot water, remove moisture before
installation.
! CAUTION
SHTS033230200041
Never touch hot water or hot oil and heated synchronizer unit and
bushing with your bare hand. This can result in personal injury.
3. INSTALL THE REVERSE GEAR.

(1) Install the needle roller bearing and reverse gear.
(2) Install the constant hub and constant sleeve.
(3) Hold the constant hub with jig.
! CAUTION
When installing the output shaft assembly in the transmission
case, be careful not to drop the reverse gear from the shaft.
SHTS033230200042
4. INSTALL THE 3RD AND 4TH GEAR.

(1) Install the needle roller bearing and 3rd gear.
(2) Install the 3rd-4th gear synchronizer unit.
(3) Install the pin, 4th gear, needle roller bearing and bushing.
SHTS033230200043
5. INSTALL THE GEARS, BUSHINGS, NEEDLE ROLLER BEAR-

ING, SYNCHRONIZER UNITS AND OTHER PARTS ON THE
OUTPUT SHAFT.
NOTICE
Coat the needle roller bearings with gear oil during installation to
provided initial lubrication.
(1) Select a retainer ring that will provide a tight fit.
NOTICE
SHTS033230200044 • Make sure that the retainer ring seats in the groove.
Retainer rings are available in the following sizes: Position "A"
2.4 mm {0.0945 in.} None
2.5 mm {0.0984 in.} White
2.6 mm {0.1024 in.} Green
2.7 mm {0.1063 in.} Brown
2.8 mm {0.1102 in.} Blue

SHTS033230200045
Retainer rings are available in the following sizes: Position "B"
2.35 mm {0.0925 in.} White
2.45 mm {0.0965 in.} None
2.55 mm {0.1004 in.} Blue
! CAUTION
6. ASSEMBLE THE INPUT SHAFT.

(1) Using a press, install the cylindrical roller bearing to the input
shaft.
NOTICE
• Do not put any pressure on the outer race
SHTS033230200046
(2) Select a retainer ring.

NOTICE
Retainer rings are available in the following sizes.
2.8 mm {0.1102 in.} None
SHTS033230200047 2.9 mm {0.1141 in.} Blue
3.0 mm {0.1181 in.} Green
3.1 mm {0.1220 in.} Yellow
3.2 mm {0.1260 in.} Red
! CAUTION
7. INSTALL THE ROLLER BEARING IN THE COUNTERBORE OF

THE INPUT SHAFT.
(1) Apply gear oil to the bearings.
(2) Place spacers at both ends of the bearings.
NOTICE
Always use roller bearings of uniform diameter (15 pieces per set).
There are 3 types of roller bearings in different diameters. There
are distinguished by the colors red, blue, and white.
! CAUTION
SHTS033230200048 The retainer ring is spring steel and may fly out of the groove dur-
8. REPLACE THE OIL SEAL OF THE FRONT AND REAR BEAR-

ING RETAINER.
(1) Using a screwdriver, remove the oil seal from the bearing retainer.
(2) Using a press and a suitable installing tool, press the oil seal into
the front bearing retainer.
(3) Using a press and a special tool, press the oil seal into the rear
bearing retainer.
SST: Adapter (S0965-91250)
NOTICE
Be sure the oil seal is installed in the proper direction.
(4) Coat bearing grease to the sealing surface between the seal lips.
SHTS033230200049
9. INSTALL THE SPEEDOMETER DRIVEN GEAR BUSHING.

(1) Install the O-ring and oil seal to the bushing.
O-RING
NOTICE
• Coat the O-ring, oil seal and driven gear with bearing grease.
• Make sure that the oil seal is installed in the correct direction
when replacing it.
(2) Match the mark line on the bushing with the mark line on the rear
bearing retainer.
(3) Align the speedometer driven gear bushing hole with the hole of
OIL SEAL the rear bearing retainer.
SHTS033230200050
The mark should be

Number of the drive Number of the
matched to the
gear teeth driven gear teeth
mark on retainer
7 18 18
SHTS033230200051
10. INSTALL THE OUTPUT SHAFT ASSEMBLY IN THE TRANS-

MISSION CASE.
(1) Using ropes or some other lifting device, carefully lower the output
shaft assembly into the case.
(2) When installing the output shaft assembly, install the synchronizer
ring and cone of the input shaft gear.
(3) Place the output shaft assembly in position.
SHTS033230200052
11. INSTALL THE INPUT SHAFT INTO THE TRANSMISSION

CASE.
(1) Mesh the synchronizer cone to the input shaft.
(2) Align the synchronizer hub slot with synchronizer ring.
SHTS033230200053
12. INSTALL THE FRONT BEARING RETAINER.

(2) Apply liquid gasket or sealing tape to the bolt "A".
NOTICE
• When installing the bearing retainer, the gasket must be
installed in such a way that the gasket notch matches the oil
drain hole on the case so as not to block the hole.
A • The liquid gasket must be ThreeBond #1215 or equivalent.
SHTS033230200054

NOTICE
(2) Apply liquid gasket or sealing tape to the bolt.
SHTS033230200055
14. INSTALL THE POWER TAKE-OFF COVER.

NOTICE
SHTS033230200056
15. INSTALL THE OUTPUT SHAFT LOCK NUT.

(1) Before tightening the lock nut engage two gears so that the shaft
can not be turned around.
(2) Install the lock nut to the output shaft and tighten it.
NOTICE
Do not damage the O-ring.
SHTS033230200057
16. MEASURE THE GEAR BACKLASH, END PLAY AND RADIAL

PLAY.
(1) Block the counter shaft with a pry bar when measuring.
(2) Measure the gear backlash, end play and radial play at four points
of each gear.
<BACKLASH "A"> Unit: mm {in.}
Reverse gear
0.08-0.16 {0.0032-0.0062}
1st gear
2nd gear
3rd gear 0.05-0.13 {0.0020-0.0051} 0.4 {0.0157}
4th gear
5th gear
0.08-0.16 {0.0032-0.0062}
Input shaft gear
<END PLAY "B"> Unit: mm {in.}
Reverse gear
SHTS033230200058
1st gear
2nd gear 0.15-0.30 {0.0060-0.0118} 0.5 {0.0197}

3rd gear
4th gear
5th gear 0.15-0.50 {0.0049-0.0162}
<RADIAL PLAY "C"> Unit: mm {in.}
Assembly Standard
Reverse gear 0.015-0.085 {0.0006-0.0033}
1st gear 0.012-0.061 {0.0005-0.0024}
2nd gear 0.012-0.061 {0.0005-0.0024}
3rd gear 0.013-0.083 {0.0006-0.0032}
4th gear 0.015-0.078 {0.0006-0.0030}
5th gear 0.110-0.155 {0.0044-0.0061}
17. CAULK THE OUTSIDE RIM OF THE OUTPUT SHAFT LOCK

NUT.
(1) Using a hammer and a chisel, caulk the outside rim of the lock nut
A into the groove on the output shaft.
A: More than 1.5 mm {0.0591 in.}
NOTICE
• The caulking should fit the groove thoroughly.
• The caulking should be done without rift.
SHTS033230200059

EN0332302H300002
Unit: mm {in.}
Synchronizer ring, defor- — — Replace, Visual check

mity, crack and excessive if necessary.
damage
Gear excessive wear, — — Replace, Visual check

chips and cracks if necessary.
Clearance between syn- 2nd gear 0.2 Replace the syn- Measure
chronizer ring and syn- 1.1-2.55 {0.0079} chronizer ring
chronizer cone or gear {0.044-0.101} and/or gear sub
sub assembly assembly.
3rd, 4th gear
1.15-1.8
{0.046-0.070}
5th, Input gear

1.1-1.9
{0.044-0.074}
Oil seal lip wear and dam- — — Replace, Visual check

age if necessary.
Cylindrical roller bearing — — Replace, Visual check

and ball bearing improper if necessary.
rotation

COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS

COMPONENT LOCATOR
EN0332302D100003
SHTS033230200066
1 Seal cover 9 Counter shaft

2 Cylindrical roller bearing 10 Thrust washer
3 Retainer ring 11 Lock plate
4 Counter drive gear 12 Reverse idler gear
5 Counter 5th gear 13 Needle roller bearing
6 Counter 4th gear 14 Reverse idler shaft
7 Counter 3rd gear 15 Set screw
8 Woodruff key 16 Transmission case

A 64-86 {653-876, 48-63} B 37.5-48.5 {383-494, 28-36}
OVERHAUL
EN0332302H200003
1. REMOVE THE IDLER SHAFT SET SCREW.

(1) Using a screwdriver, remove the reverse idler shaft set screw.
SHTS033230200067
2. REMOVE THE IDLER SHAFT AND IDLER GEAR.

(1) Using the special tool, pull out the reverse idler shaft while holding
the reverse idler gear thrust washers and bearing inside the case.
SST: Sliding Hammer (S0942-01442)
SHTS033230200068
3. REMOVE THE COUNTER SHAFT REAR BEARING.

! CAUTION
The retainer ring is spring steel and may fly out of groove during
removal. Wear safety glasses during removal.
SHTS033230200069
(2) Install the special tools on the rear cylindrical roller bearing and
remove it.
SST:
Hook (S0965-31190)
Puller (S0965-01900)
NOTICE
Insert the hook's click into the groove for the retainer ring then
SHTS033230200070
4. REMOVE THE COUNTER SHAFT FROM THE TRANSMISSION

CASE.
(1) Tie a rope or hook around the counter shaft and carefully pry the
counter shaft assembly rearward until the front end of the shaft is
cleared out of the front cylindrical roller bearing.
(2) Carefully lift the counter shaft assembly from the case.
SHTS033230200071
5. REMOVE THE CYLINDRICAL ROLLER BEARING INNER

RACE.
(1) Using the special tool on the inner race, pull out the front cylindri-
cal roller bearing inner race from the counter shaft.
SHTS033230200072
6. REMOVE THE COUNTER SHAFT GEARS.

! CAUTION
SHTS033230200073
(2) Support the counter shaft drive gear as close as possible to the
gear hub and press the counter shaft front end until it is free of the
drive gear.
(5) Support the counter 3rd gear under the gear teeth and press the
NOTICE
When removing the counter shaft gears, do not allow the shaft to
SHTS033230200074 drop to on a hard surface.
! CAUTION
Stay out from under the shaft during removal. The shaft could
drop suddenly, which can result in personal injury.
1. INSTALL THE COUNTER DRIVE GEAR, COUNTER 3RD, 4TH

AND 5TH GEAR.
(1) Select the proper size key according to the size of the key groove.
Thickness "T" Shape
12.018-12.029 mm
{0.4732-0.4735 in.}
SHTS033230200075
12.070-12.085 mm
{0.4752-0.4757 in.}
(2) Press the counter shaft into the gears making certain that the key
and keyway are aligned.
NOTICE
Be sure that the gears are installed in the proper direction.
SHTS033230200078
shaft.
NOTICE
2.45 mm {0.0965 in.} White
SHTS033230200079 2.55 mm {0.1004 in.} Red
2.65 mm {0.1043 in.} Yellow
2.75 mm {0.1083 in.} Blue
2.85 mm {0.1122 in.} Green
2.95 mm {0.1161 in.} Brown
! CAUTION
2. INSTALL THE COUNTER SHAFT IN THE TRANSMISSION

CASE.
NOTICE
SHTS033230200071
3. DISTANCE BETWEEN THE GEAR CASE OUTER SURFACE

AND THE FRONT BEARING OUTER RACE.
Assembly Standard: 6.5-7.0mm {0.26-0.28 in.}
4. PRESS IN THE SEAL COVER NOT TO HAVE MISMATCH WITH

THE CASE FRONT.
SHTS033230200080
5. INSTALL THE THRUST WASHER AND LOCK PLATE.

(1) Install the thrust washer and lock plate on the rear end of counter
shaft.
(2) Secure the bolts by staking the lock plate.
NOTICE
• Caulk the lock plate to the flat surface of the bolt.
• For the lock plate contacting the protruding portion of the
bolt, caulk only the half on the tightening side.
SHTS033230200081
6. INSTALL THE REVERSE IDLER GEAR.

(1) Coat the two thrust washers with disulfide molybdenum grease to
hold the washers in place against each side of the idler gear.
(2) Insert the idler shaft until the thread hole of the set screw in the
shaft is aligned correctly with the thread hole in the case rib, so
that the screw can be installed.
(3) Tighten the set screw until the screw head is completely below the
transmission case surface.
SHTS033230200067
7. MEASURE THE REVERSE IDLER GEAR END PLAY.

SHTS033230200082
8. INSTALL THE SEAL COVER.

(1) Coat seal cover with liquid gasket.
NOTICE
SHTS033230200083
9. MEASURE THE BACKLASH BETWEEN THE REVERSE IDLER

GEAR AND THE COUNTER SHAFT REVERSE GEAR.
10. MEASURE THE REVERSE IDLER GEAR RADIAL PLAY.

SHTS033230200084

EN0332302H300003
All gears for cracks and — — Replace, Visual check

defects if necessary.
Idler gear, shaft and nee- — — Replace, Visual check

dle roller bearing wear and if necessary.
damage
Counter shaft wear, chips — — Replace, Visual check

and cracks if necessary.
Counter shaft key way — — Replace the Visual check

damage and looseness counter shaft
and/or key, If
necessary.
2A64AA(5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧡㧟ಽ
TRANSMISSION MAIN UNIT (EATON FS6109) TR02–1
TR02 TRANSMISSION MAIN UNIT

(EATON FS6109) TR02-004

DATA AND SPECIFICATION .......................... TR02-2
TR02–2 TRANSMISSION MAIN UNIT (EATON FS6109)
DATA AND SPECIFICATION
EN0332502I200001
Manufacture EATON
Transmission Model FS6109
CRAWLER 12.637 LOW RANGE
1st 8.806
2nd 6.550
LOW RANGE
3rd 4.768
4th 3.548
Gear ratios
5th 2.481
6th 1.845
7th 1.343 HIGH RANGE
8th 1.000
REVERSE 13.210
Without power take-off Approx. 8.5 litters {1.87 lmp.gal., 2.25 US.gal.}
Oil capacity, gear box
With power take-off Approx. 9 litters {1.98 lmp.gal., 2.38 US.gal.}
Lubricant type Mild EP gear oil (API GL-4, MIL-L-2105)
At -26 °C to 21 °C (-14.8 °F to 68.0 °F) SAE 80W
Viscosities At -12 °C to 37 °C (10.4 °F to 98.6 °F) SAE 90
At -26 °C to 38 °C (-14.8 °F to 100.4 °F) SAE 80W-90
NOTICE
For other details, refer to EATON manuals.

EN0332502H100001

! CAUTION

ATTACHMENTS.

SHTS033250200001

(2) Support the transmission using a transmission jack or lifting wires
to prevent it from falling.
(4) Remove the transmission.
SHTS033250200002

SPLINE.
SHTS033250200003

disc spline align.
NOTICE
Do not let the rear of the transmission drop and do not let the
transmission hang unsupported in the spline hubs of the driven
discs because it distorts them and could cause poor clutch opera-
tion or clutch release problems.
(2) Install the upper nuts or bolts around the clutch housing.
(3) Lower the transmission jack and pull the jack out from under the
vehicle.
SHTS033250200002
(4) Install the remaining nuts or bolts around the clutch housing.
Tightening Torque:
37.5-48.5 N⋅m {382-494 kgf⋅cm, 28-35 lbf⋅ft}
4. CONNECT THE TRANSMISSION CONTROL CABLE WITH

THE CABLE BRACKET.

MENTS.
SHTS033250200004
DISASSEMBLY AND ASSEMBLY

NOTICE
When disassembling and assembling the transmission, refer to
the MANUFACTURE ORIGINAL MANUAL.
2A64AA(5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧡㧣ಽ

(EATON FS8209) TR02-005

DATA AND SPECIFICATION .......................... TR02-2
EN0332602I200001
Manufacture EATON
Transmission Model FS8209
CRAWLER 12.637 LOW RANGE
1st 8.806
2nd 6.550
LOW RANGE
3rd 4.768
4th 3.548
Gear ratios
5th 2.481
6th 1.845
7th 1.343 HIGH RANGE
8th 1.000
REVERSE 13.210
Without power take-off Approx. 8.5 litters {1.87 lmp.gal., 2.25 US.gal.}
Oil capacity, gear box
With power take-off Approx. 9 litters {1.98 lmp.gal., 2.38 US.gal.}
Lubricant type Mild EP gear oil (API GL-4, MIL-L-2105)
At -26 °C to 21 °C (-14.8 °F to 68.0 °F) SAE 80W
Viscosities At -12 °C to 37 °C (10.4 °F to 98.6 °F) SAE 90
At -26 °C to 38 °C (-14.8 °F to 100.4 °F) SAE 80W-90
NOTICE
For other details, refer to EATON manuals.

EN0332602H100001

! CAUTION

ATTACHMENTS.

SHTS033260200001

(2) Support the transmission using a transmission jack or lifting wires
to prevent it from falling.
(4) Remove the transmission.
SHTS033260200002

SPLINE.
SHTS033260200003

disc spline align.
NOTICE
Do not let the rear of the transmission drop and do not let the
transmission hang unsupported in the spline hubs of the driven
discs because it distorts them and could cause poor clutch opera-
tion or clutch release problems.
(2) Install the upper nuts or bolts around the clutch housing.
vehicle.
SHTS033260200002
(4) Install the remaining nuts or bolts around the clutch housing.
Tightening Torque:
37.5-48.5 N⋅m {382-494 kgf⋅cm, 28-35 lbf⋅ft}
4. CONNECT THE TRANSMISSION CONTROL CABLE WITH

THE CABLE BRACKET.

MENTS.
SHTS033260200004

NOTICE
the MANUFACTURE ORIGINAL MANUAL.
2A64AA<(5A0Q6TGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧤ᤨ㧟㧤ಽ
TRANSMISSION MAIN UNIT (ZF9S109) TR02–1

(ZF9S109) TR02
TR02-006
(ZF9S109).................................................. TR02-2
2A64AA<(5A0Q6TGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧤ಽ
TR02–2 TRANSMISSION MAIN UNIT (ZF9S109)
TRANSMISSION ASSEMBLY (ZF9S109)

EN0332702H100001

! CAUTION
• Do not work on the transmission while it is still hot. This can
• In using the transmission jack, exercise good care to
mounting or dismounting to prevent dropping from the jack
because the transmission is heavy and unstable.
4. DISCONNECT THE PARKING BRAKE CABLE.

ATTACHMENTS.

SHTS033270200001
8. REMOVE THE TRANSMISSION;

TRANSMISSION MAIN UNIT (ZF9S109) TR02–3

SPLINE.
SHTS033270200002

disc spline align.
wheel housing.
vehicle.
Tightening Torque:
64-84 N⋅m {653-857 kgf⋅cm, 48-61 lbf⋅ft}
SHTS033270200001

THE CABLE BRACKET.

MENTS.
6. CONNECT THE PARKING BRAKE CABLE.

FILLER PLUG HOLE.

NOTICE
the MANUFACTURER'S ORIGINAL MANUAL.
2A64AA.:5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧡㧥ಽ
P.T.O. (POWER TAKE-OFF) (TRANSMISSION SERIES: LX06S) TR05–1

TR05
(TRANSMISSION SERIES: LX06S) TR05-001
POWER TAKE-OFF ASSEMBLY .............. TR05-2

DESCRIPTION ................................................ TR05-2
POWER TAKE-OFF UNIT ......................... TR05-4

COMPOMENT LOCATOR............................... TR05-4
OVERHAUL ..................................................... TR05-5
INSPECTION AND REPAIR ............................ TR05-9
TR05–2 P.T.O. (POWER TAKE-OFF) (TRANSMISSION SERIES: LX06S)
POWER TAKE-OFF ASSEMBLY

EN0332005I200001
POWER TAKE-OFF
Side power take-off

Type
Driven by engaging the output shaft gear with counter 4th gear
Direction of rotation Opposite engine's
Gear ratio
16/31
(P.T.O. output gear/ P.T.O. input gear)
Size of output shaft flange 25 x 50 mm {0.985 x 1.968 in.} (A x B: Refer to description below)
POWER TAKE-OFF CONTROL
Two switches in the cab engage and disengage the power take-
Type off. These switches actuate a solenoid valve which regulate the
compressed air to the control cylinder.
DESCRIPTION
EN0332005C100001
SHTS033200500001
POWER TAKE-OFF UNIT

1 Shift fork 11 Output shaft flange
2 Shift shaft 12 Output shaft
3 O-ring 13 Shift sleeve
4 Cylinder cup 14 Power take-off case
5 Spring pin 15 Input gear
6 Compression spring 16 Input shaft
7 Shim 17 Output gear
8 Oil seal 18 Taper roller bearing
9 Woodruff key 19 Collar
10 Lock nut 20 Screw plug
TROUBLESHOOTING
EN0332005F300001

Noise Bearing worn and/or damaged. Replace bearing.
Output gear worn and/or damaged. Replace gear.
To much play in gear backlash. Use proper power take-off gasket.
Shortage gear oil and/or low oil viscos- Add oil or change oil as required.
ity.
Can not be operated Faulty switches Replace switch.
Faulty solenoid valve. Replace solenoid valve.
POWER TAKE-OFF UNIT

COMPOMENT LOCATOR
EN0332005D100001
SHTS033200500002
1 Bracket 12 Output shaft 23 Needle roller bearing

2 Cylinder cap 13 Woodruff key 24 Input shaft
3 Packing 14 Needle roller bearing 25 Spring pin
4 Shift rod 15 Output gear 26 Power take-off case gasket
5 O-ring 16 Collar 27 Power take-off case adapter
6 Compression spring 17 Oil seal 28 Power take-off case
7 Shift fork 18 Output shaft flange 29 Screw plug
8 Spring pin 19 Plain washer 30 Power take-off position switch
9 Shim 20 Lock washer 31 Packing
10 Taper roller bearing 21 Spacer 32 Cap
11 Shift sleeve 22 Input gear

A 19-25 {194-255, 14-18} E 49.0-68.5 {500-698, 36-50}
B 39.2-47.0 {400-480, 29-34} F 39.5-58.5 {400-600, 29-43}
C 19-25 {194-255, 14-18} G 54-68 {551-693, 40-50}
D 63.5-82.5 {648-841, 47-60}
OVERHAUL
EN0332005H200001

! CAUTION
Do not work on the transmission while it is still hot.
This can result in personal injury.
1. SET THE POWER TAKE-OFF ON A VISE.

REMOVE THE INPUT GEAR.
(1) Drive the spring pin into the hole of the shaft.
(2) Drive out the input shaft.
SHTS033200500003
2. REMOVE THE OUTPUT SHAFT FLANGE.

(1) Remove the lock nut.
(2) Use a suitable puller to remove the output shaft flange.
SHTS033200500004
3. REMOVE THE OUTPUT SHAFT.

(1) Remove the woodruff key.
(2) Remove the cap.
(3) Use a suitable tool to pull out the output shaft from the case. As
the output shaft is removed, remove the taper roller bearing, shift
sleeve, output gear, needle roller bearing, collar and shift fork
from the output shaft and power take-off case.
SHTS033200500005
4. REMOVE THE SHIFT ROD.

(1) Remove the screw plug.
(3) Remove the cylinder cap.
SHTS033200500006
(4) Remove the shift rod.
SHTS033200500007
1. INSTALL THE O-RING ON THE SHIFT ROD.

NOTICE
• Coat the O-ring with grease.
• Be sure the O-ring is inserted in the proper direction.
SHTS033200500008
2. INSTALL THE OIL SEAL INTO THE POWER TAKE-OFF CASE.

NOTICE
• Coat the sealing surface between the seal lips with chassis
grease.
SHTS033200500009
3. INSTALL THE SHIFT ROD AND SHIFT FORK TO THE POWER

TAKE-OFF CASE.
(1) Set the shift fork in its original position.
NOTICE
Be sure the shift fork is installed in the correct direction.
(2) Insert the shift rod into the case and the shift fork.
(3) Rotate the shift rod so that spring pin hole of the shift rod is
aligned with spring pin hole of the shift fork.
(4) Install the spring pin into the spring pin hole.
(5) Install the screw plug.
SHTS033200500006
NOTICE
Wrap seal tape around the screw plug.
(6) Install the cylinder cap.
NOTICE
Apply grease to the inner surface of the cylinder cap.
4. INSTALL THE OUTPUT SHAFT TO THE POWER TAKE-OFF

CASE.
(1) Install the taper roller bearing outer race into the case.
(2) Set the shift sleeve in its original position.
(3) Install the output shaft through the shift sleeve, needle roller bear-
ing, output gear and collar into the case.
(4) Drive the output shaft into the taper roller bearing inner race.
(5) Drive the taper roller bearing on the output shaft.
(6) Drive the outer race in the case.
SHTS033200500010
5. CHECK THE OUTPUT SHAFT AXIAL PLAY.

(1) Use a dial gauge to check the output shaft axial play.
Assembly Standard: 0-0.05 mm {0-0.0019 in.}
(2) If it is not within specification, adjust the axial play with shims.
Shims are available in following sizes.
0.05 mm {0.0020 in.}
0.1 mm {0.0039 in.}
Shim Thickness:
0.2 mm {0.0079 in.}
0.5 mm {0.0197 in.}
SHTS033200500011
6. INSTALL THE INPUT GEAR.

(1) Place the taper roller bearing, input gear, shims and spacer in its
original position.
(2) Drive the input shaft through the input gear into the case.
NOTICE
Rotate the input shaft so that slot of the input shaft is aligned with
hole of the case.
SHTS033200500012
2A64AA.:5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧝ಽ
7. CHECK THE INPUT GEAR AXIAL PLAY.

(1) Use a dial gauge to check the input gear axial play.
Assembly Standard:0-0.05 mm {0-0.0019 in.}
Shims are available in following sizes.
0.05 mm {0.0020 in.}
0.1 mm {0.0039 in.}
Shim Thickness:
0.2 mm {0.0079 in.}
0.5 mm {0.0197 in.}
SHTS033200500013
8. AFTER MEASURING THE AXIAL PLAY, INSTALL THE SPRING

PIN INTO THE HOLE.
SHTS033200500003
1. MEASURE THE BACKLASH BETWEEN THE GEAR "A" AND

"B".
SHTS033200500014
(1) Put the fuse (φ1 x 10 mm {0.394 in.}) on the surface of gear B with
grease.
(2) Rotate the gears and measure the thickness of fuse.
(3) The measurement should be carried out the three points on the
gears.
Assembly Standard:
0.08-0.21 mm {0.0031-0.0082 in.}
(4) If it is not within specification, adjust the backlash with adapter.
Adapters are available in following size.
SHTS033200500015
Groove line Adapter Thickness
None 1.98 mm {0.0779 in.}
One 1.87 mm {0.0736 in.}
Two 1.77 mm {0.0697 in.}
NOTICE
Gasket thickness: 0.19 mm {0.0075 in.}
2. INSTALL THE POWER TAKE-OFF ON THE TRANSMISSION.

(1) Install the power take-off on the transmission with gasket.
NOTICE
The trace of the liquid gasket should be continuous. The liquid
gasket should be "ThreeBond #HP-17" or equivalent.
(2) Install the reamer bolts to the position "A".
3. FILL THE TRANSMISSION WITH TRANSMISSION OIL.
SHTS033200500016

EN0332005H300001
Output shaft and output — — Replace, Visual check

gear: if necessary.
Wear and damage
O-ring: — — Replace, Visual check

Wear if necessary.

Shift rod and cylinder cap — — Replace, Visual check

bore: if necessary.
Wear and damage

Improper rotation if necessary.
2A64AA.,5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧜ಽ
P.T.O. (POWER TAKE-OFF) (TRANSMISSION SERIES: LJ06S) TR05–1

TR05
(TRANSMISSION SERIES: LJ06S) TR05-002

DESCRIPTION ................................................ TR05-2

OVERHAUL ..................................................... TR05-5
2A64AA.,5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧠ಽ
TR05–2 P.T.O. (POWER TAKE-OFF) (TRANSMISSION SERIES: LJ06S)

EN0332205I200001
POWER TAKE-OFF
Side power take-off

Type
Driven by engaging the output shaft gear with counter 4th gear
Gear ratio
23/26
(P.T.O. output gear/ P.T.O. input gear)
Size of output shaft flange 25 x 50 mm {0.985 x 1.968 in.} (A x B: Refer to DESCRIPTION below)
Two switches in the cab engage and disengage the power take-off.
Type These switches actuate a solenoid valve which regulate the com-
pressed air to the control cylinder.
DESCRIPTION
EN0332205C100001
SHTS033220500001
POWER TAKE-OFF UNIT

1 Shift fork 8 Shim 15 Power take-off case
2 Shift shaft 9 Oil seal 16 Input gear
3 O-ring 10 Woodruff key 17 Input shaft
4 Shift shaft piston cup 11 Lock nut 18 Output gear
5 O-ring 12 Output shaft flange 19 Taper roller bearing
6 Compression spring 13 Output shaft 20 Collar
7 Case cover 14 Shift sleeve
TROUBLESHOOTING
EN0332205F300001

Noise Bearing worn and/or damaged Replace bearing.
Output gear worn and/or damaged Replace gear.
Too much play in gear backlash Use proper power take-off gasket.
ity
Faulty solenoid valve Replace solenoid valve.
POWER TAKE-OFF UNIT

COMPONENT LOCATOR
EN0332205D100001
SHTS033220500002
1 Taper roller bearing 14 Case cover 27 Woodruff key

2 Retainer ring 15 O-ring 28 Taper roller bearing
3 Input gear 16 Compression spring 29 Shim
4 Power take-off case 17 Shift shaft piston cup 30 Gasket
5 Spacer 18 Shift shaft 31 Seal cover
6 Shim 19 O-ring 32 Oil seal
7 Input shaft 20 O-ring 33 Output shaft flange
8 Spring pin 21 Taper roller bearing 34 Plain washer
9 Power take-off case gasket 22 Collar 35 Lock washer
10 Power take-off case adapter 23 Needle roller bearing 36 Set screw
11 Elbow 24 Output gear 37 Bracket
12 Power take-off position switch 25 Shift sleeve
13 Shift fork 26 Output shaft

A 19-25 {200-250, 15-18} F (Transmission gear ratio: 1st-6.893, 6th-0.770)
B 39.5-58.5 {400-600, 29-43} 54-68 {551-693, 40-50}
C 48.5-67.5 {500-700, 37-50} (Transmission gear ratio: 1st-6.746, 6th-0.823)
D 19-25 {200-250, 15-18} 44.5-53.5 {454-545, 33-39}
E 39.2-47.0 {400-480, 29-34}
2A64AA.,5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧠ಽ
OVERHAUL
EN0332205H200001

! CAUTION

EXHAUST ALL AIR FROM THE AIR TANKS.

REMOVE THE INPUT GEAR.
(2) Drive out the input shaft.
SHTS033220500003
2. REMOVE THE OUTPUT SHAFT FLANGE.

SHTS033220500004
3. REMOVE THE SHIFT SHAFT.

(1) Remove the shift shaft set screw.
(2) Remove the case cover and compression spring.
(3) Unscrew the shift shaft to separate the shift shaft from the shift
fork.
SHTS033220500005

(1) Remove the woodruff key.
(2) Remove the seal cover.
(3) Use a suitable tool to pull out the output shaft from the case. As
the output shaft is removed, remove the taper roller bearing, shift
sleeve, output gear, needle roller bearing, collar and shift fork
from the output shaft and power take-off case.
SHTS033220500006
1. INSTALL THE PISTON CUP ON THE SHIFT SHAFT.

NOTICE
• Coat the piston cup with grease.
• Be sure the piston cup is installed in the proper direction.
SHTS033220500007
2. INSTALL THE OIL SEAL INTO THE SEAL COVER.

NOTICE
• Coat the sealing surface between the seal lips with grease.
SHTS033220500008
3. INSTALL THE SHIFT SHAFT AND SHIFT FORK TO THE

POWER TAKE-OFF CASE.
(1) Install the O-ring on the case.
NOTICE
Coat the O-ring with grease.
SHTS033220500009

NOTICE
Be sure the shift fork is installed in the correct direction.
(3) Screw the shift shaft into the thread of the shift fork.
(4) Rotate the shift shaft so that slot of the shift shaft is aligned with
set screw hole.
SHTS033220500010
4. INSTALL THE OUTPUT SHAFT TO THE POWER TAKE-OFF

CASE.
(1) Install the taper roller bearing into the case.
(2) Set the shift sleeve in its original position.
(3) Install the output shaft through the shift sleeve, needle roller bear-
ing, output gear and collar into the case.
SHTS033220500011
5. INSTALL THE CASE COVER ON THE POWER TAKE-OFF

CASE.
(1) Install the O-ring and compression spring on the case cover.
NOTICE
Coat the O-ring and inside of the case cover with grease.
SHTS033220500012

Shim Thickness: 0.05 mm {0.0020 in.}
0.10 mm {0.0039 in.}
0.20 mm {0.0079 in.}
0.50 mm {0.0197 in.}
SHTS033220500013
7. INSTALL THE INPUT GEAR.

(1) Place the taper roller bearing, input gear, shims and spacer in its
original position.
(2) Drive the input shaft through the input gear into the case.
NOTICE
Rotate the input shaft so that slot of the input shaft is aligned with
hole of the case.
SHTS033220500014
8. CHECK THE INPUT GEAR AXIAL PLAY.

(1) Use a dial gauge to check the input gear axial play.
0.10 mm {0.0039 in.}
0.20 mm {0.0079 in.}
0.50 mm {0.0197 in.}
SHTS033220500015
9. AFTER MEASURING THE AXIAL PLAY, INSTALL THE SPRING

PIN INTO THE HOLE.
SHTS033220500016

"B".
SHTS033220500017
(1) Put the fuse (φ1 x 10 mm {0.394 in.}) on the surface of gear "B"
with grease.
gears.
(4) If it is not within specification, adjust the backlash with adapter.
SHTS033220500018
Groove line Transmission gear ratio Adapter Thickness
1st-6.893, 6th-0.770 6.12 mm {0.2409 in.}
None
1st-6.746, 6th-0.823 8.02 mm {0.3157 in.}
1st-6.893, 6th-0.770 5.99 mm {0.2358 in.}
One
1st-6.746, 6th-0.823 7.89 mm {0.3106 in.}
1st-6.893, 6th-0.770 5.86 mm {0.2307 in.}
Two
1st-6.746, 6th-0.823 7.76 mm {0.3055 in.}
NOTICE
Gasket thickness: 0.19 mm {0.0075 in.}

NOTICE
gasket should be ThreeBond #HP-17 or equivalent.
SHTS033220500019

EN0332205H300001

gear: if necessary.
Wear and damage
O-ring and cup: — — Replace, Visual check

Wear if necessary.

Shift shaft and case cover — — Replace, Visual check

bore: if necessary.
Wear and damage

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P.T.O. (POWER TAKE-OFF) (TRANSMISSION SERIES: MF06S) TR05–1

TR05
(TRANSMISSION SERIES: MF06S) TR05-003

DESCRIPTION ................................................ TR05-2

OVERHAUL ..................................................... TR05-5
2A64AA/(5A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧣ಽ
TR05–2 P.T.O. (POWER TAKE-OFF) (TRANSMISSION SERIES: MF06S)

EN0332305I200001
POWER TAKE-OFF
Side power take-off

Type
Driven by engaging the output shaft gear with reverse idler gear
Gear ratio
12/29
(P.T.O. output gear/ reverse idler gear)
Size of output shaft flange 35 x 60 mm {1.378 x 2.362 in.} (A x B: Refer to DESCRIPTION below)
Two switches in the cab engage and disengage the power take-off.
Type These switches actuate a solenoid valve which regulate the com-
pressed air to the control cylinder.
DESCRIPTION
EN0332305C100001
SHTS033230500001
POWER TAKE-OFF UNIT

1 Shift fork 8 Lock nut
2 O-ring 9 Output shaft flange
3 Shift shaft piston cup 10 Power take-off case
4 Shift shaft 11 Output shaft
5 Case cover 12 Output gear
6 Oil seal 13 Taper roller bearing
7 Woodruff key
TROUBLESHOOTING
EN0332305F300001

Noise Bearing worn and/or damaged Replace bearing.
Output gear worn and/or damaged Replace gear.
Too much play in gear backlash Use proper power take-off gasket.
ity
Faulty solenoid valve Replace solenoid valve.
POWER TAKE-OFF UNIT

COMPONENT LOCATOR
EN0332305D100001
SHTS033230500002
1 Power take-off case 13 Oil seal

2 Nut 14 Output shaft flange
3 Power take-off position switch 15 Plain washer
4 Connector 16 Lock washer
5 Power take-off case gasket 17 Lock nut
6 Taper roller bearing 18 Shift fork
7 Output gear 19 O-ring
8 Output shaft 20 Collar
9 Woodruff key 21 Shift shaft
10 Shim 22 Shift shaft piston cup
11 O-ring 23 Case cover
12 Seal cover 24 Elbow

A 39.2-47 {400-480, 29-34} D 39.5-58.5 {400-600, 29-43}
B 44.5-53.5 {450-545, 33-39} E 19-25 {200-250, 15-18}
C 48.5-67.5 {500-690, 36-49} F 49-62 {500-630, 36-45}
OVERHAUL
EN0332305H200001

! CAUTION


REMOVE THE OUTPUT SHAFT FLANGE.
SHTS033230500003
2. REMOVE THE SHIFT SHAFT.

(1) Remove the case cover.
(2) Unscrew the shift shaft to separate the shift shaft from the shift
fork.
SHTS033230500004

(1) Remove the seal cover.
(2) Remove the shift fork from the output gear.
SHTS033230500005
(3) Use a suitable sliding hammer to pull out the output shaft with
taper roller bearing from the case. As the output shaft is remove
the output gear and taper roller bearing from the output shaft and
P.T.O. case.
SHTS033230500006
1. INSTALL THE PISTON CUP ON THE SHIFT SHAFT.

NOTICE
• Coat the piston cup with grease.
• Be sure the piston cup is installed in the proper direction.
SHTS033230500007
2. INSTALL THE OIL SEAL INTO THE SEAL COVER.

NOTICE
• Coat the sealing surface between the seal lips with grease.
SHTS033230500008
3. INSTALL THE SHIFT FORK AND OUTPUT SHAFT TO THE

(1) Install the output shaft through the output gear into the case.
(3) Set the taper roller bearing in its original position.
SHTS033230500005
SHTS033230500009
4. INSTALL THE SHIFT SHAFT AND SHIFT FORK TO THE

(1) Install the O-ring and collar on the case.
NOTICE
Coat the O-ring with grease.
(2) Screw the shift shaft into the thread of the shift fork.
(3) Check the rotating torque of shift shaft.
Assembly Standard: More than 4.9 N⋅m {50 kgf⋅cm, 3.61 lbf⋅ft}
SHTS033230500010
(4) Rotate the shaft so that slot of the shift shaft is aligned with set
screw hole.
SHTS033230500011
5. CHECK THE SHIFT FORK STROKE.

(1) Use a suitable measuring tool check the shift stroke.
(2) If it is not within specification, adjust the stroke by rotating the shift
shaft.
SHTS033230500012
6. INSTALL THE CASE COVER ON THE CASE.

(1) Install the O-ring on the case cover.
NOTICE
Coat the O-ring and inside of the case cover with grease.
SHTS033230500013

0.10 mm {0.0039 in.}
0.20 mm {0.0079 in.}
0.50 mm {0.0197 in.}
SHTS033230500014
8. INSTALL THE LOCK NUT ON THE OUTPUT SHAFT.

(1) Secure the lock nut by caulking the lock plate.
NOTICE
• Stake the lock plate with the flat surface of the nut.
• For the lock plate contacting the protruding portion of the
nut, caulk only the half on the tightening side.
SHTS033230500015

"B".
SHTS033230500016
(1) Put the fuse (φ1 x 10 mm {0.394 in.}) on the surface of gear "A"
with grease.
gears.
Assembly Standard:
0.080-0.16 mm {0.0032-0.0062 in.}
NOTICE
Power take-off case gasket thickness: 0.5 mm {0.0197 in.}
SHTS033230500017

NOTICE
gasket should be ThreeBond #HP-17 or equivalent.
SHTS033230500018

EN0332305H300001

gear: if necessary.
Wear and damage
O-ring and cup: — — Replace, Visual check

Wear if necessary.

Shift shaft and case cover — — Replace, Visual check

bore: if necessary.
Wear and damage

2A64AA'#610A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧡ಽ
P.T.O. (POWER TAKE-OFF) (EATON) TR05–1
P.T.O. (POWER TAKE-OFF) (EATON)

TR05
TR05-004

DESCRIPTION ................................................ TR05-2
POWER TAKE-OFF UNIT

(MODEL FOR TAIWAN) ............................ TR05-4
OVERHAUL ..................................................... TR05-4
POWER TAKE-OFF UNIT

(MODELS FOR CHILE, THAILAND
AND INDONESIA)..................................... TR05-6
OVERHAUL ..................................................... TR05-7
TR05–2 P.T.O. (POWER TAKE-OFF) (EATON)

EN0332505I200001
POWER TAKE-OFF
Model for Taiwan and Indonesia Counterclockwise viewed from output shaft flange
Direction of rotation
Models for Chile and Thailand Clockwise viewed from output shaft flange
Model for Taiwan Pitch circle diameter 74.5 mm {2.93 in.}

Size of output shaft
flange Models for Chile, Thailand and
Pitch circle diameter 79.3 mm {3.12 in.}
Indonesia
Type Electric-pneumatic control
DESCRIPTION
EN0332505C100001
MODEL FOR TAIWAN
SHTS033250500001
POWER TAKE-OFF UNIT

1 Output shaft flange 3 Adapter
2 Power take-off unit
MODELS FOR CHILE, THAILAND AND INDONESIA
SHTS033250500002
POWER TAKE-OFF UNIT

1 Harness 4 Output shaft flange
2 Elbow 5 Lock bolt
3 Connector 6 Adapter
TROUBLESHOOTING
EN0332505F300001

Noise Bearing worn and/or damaged. Replace bearing.
Output gear worn and/or damaged. Replace gear.
To much play in gear backlash. Use proper power take-off gasket.
ity.
2A64AA'#610A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧝ಽ
POWER TAKE-OFF UNIT (MODEL FOR TAIWAN)

COMPOMENT LOCATOR
EN0332505D100001
SHTS033250500003
1 Power take-off unit 4 Adapter

2 Output shaft flange 5 Stud bolt
3 Gasket

A 35-39 {357-550, 26-39}
OVERHAUL
EN0332505H200001

! CAUTION

2. REMOVE THE POWER TAKE-OFF COVER AND GASKET.

(1) Remove the power take-off cover and gasket then clean the aper-
ture pad using a putty knife or wire brush.
NOTICE
Stuff a rag in the aperture opening to prevent dirt from entering
the transmission while you are cleaning it.
1. CHECK THE BACKLASH.

(1) Using your hand, rock the P.T.O. drive gear in the transmission
and the driven gear in the P.T.O. assembly.
NOTICE
Rocking the gears provides two important factors.
a. It shows you the amount of backlash that has been designed
into each unit.
b. It is helpful in establishing the proper backlash when install-
ing the P.T.O.
SHTS033250500004
SHTS033250500005
(2) Follow the one of the methods showing below to get a proper
backlash using spacers between P.T.O. and adaptor. Use at least
one spacer (0.3 mm {0.012 in.}, 0.5 mm {0.020 in.}, or 1.0 mm
{0.039 in.}) in order to get a proper backlash.
Standard: 0.15-0.4 mm {0.006-0.016 in.}
Change of backlash:
0.165 mm {0.0065 in.}/ Spacer of thickness 0.3 mm {0.012 in.}
(3) Measuring the backlash at the output flange
a. Measure the free play of the P.T.O. Fix the P.T.O. gear so
that it will not turn when the P.T.O. is on. And use a dial
gauge or similar to measure the change in position of one of
the output flange bolt holes. This value is "A".
b. Fix the counter shaft gear such that it will not turn. And attach
the P.T.O. to the transmission. With the P.T.O. is ON. Use a
dial gauge or similar to measure the change in position of one
of the output flange bolt holes. This value is "B".
c. Calculate the backlash using the formula bellow.
Calculation formula: (B-A) x 1.319
SHTS033250500006
(4) Measuring the backlash caused with a fuse

a. Use grease to paste a fuse (φ1 x 10 mm {0.39 in.}) to the sur-
face of a tooth of P.T.O. gear. Rotate counterclockwise the
output flange. Make the teeth interlock over the fuse.
b. Measure the thickness of the clashed fuse with a micrometer
(at three points on the perimeter). This value is the backlash.
SHTS033250500007
POWER TAKE-OFF UNIT

(MODELS FOR CHILE, THAILAND AND INDONESIA)
COMPOMENT LOCATOR
EN0332505D100002
SHTS033250500008
1 P.T.O. shift housing 7 Stud bolt

2 Power take-off unit 8 Adapter
3 Output shaft flange 9 Copper washer
4 Connector 10 Hexagon bolt
5 Elbow 11 Bracket
6 Gasket 12 Harness

A 48-54 {490-550, 36-39} C 41-47 {419-479, 31-34}
B 10.8-16.2 {111-165, 9-11} D 23-27 {235-275, 17-19}
OVERHAUL
EN0332505H200002

! CAUTION

2. REMOVE THE POWER TAKE-OFF COVER AND GASKET.

(1) Remove the power take-off cover and gasket then clean the aper-
ture pad using a putty knife or wire brush.
NOTICE
Stuff a rag in the aperture opening to prevent dirt from entering
the transmission while you are cleaning it.
1. CHECK THE BACKLASH.

(1) Using your hand, rock the P.T.O. drive gear in the transmission
and the driven gear in the P.T.O. assembly.
NOTICE
Rocking the gears provides two important factors.
a. It shows you the amount of backlash that has been designed
into each unit.
b. It is helpful in establishing the proper backlash when install-
ing the P.T.O.
SHTS033250500004
SHTS033250500005
2. CHECK THE BACKLASH BETWEEN THE P.T.O. DRIVE GEAR

IN THE TRANSMISSION AND THE DRIVEN GEAR IN THE
ADAPTER.
(1) Install the correct number of gaskets and adapter to the transmis-
sion.
NOTICE
• Do not use sealant between gaskets because you may want
to add or subtract gaskets to obtain proper backlash.
• Do not stack more than 3 gaskets together.
• Usually one thick gasket 0.50 mm {0.20 in.} will be required.
SHTS033250500009
(2) Secure the adapter to the transmission.
(3) Mount the dial gauge so that it registers movement of the driven
gear of the adapter.
NOTICE
See figure for proper location of dial indicator contact point. (Two
common type dial gauges shown.)
(4) Hold the P.T.O. drive gear in transmission with a screw driver or
bar and rock the driven gear in adapter back and forth with your
hand.
(5) Note the total movement on the dial gauge. Then, adjust the
backlash by adding or subtracting gaskets.
NOTICE
A 0.25 mm {0.010 in.} gasket will change backlash approx. 0.152
mm {0.006 in.}. A 0.51 mm {0.020 in.} gasket changes backlash
approx. 0.305 mm {0.012 in.}.
(6) After checking for proper backlash, remove the adapter and gas-
kets from the transmission. Keep the gaskets as a "package".
3. CHECK THE BACKLASH BETWEEN DRIVEN GEAR IN THE

ADAPTER AND INPUT GEAR IN THE P.T.O.
(1) Bench mount the adapter to the P.T.O. with gasket.
(2) Mount the dial gauge, then hold the input gear in P.T.O. with a
screw driver or bar and rock the driven gear in adapter back and
forth with your hand.
(3) Note the total movement on the dial gauge.
(4) Adjust the backlash by adding or subtracting gaskets.
SHTS033250500010
4. MOUNT THE ADAPTER AND THE P.T.O.

(1) Remount the adapter assembly, all gaskets and the P.T.O. to the
transmission in their respective sequence.
(2) Secure all nuts and hexagon bolts to proper torque.
(3) Run the P.T.O. momentarily and check for noise.
NOTICE
The transmission and P.T.O. have no lubrication at this time so
running time should be as short as possible.
a. If the P.T.O. whines it may be mounted too tight, too little
backlash. This indicates that gaskets should be added.
b. If the P.T.O. clatters it may be mounted too loose, too much
SHTS033250500011
backlash. This indicates that gaskets should be removed.
2A64AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧡ಽ
TRANSMISSION/TRANSFER CONTROL TR06–1
TRANSMISSION/TRANSFER CONTROL TR06-001

TR06
TRANSMISSION CONTROL UNIT ........... TR06-2

TRANSMISSION CONTROL LINKAGE ... TR06-3

ADJUSTMENT................................................. TR06-5
POWER SHIFT
(TRANSMISSION SERIES:
LX06S, LJ06S) .......................................... TR06-8
DESCRIPTION ................................................ TR06-8
PROPOSAL TOOL .......................................... TR06-9
OVERHAUL ................................................... TR06-11
POWER SHIFT
(TRANSMISSION SERIES: MF06S)....... TR06-21
DESCRIPTION .............................................. TR06-21
SPECIAL TOOL ............................................. TR06-22
OVERHAUL ................................................... TR06-24
TR06–2 TRANSMISSION/TRANSFER CONTROL
TRANSMISSION CONTROL UNIT

TROUBLESHOOTING
EN03Z0306F300001
WITH POWER SHIFT

Damaged power shift or faulty opera- Replace power shift.
tion
spring, etc.)
Shift operations are rough or heavy. Faulty power shift operation [Air leak- Replace power shift.
age (entering of foreign particles) in
valves]
Faulty power shift operation (air leak- Inspect piping and correct problems.
age in air pipes)
Mixing of contaminated water of for- Inspect parts and correct problems.
eign particles due to damaged boot of
power shift (rusted ball joint, damaged
O-ring, damaged packing, rusted or
damaged rod)
Loose mounting bolts and nuts Inspect and tighten.
Power shift slips out of gear on Faulty adjustment of control cable Adjust.
rough road. assembly
WITHOUT POWER SHIFT

spring, etc.)
Loosen mounting bolts and nuts Inspect and tighten.
TRANSMISSION CONTROL LINKAGE

COMPONENT LOCATOR
EN03Z0306D100001
CAB SIDE (REPRESENTATIVE TYPE)
SHTS03Z030600001
1 Shift lever knob 8 Select lever

2 Shift lever boot 9 Shift lever
3 Plate 10 Control rod support
4 Ball joint 11 Ball
5 Rubber seat 12 E-ring
6 Distance piece 13 Spring
7 Rubber cushion

A 6.9-8.9 {70-90, 5.1-6.5}
CHASSIS SIDE (REPRESENTATIVE TYPE)
SHTS03Z030600002
1 Cable retaining bracket 5 Control cable (Shift)

2 Clip 6 Pin
3 Gear control insulator 7 Clamp
4 Control cable (Select)

EN03Z0306H100001
1. COAT THE LITHIUM BASE GREASE OR CHASSIS GREASE.

(1) Coat lithium base grease to the following parts.
a. Shift lever and ball contact point.
b. Shift lever and ball joint contact point.
c. Select lever and spring contact point.
d. Shift lever and select lever contact point.
SHTS03Z030600003
ADJUSTMENT
EN03Z0306H300001
(RHD MODEL)
ADJUSTMENT PROCEDURE
STEERING WHEEL 1. ADJUST THE NEUTRAL POSITION OF THE GEAR SHIFT
CENTER
P
LEVER.
SHIFT KNOB (1) Check that the distance between the knob center and the steering
CENTER wheel center conforms to the following;
RHD MODEL
Transmission series Assembly standard
LX06S, LJ06S 310-340 mm {12.205-13.385 in.}

SHTS03Z030600004 MF06 350-380 mm {13.780-14.960 in.}
EATON FS6109, FS8209 375-405 mm {14.764-15.944 in.}
ZF9S109 340-370 mm {13.386-14.567 in.}
LHD MODEL
(LHD MODEL)
Transmission series Assembly standard
STEERING WHEEL
CENTER LX06S, LJ06S 370-400 mm {14.567-15.748 in.}
P
SHIFT KNOB
CENTER MF06S 410-440 mm {16.142-17.323 in.}
EATON FS6109, FS8209 385-415 mm {15.157-16.339 in.}
SHTS03Z030600005
(2) If not, adjust the length of the select control cable.

BALL JOINT
CONTROL CABLE Length of cable Position of selecting direction
(FOR SELECTING
DIRECTION)
Distance gets shorter.
To lengthen it
(Lever leans right side.)
CHANGE THE
LENGTH OF
Distance gets longer.
CABLE To shorten it
(Lever leans left side.)
GUIDE PIPE
NOTICE
• Do not adjust cables with holding guide pipe.
SHTS03Z030600006
• When changing the length of cable, do not bend the cable.
(3) Check that the distance between the knob center and the instru-
ment cluster conforms to the following;
Assembly standard: 235-265 mm {9.252-10.433 in.}
SHTS03Z030600007
(4) If not, adjust the length of the shift lever control cable.
BALL JOINT Length of cable Position of selecting direction
Distance gets longer.

To lengthen it
(Lever leans backward.)
CHANGE THE CONTROL CABLE
LENGTH OF (FOR SHIFT Distance gets shorter.
CABLE DIRECTION) To shorten it
(Lever leans frontward.)
GUIDE PIPE
NOTICE
• Do not adjust cables with holding guide pipe.
SHTS03Z030600008
• When changing the length of cable, do not bend the cable.
2. CHECK THE SHIFT AND SELECT STROKE.

LX06S, LJ06S, MF06S
Select stroke: Unit: mm {in.}
1 3 Transmission series S1 S3
5
45-55
S2 LX06S, LJ06S, MF06S —
{1.772-2.165}
N
50-70 60-80
S2 EATON FS6109/8209
{1.968-2.755} {2.362-3.149}
R 2 4 6 30-50
ZF9S109 —
{1.181-1.968}
S1 S1 S1
SHTS03Z030600009
Shift stroke: Unit: mm {in.}

EATON FS6109/8209
Transmission series S2
R 5 7
1 3 Without power shift 100-120 {3.937-4.724}
LX06S, LJ06S
S2 With power shift 90-110 {3.544-4.330}
N Without power shift 100-130 {4.331-5.118}
MF06S
S2 With power shift 75-95 {2.952-3.740}
Lo 6 8 EATON FS6109/8209 110-130 {4.331-5.118}

2 4
ZF9S109 100-120 {3.937-4.724}
S3 S1
SHTS03Z030600010
ZF9S109
R 1 3 5 7
S2
N
S2
C 2 4 6 8
S1 S1 S1 S1
SHTS03Z030600011
POWER SHIFT (TRANSMISSION SERIES: LX06S, LJ06S)

DESCRIPTION
EN03Z0306C100001
2 3 4 5
A B
C
C
1 6 7 D 6 E 8 E 6 D 7 6
SHTS03Z030600012
1 Valve joint 8 Return spring

2 Joint A Front
3 Booster cylinder B Rear
4 Piston C Air inlet and outlet
5 Cover D Air inlet
6 Valve seal E Air outlet
7 Valve seat F Compressed air
PROPOSAL TOOL
EN03Z0306K100001
JIG "A" Unit: mm {in.}
{0 Ø10
}
94
.3
45 {1.772}
32 {1.260} 18 {0.709}
90˚
{1.260}
32
JIG "B"
40 {1.575}
2 {0.079} 24 {0.945}
Ø9.8 Ø12
15.5 {0.610}
{0.386} {0.472}
8 {0.315}
20˚
R2 79}
.0
{0 Ø7 {0.276}
JIG "C"
125 {4.921}
3 {0.118} 105 {4.134}
47 {1.850} 19 {0.748} 36 {1.417}
8 {0.315}
{0.591}
{0.543}
{0.394}
{0.512}
Ø13.8
Ø10
Ø13
Ø15
20˚
6˚
R3 18}
.1
{0
SHTS03Z030600013
COMPONENT LOCATOR
EN03Z0306D100002
SHTS03Z030600014
1 Ball joint stud 11 O-ring

2 Dust boot "C" 12 Cover
3 Ball joint 13 Valve seal
4 Joint 14 Power shift valve sub-assembly
5 Dust boot "A" 15 Valve seat "A"
6 Spring pin 16 Ball joint assembly
7 Rod seal "A" 17 Dust boot "B"
8 Booster cylinder 18 Rod seal "B"
9 Piston 19 Valve seat "B"
10 Piston seal

A 4.0-7.8 {40-80, 2.9-5.7}
OVERHAUL
EN03Z0306H200001
1. REMOVE THE AIR PIPE OF THE POWER SHIFT.

(1) Loosen the flare nuts of air pipe on the side of the power shift unit
to remove the pipe.
NOTICE
Cover the removed air pipe and power shift unit to prevent foreign
materials from entering.
SHTS03Z030600015
1. MOUNT THE POWER SHIFT.

(1) Mount the power shift to the transmission assembly.
Tightening Torque:
40.2-46.1 N⋅m {410-470 kgf⋅cm, 30-33 lbf⋅ft}
(2) Install the shift lever shaft to the power shift.

Tightening Torque:
75.5-91.2 N⋅m {770-929 kgf⋅cm, 56-67 lbf⋅ft}
SHTS03Z030600016
1. CAUTIONS DURING DISASSEMBLY

(1) In order to maintain airtightness, handle all parts with care and do
not forcefully remove any parts.
(2) Disassembly and assembly should be done in a clean position.
Especially, remove dirt and dust attached to exterior parts before
disassembling them and do operation with bare hands when
assembling them, being careful not to allow foreign materials to
enter.
2. DISASSEMBLE THE POWER SHIFT.

(1) Remove the clips and exhaust hoses.
(2) Remove the boot C by inserting a spacer 13-15 mm {0.512-0.590
in} wide under the ball joint assembly and drive out the spring pin
with a 5.0 mm {0.197 in.} diameter tapping rod.
(3) Remove the joint assembly.
HINT
If the fitting part of the rod and joint assembly cannot be removed,
tap the joint assembly body lightly to remove it. At this time, be
careful not to damage the rod part in the booster cylinder.
SHTS03Z030600017
(4) Remove the boot "A" and "B".
SHTS03Z030600018
(5) Put the ball joint assembly on the jig "A" and drive out the spring
pin with a tapping rod to remove the ball joint assembly.
HINT
If the fitting part of the rod and ball joint assembly cannot be
removed, tap the ball joint assembly body lightly to remove it. At
this time, be careful not to damage the rod part in the booster cyl-
inder.
SHTS03Z030600019
(6) When removing the power shift valve sub-assembly and piston
from booster cylinder, rod seals can be damaged by holes for
spring pin at the end. So wipe off grease on the end of the shaft
and make sure that there is no flaws, burrs and gouge on the
seals.
NOTICE
Remove flaws completely with a emery paper (No.1000) if there is
any flaw, burr and gouge.
SHTS03Z030600020
3. PULL OUT THE POWER SHIFT VALVE AND PISTON.

(1) Remove the power shift valve sub-assembly from the booster cyl-
inder slowly.
SHTS03Z030600021
(2) Pull out the valve seat "A" by inserting a hexagonal wrench 4 mm
{0.157 in.} width across flats into the hole of the valve seat "A".
NOTICE
Be careful not to damage the inner surface of the cylinder.
HEXAGONAL
WRENCH
VALVE SEAT
SHTS03Z030600022
(3) Remove the O-ring on the inner part of the cylinder using a flat
blade precision screwdriver etc.
NOTICE
Be careful not to damage the inner surface of the cylinder.
SHTS03Z030600023
4. REMOVE THE ROD SEALS.

(1) Push aside the upper part of the rod seals inside slowly using a
CASE flat blade precision screwdriver etc.
GUIDE SEAL
SHTS03Z030600024
(2) Pull up the rod seals slowly by inserting another flat blade preci-
sion screwdriver between the cylinder and the rod seals with the
rod seals pushed aside inside, and remove the rod seals.
NOTICE
Be careful not to damage the inner groove of the cylinder by the
point of the precision screwdriver etc.
SHTS03Z030600025
5. REMOVE THE VALVE SEAL.

VALVE SEAL (1) Attach the V-shaped plate 1.2-1.5 mm {0.0473-0.0590 in.} wide
under the valve seal and push up the valve seal to rise it up.
FLAT BLADE
PRECISION
SCREWDRIVER
V-SHAPED
PLATE
PUSH
SHTS03Z030600026
(2) Remove the valve seal by inserting a flat blade precision screw-
driver between the power shift valve sub-assembly and valve seal.
NOTICE
Be careful not to damage the valve shaft and valve seal.
SHTS03Z030600027
1. CAUTIONS DURING ASSEMBLY

not forcefully assemble any parts.
(2) Assemble parts carefully so that dirt and foreign materials do not
enter the assembled parts.
2. ASSEMBLE THE PISTON SEAL AND VALVE SEAL.

(1) Apply silicone grease to the piston seal and install it to the piston.
SHTS03Z030600028
(2) Apply silicone grease to the valve seal "A" and "B" and install
them to the valve sub-assembly using a jig "B" and a Jig "C".
NOTICE
VALVE
Be careful not to distort the valve seals.
JIG "C" JIG "B"
(3) Apply silicone grease to the valve seal "C" and "D" and install it to
the valve sub-assembly.
SHTS03Z030600029
3. ASSEMBLE THE ROD SEAL.

(1) Push the rod seals in the booster cylinder, bending them to fit
them in easily with fingers.
DUST RIP SIDE Install the rod seals into the groove of the booster cylinder surely
using a flat blade precision screwdriver.
NOTICE
• Be careful of installing direction of the rod seals.
• Be careful not to damage the lip part of the booster cylinder
and rod seals.
SHTS03Z030600030
(2) Apply silicone grease to the inner surface of the rod seals.
SHTS03Z030600031
4. ASSEMBLE THE PISTON AND POWER SHIFT VALVE SUB-

ASSEMBLY.
(1) Apply silicone grease to the inner surfaces of the valve cylinder
part and piston cylinder part in the booster cylinder.
(2) Apply silicone grease to the outer periphery of the piston seal and
insert the piston assembly into the booster cylinder slowly.
SHTS03Z030600032
(3) Insert the O-ring into the inner part of the booster cylinder.
(4) Fit the O-ring to the outer periphery of the valve seat "A".
(5) Apply silicone grease to the inner surface of the valve seat "A"
O-RING and insert it into the inner part of the booster cylinder slowly.
NOTICE
Be careful of inserting direction of the valve seat.
VALVE SEAT
O-RING
POSITION
O-RING
SHTS03Z030600033
(6) After applying silicone grease to the outer periphery of the valve
seal, insert the valve sub-assembly into the booster cylinder
slowly.
(7) Fit the O-ring to the valve seat "B".
SHTS03Z030600034
(8) Apply silicone grease to the inner surface of the valve seat "B"
and insert it into the booster cylinder slowly.
NOTICE
Be careful of inserting direction of the valve seat.
SHTS03Z030600035
5. INSTALL THE COVER.

(1) Install the O-ring to the booster cylinder.
(2) Apply silicone grease to the inner surface of the bearing in the
cover and install the cover to the booster cylinder.
NOTICE
Tighten the bolts in twice to prevent the cover from distorting due
to warp of the cover.
6. CHECK THE OPERATION.

(1) By moving the top of piston 3 or 4 times, make sure that it moves
smoothly and sliding resistance is 9.8 N {1 kgf, 2.2 lbf} or less.
SHTS03Z030600036 (2) Move the valve sub-assembly to male sure that its motion is
smooth without binding.
7. ASSEMBLE THE BALL JOINT ASSEMBLY.

JOINT (1) Apply silicone grease to the whole of the ball and the inner sur-
face of the ball joint case.
(2) Install the ball with it stood into the joint.
BALL
SHTS03Z030600037
8. ASSEMBLE THE JOINT ASSEMBLY.

(1) Apply silicone grease to the O-ring and the inner surface of the
joint.
LEVER (2) Install each component part to the lever assembly and install the
ASSEMBLY
E-ring.
NOTICE
Be careful of installing position of the joint.
WASHER (NYLON)
O-RING
JOINT
O-RING
WASHER (NYLON)
WASHER
E-RING
SHTS03Z030600038
9. ASSEMBLE THE BALL JOINT ASSEMBLY.

(1) Put the ball joint assembly on a jig "A" and align the hole of the
valve assembly with the ball joint assembly to drive a new spring
pin into them.
(2) Cover the ball joint assembly with the dust boot "B" and install the
dust boot "B" into the groove of the booster cylinder.
SHTS03Z030600039
(3) Cover the convex portion of the ball joint assembly with the dust
boot "B", aligning the convex portion with the hole part of the dust
boot "B".
Install the inner convex portion of the dust boot "B" into the groove
of the ball joint assembly securely.
CONVEX PORTION OF
THE JOINT ASSEMBLY
ALIGN
HOLE PART OF
THE BOOT
SHTS03Z030600040
BOOT "B" CASE

JOINT ASSEMBLY INSTALL SECURELY
SHTS03Z030600041
(4) Align the concave mark with the convex mark of boot "B".
SHTS03Z030600042
(5) Install the boot "A" to the groove of the booster cylinder and align
the concave mark of the boot "A" with the convex mark of the
booster cylinder.
SHTS03Z030600043
(6) Apply silicone grease to the inner surface of the boot "C" and
install it to the joint assembly.
SHTS03Z030600044
(7) Insert the top of the lever of the joint assembly to the boot "B"
strongly.
Fit the boot "B" to the groove of the lever securely.
FIT SECURELY
BOOT "B"
SHTS03Z030600045
(8) Insert a spacer 13-15 mm {0.512-0.590 in.} wide under the ball
joint assembly.
And align the hole position of the ball joint assembly with the one
of piston to drive the spring pin into them using a 7-8 mm {0.2756-
0.3149 in.} diameter tapping rod.
SHTS03Z030600017
1. INSPECT AIR LEAKAGE.

(1) Supply the compressed air of 735 kPa {7.5 kgf/cm2, 107 lbf/in.2}
and mark sure of the neutral of the valve and the valve operation
of the both pushing and pulling direction.

EN03Z0306H300002
Valve seal, piston seal and dust — — Replace the Visual check
boot: parts with new
Setting, hardening, wear and defor- one,
mation if necessary.
NOTICE
As for the rod seal and O-ring,
replace them with new one at regu-
lar maintenance as a rule.
Piston and power shift sub-assem- A: 50 mm — Replace the Visual check

bly: {1.969 in.} parts, if there is
Flaws and scratches due to wear in B: 60 mm any flaw and 50 mm {1.969 in.}
the sliding surface "A" and "B" as {2.363 in.} scratch.
shown in figure. Remove flaws 60 mm {2.363 in.}
with a emery
paper (No.1000)
if it is light.
Piston cylinder part and valve cylin- — — Replace the Visual check
der part: parts, if there is
VALVE
Flaws and scratches any flaw and CYLINDER
scratch.
Remove flaws FITTING PISTON
GROOVE CYLINDER
with a emery
paper (No.1000)
if it is light.
Fitting groove part for rod seals: — — Replace the

Flaws and scratches parts,
if necessary.
Other parts: — — Replace the Visual check and measure

Wear, play and damage parts,
NOTICE if necessary.
If there is adhesion of foreign mate-
rials in the mesh filter of the cover,
remove the foreign materials.
POWER SHIFT (TRANSMISSION SERIES: MF06S)

DESCRIPTION
EN03Z0306C100002
7 8 2 9 10 11 12
1 2 3 4 5 6
13
24 17 16
23 15 7 14
22 21 20 2 19 18
SHTS03Z030600048
1 Valve lifter 13 Shifter rod

2 Seal ring 14 Gear control lever
3 Spring "A" 15 Actuating rod
4 Spring "B" 16 Straight pin
5 Set screw 17 Pipe
6 Piston 18 Spring "C"
7 Retainer ring 19 O-ring
8 Valve seal 20 Housing
9 Boot "A" 21 Valve seat
10 Plate 22 Cylinder
11 Striker 23 Boot "B"
12 Guide sleeve 24 Connector
SPECIAL TOOL
EN03Z0306K100002
Prior to starting a power shift overhaul, it is necessary to have these special tools.
S0966-51370 INSERT TOOL
S0966-51380 INSERT TOOL
S0966-51390 SLEEVE
COMPONENT LOCATOR
EN03Z0306D100003
A
24
29 Y
2
27
C
25
1 X
27
9
6
27
B 7
4 18
4 9
D
26 16
10
9 14
5 17 8
12 13
4 28 19
10 3
9 4
E
Y 21 13 9
13
9 11
22 5
15
20 12
14
23 16
X
9 13
17
SHTS03Z030600053
1 Gear control lever 16 Valve seat

2 Boot "A" 17 Valve seal
3 Boot "B" 18 Spring "B"
4 Retainer ring 19 Spring "A"
5 Plate 20 Clamp
6 Striker 21 Straight pin
7 Guide sleeve 22 Pipe
8 Connector 23 Actuating rod
9 O-ring 24 Set screw
10 Filter 25 Cylinder
11 Collar 26 Piston
12 Tube 27 Seal ring
13 Square ring 28 Shifter rod
14 Valve lifter 29 Housing
15 Spring "C"

A 1.9-3.4 {20-35, 1.5-2.5} D 7.8-11.7 {80-120, 5.8-8.6}
B 23.5-26.5 {240-270, 18-19} E 58-68 {600-700, 44-50}
C 98-117 {1,000-1,200, 73-86}
OVERHAUL
EN03Z0306H200002
1. CAUTIONS DURING DISASSEMBLY

not forcefully remove any parts.
(2) Remove dirt and dust attached to exterior parts before disassem-
bling them.
2. REMOVING THE BOOTS

(1) Remove the nut and the lever.
(2) Remove boots.
3. REMOVING THE STRIKER

(1) Remove the retainer ring, plate, guide sleeve and striker.
SHTS03Z030600054
4. REMOVING THE VALVE ASSEMBLY

(1) Remove the nut.
NOTICE
When working with the shifter rod fixed in place, the guide sleeve
should be left installed for greater stability.
SHTS03Z030600055
(2) Remove the connector.

(3) Remove the O-ring and filter from the connector.
SHTS03Z030600056
(4) Use a suitable bar or similar tool carefully push out the valve
VALVE ASSEMBLY assembly.
NOTICE
Avoid excessive force so that the valve seat and square ring are
not damaged.
SHTS03Z030600057
5. DISASSEMBLING THE VALVE ASSEMBLY

(1) Remove the collar with attached filter and the tube on one side.
(2) Use a pin or similar tool and remove the retainer ring, and then
remove each parts.
NOTICE
Keep springs "A","B" and "C" in order so that they are not
installed in the wrong positions.
SHTS03Z030600058
B C
A
SHTS03Z030600059
(3) Remove the clamp. Then pull out the straight pin and disassemble
the pipe and actuating rod.
SHTS03Z030600060
6. REMOVING THE CYLINDER AND PISTON ASSEMBLY

(1) Use a hexagonal socket wrench and remove the housing set
screw.
(2) Loosen the cylinder threaded part with the special tool provided
for that purpose, and remove the cylinder and piston assembly.
SST: Socket wrench (S0962-21200)
NOTICE
Loosen the cylinder threaded part carefully because it is fixed
with adhesive.
(3) Remove the O-ring from the cylinder.

SHTS03Z030600061
7. DISASSEMBLING THE PISTON ASSEMBLY

(1) Remove the retainer ring and the piston with attached seal ring.
(2) Remove the O-ring from the shifter rod and the retainer ring on
the opposite side.
PISTON NOTICE
Be careful not to damage the shifter rod.
(3) Remove the seal ring from the piston.
SHTS03Z030600062
8. REMOVING THE SEAL RING INSIDE THE HOUSING AND

CYLINDER
(1) Remove the plate holding the seal ring inside the housing, and
take out the seal ring.
SHTS03Z030600063
(2) Using a slotted screwdriver or similar tool, remove the seal ring
inside the cylinder.
NOTICE
Be careful not to damage the cylinder.
SHTS03Z030600064
1. CAUTIONS DURING ASSEMBLY

(1) To maintain airtightness, handle all parts with care and do not
forcefully assembly any parts.
(2) Assemble parts carefully so that dirt and foreign objects do not
enter the assembled parts.
2. ASSEMBLING THE VALVE ASSEMBLY

(1) Insert the straight pin into the actuating rod and install the pipe.
(2) Install the clamp.
(3) Apply grease (Airmaster Paste) to the new part's O-ring and
square ring.
(4) Install O-rings on the valve seal and valve lifter.
(5) Install square ring on the valve seat and tube.
SHTS03Z030600060
(6) Install the tube, valve lifter, spring, valve seat, and valve seal, and
plate on the pipe.
(7) Using the special tool, install a new retainer ring in the pipe
groove.
SST:
Insert tool (S0966-51370)
Insert tool (S0966-51380)
NOTICE
• Do not deform the retainer ring.
• Make sure the retainer ring is securely installed in the
SHTS03Z030600065
groove.
(8) Install the collar with attached filter.
3. ASSEMBLING THE PISTON ASSEMBLY

(1) Apply grease (Airmaster Paste) to the new seal ring and piston.
(2) Install a new retainer ring in one side of the shifter rod groove.
(3) Install a new O-ring on the shifter rod.
(4) Insert the piston into the shifter rod and install a new retainer ring
PISTON
in the shifter rod groove on the opposite side.
(5) Measure the retainer ring mating face gap and make sure the
retainer ring is securely installed in the shifter rod groove.
Standard value: Less than 6 mm {0.2362 in.}
SHTS03Z030600062
4. INSTALLING THE SEAL RING INSIDE THE HOUSING AND

CYLINDER
(1) Apply grease (Airmaster Paste) to the new seal ring.
(2) Install the seal ring inside the housing, making sure it is in the
SEAL RING right direction.
NOTICE
If the seal ring is installed in a wrong direction, air will leak out.
SHTS03Z030600066
(3) Apply grease (Airmaster Paste) to the new seal ring.

(4) Install the seal ring in the cylinder.
SEAL RING
SHTS03Z030600067
5. INSTALLING THE CYLINDER AND PISTON ASSEMBLY

(1) Apply grease (Airmaster Paste) to the new O-ring and install the
O-ring on the cylinder.
(2) Assemble the piston assembly on the cylinder.
SHTS03Z030600068
(3) Apply an adhesive to the cylinder threaded part (LOCTITE 242 or

ThreeBond 1401B), and install the cylinder in the housing.
(4) Tighten the cylinder threaded part, using the special tool provided
for that purpose.
SST: Socket wrench (S0962-21200)
(5) Install a new set screw in the housing, using a hexagonal socket
wrench.
(6) Caulk two points between the housing and set screw, using a cen-
ter punch or hammer.
SHTS03Z030600069
6. INSTALLING THE VALVE ASSEMBLY

SLEEVE (1) Apply grease (Airmaster Paste) to the entire interior surface of the
piston assembly shifter rod.
(2) Insert the valve assembly, into the shifter rod using the special
tool provided for that purpose.
SST: Sleeve (S0966-51390)
NOTICE
The special tool must be used because the shifter rod thread will
damage the O-ring and square ring.
SHTS03Z030600070
(3) Install a new O-ring and filter on the connector.

(4) Install the connector.
NOTICE
• The connector tightening torque must be observed to avoid
damaging the valve.
• When working with the shifter rod fixed in place, the guide
sleeve should be left installed for greater stability.
SHTS03Z030600056
(5) Install the nut.
SHTS03Z030600055
7. INSTALLING THE STRIKER

GUIDE SLEEVE (1) Apply grease (Airmaster Paste) to the guide sleeve, shifter rod,
and striker.
(2) Line up the actuating rod flat surface and the shifter rod and guide
sleeve installation hole, and then install the guide sleeve and
striker.
(3) Install the plate.
(4) Install a new retainer ring in the shifter rod groove.
(5) Measure the retainer ring mating face gap and make sure that
retainer ring is securely installed in the shifter rod groove.
Standard valve: Less than 6 mm {0.2362 in.}
SHTS03Z030600071
8. INSTALLING THE BOOTS

BOOT "A" BOOT "B" (1) Install boot "B" over the nut and cylinder groove.
NOTICE
Install boot "B" so that the drip hole is at the bottom.
(2) Install boot "A" over the housing, actuating rod, and striker groove.
(3) Install the lever on the actuating rod with a bolt and nut.
SHTS03Z030600072
2A64AA/QMWLKMCKHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧟ಽ

EN03Z0306H300003
Spring length A: Replace if the Measure

41.3 (38.8-43.7) mm standard range
{1.53-1.72 in.} is exceeded.
B:
31.9 (30.0-33.8) mm
A {1.18-1.33 in.}
C:
25.0 (23.5-26.5) mm
B {0.92-1.04 in.}
Boots wear and damage — — Replace, Visual check

if necessary.
Filter dirtiness — — Replace, Visual check

if necessary.
2A22AA.&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧣ಽ
PROPELLER SHAFT (LD0932) PP02–1
PROPELLER SHAFT (LD0932)

P 02
PP02-001
PROPELLER SHAFT ASSEMBLY ........... PP02-2

DATA AND SPECIFICATIONS........................ PP02-2
DESCRIPTION ................................................ PP02-2
TROUBLESHOOTING..................................... PP02-3
SPECIAL TOOL ............................................... PP02-3
COMPONENT LOCATOR ............................... PP02-4
OVERHAUL ..................................................... PP02-6
INSPECTION AND REPAIR .......................... PP02-12
PP02–2 PROPELLER SHAFT (LD0932)
PROPELLER SHAFT ASSEMBLY

EN0440802I200001
Type Tubular shaft type
Universal joint All metal, round bearing type with needle roller bearing
DESCRIPTION
EN0440802C100001
SHTS044080200001
1 Universal joint yoke 6 Universal joint flange

2 Needle roller bearing 7 Phasing arrow
3 Yoke shaft 8 Retainer ring
4 Center bearing 9 Sliding yoke
TROUBLESHOOTING
EN0440802F300001

Abnormal vibration when driving. Looseness of universal joint yoke and Tighten the nuts.
flange tightening nuts
Looseness of universal joint flange Replace the lock nut with new one,
lock nut then tighten the lock nut with specified
torque and caulk the nut securely.
Excessively bent propeller shaft Replace the shaft.
Worn or damaged universal joint Replace the universal joint.
Worn or damaged center bearing Replace the bearing.
Worn or damaged center bearing rub- Replace the rubber cushion.
ber cushion
Incorrect phasing of the yokes Match the phasing arrows correctly.
SPECIAL TOOL
EN0440802K100001
Prior to starting a propeller shaft overhaul, it is necessary to have this special tool.

COMPONENT LOCATOR
EN0440802D100001
FRONT
SHTS044080200003
1 Universal joint yoke 9 Lock nut

2 Retainer ring 10 Universal joint flange
3 Universal joint spider 11 Collar
4 Yoke shaft 12 Center bearing holder
5 Center bearing 13 Dust deflector
6 Center bearing plate 14 Needle roller bearing
7 Center bearing cushion 15 Thrust washer

A 588.4-784.6 {6,000-8,000, 434-578} C 41.5-61.5 {424-672, 31-45}
B 22.4-30.6 {229-312, 17-22} D 61-91 {623-927, 45-67}
REAR
SHTS044080200004
1 Universal joint yoke 6 Dust cover seal

2 Retainer ring 7 Yoke shaft
3 Needle roller bearing 8 Universal joint spider
4 Thrust washer 9 Lubrication fitting
5 Sliding yoke

A 61-91 {623-927, 45-67}
OVERHAUL
EN0440802H200001
1. DISCONNECT THE PROPELLER SHAFT FROM THE FLANGE

ON ALL THE CONNECTING POINTS.
(1) Make aligning marks on the flange and universal joint yoke.
(2) Remove the nuts and the bolts.
NOTICE
Park the vehicle on level ground, apply the parking brake and
apply wheel stoppers in the front tires or rear tires.
SHTS044080200005
1. DISASSEMBLE THE UNIVERSAL JOINT ASSEMBLY.

(1) Remove the retainer ring from the yoke.
SHTS044080200006
(2) Position the yoke under the arbor press and push universal joint
partially out of the yoke lug. The bearing race will now protrude
from the yoke.
SHTS044080200007
(3) Place the propeller shaft assembly in a vise, gripping the protrud-
ing bearing with the vise. Tap the yoke in area shown to achieve
removal of universal joint bearing.
(4) Press the opposite bearing out of the yoke lug.
(5) Remove the spider with universal joint yoke from the yoke.
NOTICE
Keep the original location of the bearings, thrust washers, spider
and retainer rings in mind. These parts have to be replaced in the
same position as before disassembly when reassembling.
SHTS044080200008
2. SEPARATE THE YOKE SHAFT AND SLIDING YOKE.

(1) Separate the yoke shaft and sliding yoke.
(2) Remove the dust cover seal from the yoke shaft.
SHTS044080200009
3. REMOVE THE CENTER BEARING.

(1) Place the propeller shaft in a vise.
(2) Uncaulk the lock nut on the shaft.
(3) Make aligning marks on the flange and shaft.
(4) Using the special tool, remove the lock nut.
(5) Remove the universal joint flange from the shaft.
SHTS044080200010
(6) Using a hammer, tap the bearing plate to make a clearance.
SHTS044080200011
(7) Using a commercial puller, remove the center bearing.

NOTICE
Be careful not to catch your fingers between bearing plate and
dust deflector.
SHTS044080200012
1. ASSEMBLE THE NEEDLE ROLLER BEARINGS.

(1) After the needle roller bearings are thoroughly cleaned, apply
clean lubricant to the rollers.
(2) Check each bearing for missing rollers.
NOTICE
Remove stale grease from the bearing cage. Lubricate with grease
containing molybdenum disulfide on the needle roller, seal lip and
both surfaces of thrust washer.
SHTS044080200013 2. INSTALL THE UNIVERSAL JOINT SPIDERS AND NEEDLE

ROLLER BEARINGS INTO THE YOKES.
(1) Put the universal joint spider into the yoke and then set the needle
roller bearings on the yoke.
NOTICE
When installing the spider to the yoke shaft, install the lubrication
fitting to the spider should be made the direction of the lubrication
fitting of the coupling flange part or the sliding yoke part as
SHTS044080200014
(2) Press the universal joint bearings into the yokes over the spider
journal.
NOTICE
Pay attention not to damage the seal lip of the universal joint bear-
ing when installing.
SHTS044080200015
(3) Install the universal joint yoke to the universal joint spider.
NOTICE
Match the phasing arrows on the universal joint yoke with the
phasing arrows on the yoke shaft or sliding yoke.
SHTS044080200016
3. CHECK THE STARTING TORQUE OF THE UNIVERSAL JOINT

USING A SPRING BALANCER.
Assembly Standard: 1.47-4.9 N⋅m {15-50 kgf⋅cm, 13-43 lbf⋅in.}
SHTS044080200017
(1) If the measuring value is below the assembly standard, replace

the retainer ring with the thicker one.
(2) If the measuring value is above the assembly standard, replace
the retainer ring with the thinner one.
NOTICE
Use retainer rings of the same thickness as possible for both
ends.
Unit: mm {in.}
Thickness of Color of thickness indication
retainer ring point
SHTS044080200018
2.22 {0.0874} Gold
2.30 {0.0906} Silver
2.38 {0.0937} Brown
4. INSTALL THE DUST COVER SEAL.

(1) Remove the stale grease from the spline of the yoke shaft.
(2) Install the new dust cover seal on the shaft by pushing it in the
seal groove.
(3) Apply the grease containing molybdenum disulfide on the spline
and sliding area of the dust cover seal.
SHTS044080200009
5. ASSEMBLE THE YOKE SHAFT AND SLIDING YOKE.

(1) Align the phasing arrows as shown in the figure.
SHTS044080200019
6. INSTALL THE CENTER BEARING PLATE AND CENTER

BEARING.
SHTS044080200020
NOTICE
Prior to installation of center bearing assembly, remove stale
grease and apply fresh grease between the bearing case and the
center bearing.
Grease:
Refer to owner's manual.
SHTS044080200021
(1) Install the universal joint flange.

a. Prior to installing, heat the universal joint flange in either
water or oil that has been heated to 80-100°C {76-212°F}.
NOTICE
• Do not heat the universal joint flange in excess of 120°C
{248°F}.
installation.
! CAUTION
Never touch hot water or oil nor heated universal joint flange with
SHTS044080200022 your bare band. This can result in personal injury.
b. Align lubrication fitting slit and grease passage in line as
shown in figure.
• A: Lubrication fitting
• B: Lubrication fitting slit
• C: Grease passage
NOTICE
Following installation, allow the assembly to cool for at least five
minutes, prior to tightening to proper specified torque.
c. Align the phasing arrows on the universal joint flange, yoke
shaft and sliding yoke in line as shown in figure.
PHASING ARROW
SHTS044080200023
d. Using the special tool, tighten the lock nut.

SHTS044080200010
(2) Caulk the lock nut.

a. Caulk deeper than 1.5 mm {0.06 in.}
b. The caulking should fill the groove thoroughly.
c. The caulking should be done without rift.
SHTS044080200024
1. CONNECT THE PROPELLER SHAFT TO THE FLANGE ON

ALL OF THE CONNECTING POINTS.
(1) Align the matching marks on the flange and universal joint yoke.
(2) Tighten the bolts and nuts.
(3) Lubricate the universal joints, sliding spline and center bearing, if
so equipped.
Grease:
SHTS044080200005

EN0440802H300001
Unit: mm {in.}
Propeller shaft damage 0-0.6 {0-0.0236} 1.0 {0.039} Replace. Measure

and bend
Crack in the welding — — Replace, Visual check

beads if necessary.
x
Sliding spline damage — — Replace,
if necessary.
Sliding spline backlash At spline 0.25 {0.0098} Replace. Measure

(Inspect the spline 0.062-0.174
backlash at sliding yoke {0.0025-0.0068}
lug 60 mm {2.362 in.}
from the shaft center.)
Clearance (C) between 0.024-0.064 0.1 {0.0039} Replace needle Measure

universal joint spider {0.0010-0.0025} roller bearing
and needle roller bear- sub-assembly or
ing (C = A - B) universal joint
spider. A B
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PROPELLER SHAFT (LF0932) PP02–1
PROPELLER SHAFT (LF0932)

P 02
PP02-002

DESCRIPTION ................................................ PP02-2
SPECIAL TOOL ............................................... PP02-3
OVERHAUL ..................................................... PP02-6
PP02–2 PROPELLER SHAFT (LF0932)

EN0440902I200001
DESCRIPTION
EN0440902C100001
SHTS044090200001

3 Yoke shaft 8 Retainer ring
TROUBLESHOOTING
EN0440902F300001

ber cushion
SPECIAL TOOL
EN0440902K100001

COMPONENT LOCATOR
EN0440902D100001
FRONT
SHTS044090200003
1 Universal joint yoke 9 Lock nut

2 Retainer ring 10 Universal joint flange
3 Universal joint spider 11 Collar
4 Yoke shaft 12 Center bearing holder
5 Center bearing 13 Dust deflector
6 Center bearing plate 14 Needle roller bearing
7 Center bearing cushion 15 Thrust washer

A 588.4-784.6 {6,000-8,000, 434-578} C 41.5-61.5 {424-672, 31-45}
B 22.4-30.6 {229-312, 17-22} D 61-91 {623-927, 45-67}
REAR
SHTS044090200004
1 Universal joint yoke 6 Dust cover seal

2 Retainer ring 7 Yoke shaft
3 Needle roller bearing 8 Universal joint spider
4 Thrust washer 9 Lubrication fitting
5 Sliding yoke

A 61-91 {623-927, 45-67}
OVERHAUL
EN0440902H200001

NOTICE
SHTS044090200005

(1) Remove the retainer ring from the yoke.
SHTS044090200006
(2) Position the yoke under the arbor press and push universal joint
partially out of the yoke lug. The bearing race will now protrude
from the yoke.
SHTS044090200007
(3) Place the propeller shaft assembly in a vise, gripping the protrud-
ing bearing with the vise. Tap the yoke in area shown to achieve
removal of universal joint bearing.
(4) Press the opposite bearing out of the yoke lug.
(5) Remove the spider with universal joint yoke from the yoke.
NOTICE
Keep the original location of the bearings, thrust washers, spider
and retainer rings in mind. These parts have to be replaced in the
same position as before disassembly when reassembling.
SHTS044090200008
2. SEPARATE THE YOKE SHAFT AND SLIDING YOKE. (REAR)

(2) Remove the dust cover seal from the yoke shaft.
SHTS044090200009

SHTS044090200010
SHTS044090200011

NOTICE
dust deflector.
SHTS044090200012

NOTICE
SHTS044090200013 2. INSTALL THE UNIVERSAL JOINT SPIDERS AND NEEDLE

ROLLER BEARINGS INTO THE YOKES.
(1) Put the universal joint spider into the yoke and then set the needle
roller bearings on the yoke.
NOTICE
fitting to the spider should be made the direction of the lubrication
fitting of the coupling flange part or the sliding yoke part as
SHTS044090200014
journal.
NOTICE
SHTS044090200015
NOTICE
SHTS044090200016
3. CHECK THE STARTING TORQUE OF THE UNIVERSAL JOINT

USING A SPRING BALANCER.
Assembly Standard: 1.47-4.9 N⋅m {15-50 kgf⋅cm, 13-43 lbf⋅in.}
SHTS044090200017
(1) If the measuring value is below the assembly standard, replace

the retainer ring with the thicker one.
(2) If the measuring value is above the assembly standard, replace
the retainer ring with the thinner one.
NOTICE
Use retainer rings of the same thickness as possible for both
ends.
Unit: mm {in.}
Thickness of Color of thickness indication
retainer ring point
SHTS044090200018
2.22 {0.0874} Gold
2.30 {0.0906} Silver
2.38 {0.0937} Brown

seal groove.
SHTS044090200009

(1) Align the phasing arrows as shown in the figure.
SHTS044090200019

BEARING.
SHTS044090200020
NOTICE
center bearing.
Grease:
SHTS044090200021

water or oil that has been heated to 80-100°C {76-212°F}.
NOTICE
{248°F}.
installation.
! CAUTION
Never touch hot water or oil nor heated universal joint flange with
SHTS044090200022 your bare band. This can result in personal injury.
shown in figure.
NOTICE
minutes, prior to tightening to proper specified torque.
PHASING ARROW
SHTS044090200023

SHTS044090200010

SHTS044090200024

so equipped.
Grease:
SHTS044090200005

EN0440902H300001
Unit: mm {in.}
Propeller shaft damage 0-0.6 {0-0.0236} 1.0 {0.039} Replace. Measure

and bend

beads if necessary.
x
if necessary.
Sliding spline backlash At spline 0.25 {0.0098} Replace. Measure

(Inspect the spline 0.062-0.174
backlash at sliding yoke {0.0025-0.0068}
lug 60 mm {2.362 in.}
from the shaft center.)
Clearance (C) between 0.024-0.064 0.1 {0.0039} Replace needle Measure

universal joint spider {0.0010-0.0025} roller bearing
spider. A B
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PROPELLER SHAFT (MC1040) PP02–1
PROPELLER SHAFT (MC1040)

P 02
PP02-003

DESCRIPTION ................................................ PP02-2
SPECIAL TOOL ............................................... PP02-3
OVERHAUL ..................................................... PP02-6
PP02–2 PROPELLER SHAFT (MC1040)

EN0441202I200001
DESCRIPTION
EN0441202C100001
SHTS044120200001

3 Yoke shaft 8 Lock plate
TROUBLESHOOTING
EN0441202F300001

ber cushion
SPECIAL TOOL
EN0441202K100001

COMPONENT LOCATOR
EN0441202D100001
FRONT
SHTS044120200003
1 Universal joint yoke 10 Dust deflector

2 Universal joint cap 11 Universal joint flange
3 Lock plate 12 Lubrication fitting
4 Universal joint spider 13 Lock nut
5 Yoke shaft 14 Collar
6 Dust deflector 15 Center bearing holder
7 Center bearing 16 Needle roller bearing
8 Center bearing plate 17 Thrust washer
9 Center bearing cushion 18 Balance piece (If so equipped)

A 25.5-31.3 {260-320, 19-23} D 96-144 {980-1,470, 71-105}
B 588.5-784.5 {6,000-8,000, 434-578} E 18.8-25.4 {190-260, 14-19}
C 127.4-156.8 {1,300-1,600, 94-115}
REAR
SHTS044120200004
1 Universal joint yoke 8 Yoke shaft

2 Universal joint cap 9 Felt ring retainer
3 Lock plate 10 Felt seal
4 Needle roller bearing 11 Lubrication fitting
5 Thrust washer 12 Universal joint spider
6 Sliding yoke 13 Balance piece (If so equipped)
7 Split retainer

A 25.5-31.3 {260-320, 19-23} B 127.4-156.8 {1,300-1,600, 94-115}
OVERHAUL
EN0441202H200001

NOTICE
SHTS044120200005

(1) Remove the lock plate.
NOTICE
For some models, one additional lock plate is installed as an addi-
tional balance on one of the bearing.
(2) Remove the balance piece, if so equipped.
NOTICE
Some models are equipped with one, two, or three balance pieces
between the lock plate and universal joint cap of one of the bear-
SHTS044120200006
ing.
(3) Remove the universal joint cap.
(4) Remove the universal joint bearings and universal joint spider
from the universal joint yoke.
a. Position the yoke under the arbor press and push the univer-
sal joint partially out of the yoke lug.
The bearing race will now protrude from the yoke.
SHTS044120200007
b. Place the propeller shaft assembly in a vise, gripping the pro-

truding bearing with the vise.
Tap the yoke in area shown to achieve removal of universal
joint bearing.
c. Press the opposite bearing out of he yoke lug.
SHTS044120200008
(5) Remove the needle roller bearings and universal joint spider from
the yoke.
SHTS044120200009

Tap the yoke in area shown to achieve removal of needle
roller bearing.
SHTS044120200010
c. Place the yoke under the arbor press with the opposite side of
universal joint spider in the up position and place a small push
tool on the universal joint spider end.
d. Press the opposite bearing out of the yoke lug.
e. Remove the spider from the yoke.
NOTICE
• Keep the location and number of lock plate or balance piece
in mind.
• Bolt lengths are different according to the number of balance
piece.
SHTS044120200011

(1) Uncaulk the felt ring retainer from the groove on the sliding yoke.
(3) Remove the felt seal, split retainers and felt ring retainer from the
yoke shaft.
! CAUTION
When uncaulking the felt ring retainer, a metal chip may pop on
impact. Wear safety glasses to protect your eyes.
SHTS044120200012

SHTS044120200013
SHTS044120200014

NOTICE
dust deflector.
SHTS044120200015

NOTICE
SHTS044120200016
2. INSTALL THE SPIDERS AND NEEDLE ROLLER BEARINGS

INTO THE YOKES.
(1) Select a thickness for the raised portion "T" of the universal joint
cap so that measurements "B" is equivalent to measurements "A".
Use universal joint caps of the same thickness as possible for
both ends.
SHTS044120200017
Universal joint caps are available in following thickness.

Unit: mm {in.}
Thickness of raised portion
Color code
"T" of universal joint cap
0.00 Silver
0.04 {0.0016} Yellow
0.08 {0.0031} Black
0.12 {0.0047} Green
SHTS044120200018
NOTICE
When measuring dimension "B", clamp the spider with bearings
on two journal ends in a vise.
SHTS044120200019
(2) Put the universal joint spider into the yoke and then set the univer-
sal joint bearings on the yoke.
NOTICE
fitting to the spider should be made an angle of 45° with the lubri-
cation fitting of the center bearing part or the sliding yoke part as
SHTS044120200020
journal.
NOTICE
(4) Install the universal joint yokes to the universal joint spider.
SHTS044120200021
NOTICE
(5) Check the universal joint cap to ensure that it is free of any wear
or damage. Insert the universal joint cap into the groove in the
needle roller bearing, fit in the lock plate, and tighten the universal
joint cap.
NOTICE
Insert the universal joint cap so that the raised portion faces the
needle roller bearing. When inserting the universal joint cap, make
sure that the raised portion fits within the bearing bore the yoke
SHTS044120200022 shaft and sliding yoke.
(6) Check the starting torque of the universal joint using a spring bal-
ancer.
(7) After tightening the universal joint cap, bend the lock plate so that
it rests snugly against two sides of the bolt. Make sure that no
gaps appear between the lock plate and the bolt. Also, upon fitting
the lock plate against the bolt, check the bent portion of the lock
plate to make sure there are no cracks or fissures.
Assembly standard:
0.98-3.92 N⋅m {10-40 kgf⋅cm, 8.7-34.7 lbf⋅in.}
a. If the measuring value is below the assembly standard,
replace the universal joint cap to a thicker one, then repeat
SHTS044120200023 the procedure, starting from step 1.
b. If the measuring value is above the assembly standard,
replace the universal joint cap to a thinner one, then repeat
the procedure, starting from step 1.

(2) Install the new split retainers, felt seal and felt ring retainer on the
shaft by pushing it in along the yoke shaft spline.
and sliding area of the felt seal.
SHTS044120200024
(4) Align the phasing arrows as shown in figure.
SHTS044120200025
(5) Caulk the felt ring retainer equally at four points on the circumfer-
ence of the felt ring retainer. Make sure the felt ring retainer is
caulked down securely into the groove on the end of the sliding
yoke.
Caulking Width: 10-15 mm {0.394-0.591 in.}
! CAUTION
When caulking the felt ring retainer, a metal chip may pop on
SHTS044120200026

BEARING ASSEMBLY.
SHTS044120200027
NOTICE
center bearing.
Grease:
SHTS044120200028

water or oil that has been heated to between 80-100 °C {176-
212 °F}.
NOTICE
{248°F}.
installation.
! CAUTION
SHTS044120200029 Never touch hot water or oil and heated universal joint flange with
your bare band. This can result personal injury.
shown in figure.
NOTICE
minutes, prior to tightening to proper torque specifications.

PHASING ARROW
SHTS044120200030

SHTS044120200013

SHTS044120200031

so equipped.
Grease:
SHTS044120200005

EN0441202H300001
Unit: mm {in.}
Propeller shaft Front 0-0.5 1.0 Replace. Measure

damage and {0-0.0197} {0.0393}
bend
Rear 0-0.6
{0-0.0236}

beads if necessary.
x
if necessary.
Sliding spline back- At spline 0.3 Replace. Measure

lash (Inspect the 0.062-0.174 {0.0118}
spline backlash at slid- {0.0025-0.0068}
ing yoke lug 80mm
{3.150 in.} from the
shaft center.)
Clearance (C) between 0.020-0.054 0.1 Replace needle Measure

universal joint spider {0.0008-0.0021} {0.0039} roller bearing
spider. A B
2A22AA*&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧡ಽ
PROPELLER SHAFT (HD1050) PP02–1
PROPELLER SHAFT (HD1050)

P 02
PP02-004

DESCRIPTION ................................................ PP02-2
SPECIAL TOOL ............................................... PP02-3
OVERHAUL ..................................................... PP02-7
PP02–2 PROPELLER SHAFT (HD1050)

EN0441002I200001
DESCRIPTION
EN0441002C100001
SHTS044100200001

TROUBLESHOOTING
EN0441002F300001

Worn or damaged center bearing (If so Replace the bearing.
equipped)
ber cushion (If so equipped)
SPECIAL TOOL
EN0441002K100001
Prior to starting a propeller shaft overhaul, it is necessary to have this special tool. (with center bearing type)

COMPONENT LOCATOR
EN0441002D100001
FRONT (MODEL: FL)
SHTS044100200003
1 Universal joint yoke 10 Dust deflector

2 Universal joint cap 11 Universal joint flange
3 Lock plate 12 Lubrication fitting
4 Universal joint spider 13 Lock nut
5 Yoke shaft 14 Collar
6 Dust deflector 15 Center bearing holder
7 Center bearing 16 Needle roller bearing
8 Center bearing plate 17 Thrust washer
9 Center bearing cushion 18 Balance piece (If so equipped)

A 49-61.8 {500-630, 36-45} D 96-144 {980-1,470, 71-105}
B 784-980 {8,000-10,000, 579-723} E 18.8-25.4 {190-260, 14-19}
C 65-87 {663-887, 48-64}
REAR (MODEL: FL)
SHTS044100200004

7 Split retainer

A 49-61.8 {500-630, 36-45} B 166.8-225.4 {1,700-2,300, 123-166}
MODEL: SG
SHTS044100200005

7 Split retainer

A 49-61.8 {500-630, 36-45} C 166.8-225.4 {1,700-2,300, 123-166}
B 63.8-85.2 {651-868, 48-62}
OVERHAUL
EN0441002H200001

NOTICE
SHTS044100200006

NOTICE
NOTICE
SHTS044100200007
ing.
the universal joint yoke.
SHTS044100200008

roller bearing.
c. Press the opposite bearing out of the yoke lug.
SHTS044100200009
the yoke.
SHTS044100200010

roller bearing.
SHTS044100200011
NOTICE
in mind.
piece.
SHTS044100200012

(3) Remove the felt seal, split retainers and felt ring retainer, or dust
seal from the yoke shaft.
! CAUTION
SHTS044100200013

SHTS044100200014
SHTS044100200015
(7) Using a commercial puller, remove the center bearing subassem-

bly.
NOTICE
dust deflector.
SHTS044100200016

NOTICE
Remove the stale grease from the bearing cage. Lubricate with
grease containing molybdenum disulfide on the needle roller, seal
lip and both surfaces of thrust washer.
SHTS044100200017

INTO THE YOKES.
cap so that measurements "B" is equivalent to measurement "A".
both ends.
SHTS044100200018

Unit: mm {in.}
Color code
0.00 Silver
0.04 {0.0016} Yellow
0.08 {0.0031} Black
0.12 {0.0047} Green
SHTS044100200019
NOTICE
SHTS044100200020
(2) Put the spider into the yoke and then set the needle roller bear-
ings on the yoke.
NOTICE
When installing the spider to the yoke, install the lubrication fit-
ting to the spider should be made an angle of 45° with the lubrica-
tion fitting of the center bearing part or the sliding yoke part as
SHTS044100200021
(3) Press the universal joint bearings into the yoke over the spider
journal.
NOTICE
SHTS044100200022
NOTICE
needle roller bearing, fit in the lock washer, and tighten the univer-
sal joint cap.
NOTICE
SHTS044100200023 sure that the raised portion fits within the bearing bore the yoke
shaft and sliding yoke.
ancer.
Assembly standard:
0.98-3.92 N⋅m {10-40 kgf⋅cm, 8.7-34.7 lbf⋅in.}
(7) After checking the starting torque, bend the lock plate so that it
rests snugly against two sides of the bolt. Make sure that no gaps
appear between the lock plate and the bolt. Also, upon fitting the
lock plate against the bolt, check the bent portion of the lock
washer to make sure there are no cracks or fissures.
SHTS044100200024 the procedure, starting from step 1.

and sliding area of the felt ring.
SHTS044100200025
SHTS044100200026
yoke.
! CAUTION
SHTS044100200027

BEARING ASSEMBLY.
SHTS044100200028
NOTICE
center bearing.
Grease:
SHTS044100200029

212 °F}.
NOTICE
{248°F}.
installation.
! CAUTION
shown in figure.
NOTICE

PHASING ARROW
SHTS044100200031

SHTS044100200014

SHTS044100200032

so equipped.
Grease:
SHTS044100200006

EN0441002H300001
Unit: mm {in.}
Propeller shaft damage and 0-0.6 1.0 Replace. Measure

bend {0-0.0236} {0.039}
Crack in the welding beads — — Replace, Visual check

if necessary.

if necessary.
Sliding spline backlash At spline 0.3 Replace. Measure

(Inspect the spline back- 0.062-0.174 {0.0118}
lash at sliding yoke lug 80 {0.0025-0.0068}
mm {3.145 in.} from the
shaft center.)
Clearance Transmis- 0.025-0.075 0.1 Replace needle Measure

(C) between sion to rear {0.0010-0.0029} {0.0039} roller bearing
universal axle sub-assembly
joint spider or universal
and needle joint spider. A B
roller bear-
ing
(C = A - B)
2A22AA*'HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧝㧜ಽ
PROPELLER SHAFT (HE1160) PP02–1
PROPELLER SHAFT (HE1160)

P 02
PP02-005

DESCRIPTION ................................................ PP02-3
SPECIAL TOOL ............................................... PP02-4
OVERHAUL ..................................................... PP02-8
PP02–2 PROPELLER SHAFT (HE1160)

EN0441102I200001
Tubular shaft type (TRANSMISSION TO REAR AXLE)

Type
Tubeless shaft type [REAR AXLE (FRONT) TO REAR AXLE (REAR)]
DESCRIPTION
EN0441102C100001
SHTS044110200001

TROUBLESHOOTING
EN0441102F300001

Worn or damaged center bearing (If so Replace the bearing.
equipped)
ber cushion (If so equipped)
SPECIAL TOOL
EN0441102K100001
Prior to starting a propeller shaft overhaul, it is necessary to have this special tool. (with center bearing type)

2A22AA*'HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧥ಽ
COMPONENT LOCATOR
EN0441102D100001
TRANSMISSION TO REAR AXLE (FRONT) (IF SO EQUIPPED)
SHTS044110200003
1 Universal joint yoke 10 Center bearing support case

2 Universal joint spider 11 Oil seal
3 Thrust washer 12 Center bearing holder
4 Needle roller bearing 13 Center bearing
5 Universal joint cap 14 Center bearing plate
6 Balance piece (If so equipped) 15 Center bearing cushion
7 Lock plate 16 Universal joint flange
8 Yoke shaft 17 Lock nut
9 Dust deflector 18 Lubrication fitting

A 49-61.8 {500-630, 36-45} D 96-144 {980-1,470, 71-105}
B 784-980 {8,000-10,000, 579-723} E 18.8-25.4 {190-260, 14-19}
C φ12: 65-87 {663-887, 48-64}
φ16: 166.8-225.3 {1,700-2,300, 123-166}
2A22AA*'HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧞㧥ಽ
TRANSMISSION TO REAR AXLE (REAR)
SHTS044110200004

7 Split retainer

A 49-61.8 {500-630, 36-45} B φ12: 65-87 {663-887, 48-64}
φ16: 166.8-225.3 {1,700-2,300, 123-166}
REAR AXLE (FRONT) TO REAR AXLE (REAR)
SHTS044110200005
1 Universal joint yoke 7 Dust seal

2 Universal joint cap 8 Yoke shaft
3 Lock plate 9 Universal joint spider
5 Thrust washer 11 Balance piece (If so equipped)
6 Sliding yoke

A 25.5-31.3 {270-310, 20-22} B 127.5-156.9 {1,300-1,600, 94-115}
OVERHAUL
EN0441102H200001

NOTICE
SHTS044110200006

NOTICE
NOTICE
SHTS044110200007
ing.
the universal joint yoke.
SHTS044110200008

roller bearing.
c. Press the opposite bearing out of the yoke lug.
SHTS044110200009
the yoke.
SHTS044110200010

roller bearing.
SHTS044110200011
NOTICE
in mind.
piece.
SHTS044110200012

(3) Remove the felt seal, split retainers and felt ring retainer, or dust
seal from the yoke shaft.
! CAUTION
SHTS044110200013
3. REMOVE THE CENTER BEARING. (IF SO EQUIPPED)

SHTS044110200014
SHTS044110200015
(7) Using a commercial puller, remove the center bearing subassem-

bly.
NOTICE
dust deflector.
SHTS044110200016

NOTICE
Remove the stale grease from the bearing cage. Lubricate with
grease containing molybdenum disulfide on the needle roller, seal
lip and both surfaces of thrust washer.
SHTS044110200017

INTO THE YOKES.
cap so that measurements "B" is equivalent to measurement "A".
both ends.
SHTS044110200018

Unit: mm {in.}
Color code
0.00 Silver
0.04 {0.0016} Yellow
0.08 {0.0031} Black
0.12 {0.0047} Green
SHTS044110200019
NOTICE
SHTS044110200020
(2) Put the spider into the yoke and then set the needle roller bear-
ings on the yoke.
NOTICE
When installing the spider to the yoke, install the lubrication fit-
ting to the spider should be made an angle of 45° with the lubrica-
tion fitting of the center bearing part or the sliding yoke part as
SHTS044110200021
(3) Press the universal joint bearings into the yoke over the spider
journal.
NOTICE
SHTS044110200022
NOTICE
needle roller bearing, fit in the lock washer, and tighten the univer-
sal joint cap.
NOTICE
SHTS044110200023 sure that the raised portion fits within the bearing bore the yoke
shaft and sliding yoke.
ancer.
Assembly standard: Unit: N⋅m {kgf⋅cm, lbf⋅in.}
Transmission to rear axle Rear axle (front) to rear axle (rear)
0.98-4.90 {10-50, 8.7-43.3} 0.98-3.92 {10-40, 8.7-34.7}
(7) After checking the starting torque, bend the lock plate so that it
rests snugly against two sides of the bolt. Make sure that no gaps
appear between the lock plate and the bolt. Also, upon fitting the
lock plate against the bolt, check the bent portion of the lock
SHTS044110200024 washer to make sure there are no cracks or fissures.

and sliding area of the felt ring.
SHTS044110200025
SHTS044110200026
yoke.
! CAUTION
SHTS044110200027

dust cover seal groove.
SHTS044110200028

BEARING ASSEMBLY. (IF SO EQUIPPED)
SHTS044110200029
NOTICE
center bearing.
Grease:
SHTS044110200030

212 °F}.
NOTICE
{248°F}.
installation.
! CAUTION
shown in figure.
NOTICE

PHASING ARROW
SHTS044110200032

SHTS044110200014

SHTS044110200033

so equipped.
Grease:
SHTS044110200006

EN0441102H300001
Unit: mm {in.}
Propeller shaft damage and 0-0.6 1.0 Replace. Measure

bend {0-0.0236} {0.039}
Crack in the welding beads — — Replace, Visual check

if necessary.

if necessary.
Sliding spline backlash At spline 0.3 Replace. Measure

(Inspect the spline back- 0.062-0.174 {0.0118}
lash at sliding yoke lug 80 {0.0025-0.0068}
mm {3.145 in.} from the
shaft center.)
Clearance Transmis- 0.025-0.075 0.1 Replace needle Measure

(C) between sion to rear {0.0010-0.0029} {0.0039} roller bearing
universal axle sub-assembly
joint spider or universal
and needle Rear axle 0.020-0.054 joint spider. A B
roller bear- (front) to {0.0008-0.0021}
ing rear axle
(C = A - B) (rear)
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧝㧞ಽ
DIFFERENTIAL CARRIER (SH13) DF02–1
DIFFERENTIAL CARRIER (SH13)

DF02
DF02-001
DIFFERENTIAL CARRIER (SH13) ........... DF02-2

DATA AND SPECIFICATIONS........................ DF02-2
DESCRIPTION ................................................ DF02-2
TROUBLESHOOTING..................................... DF02-3
SPECIAL TOOL ............................................... DF02-3
COMPONENT LOCATOR ............................... DF02-4
OVERHAUL ..................................................... DF02-6
INSPECTION AND REPAIR .......................... DF02-19
DF02–2 DIFFERENTIAL CARRIER (SH13)

EN0550402I200001
Type Single-reduction, single-speed, by hypoid gearing
Gear ratios 3.636, 3.900, 4.333, 4.625
Oil capacity 3.7 L {0.81 lmp gal. / 0.98 U.S. gal.}
DESCRIPTION
EN0550402C100001
SHTS055040200001
1 Taper roller bearing 10 Bearing cage

2 Differential carrier case 11 Adjusting shim
3 Hypoid pinion 12 Spacer
4 Hypoid ring gear 13 Differential case
5 Cylindrical roller bearing 14 Differential pinion gear
6 Thrust washer 15 Bearing cap
7 Differential side gear 16 Axle housing
8 Flange yoke coupling 17 Spider
9 Oil seal 18 Oil filler plug
TROUBLESHOOTING
EN0550402F300001

Abnormal noise (Bearing system) Worn or damaged pinion bearings Replace bearings.
Worn or damaged differential side Replace bearings.
bearings
Loose pinion bearings Adjust bearing preload.
Loose differential side bearings Adjust bearing preload.
Abnormal noise (Gear system) Inadequate backlash on ring gear and Adjust backlash.
pinion gear
Worn thrust washers Replace.
Worn differential spider Replace.
Worn or damaged ring gear and pinion Replace.
Worn or damaged differential side Replace.
gears and pinions
Loose ring gear bolts Tighten bolts.
Inadequate tooth contact of ring gear Replace or adjust tooth contact.
and pinion gear
Worn pinion spline Replace.
Abnormal noise (Rear axle system) Worn rear axle shaft spline Replace.
Worn hub bearings Replace.
Loose hub bearings Adjust bearing preload.
Loose differential case tightening bolts Tighten bolts.
Abnormal noise (Oil system, etc.) Insufficient oil Add oil; check for leakage.
Poor oil quality Change oil.
Abnormal propeller shaft noise Refer to the Chapter "PROPELLER
SHAFT".
SPECIAL TOOL
EN0550402K100001
Prior to starting a differential carrier overhaul, it is necessary to have these special tools.
S0966-51150 ADJUSTER TOOL
S0964-01022 GAUGE ASSEMBLY

COMPONENT LOCATOR
EN0550402D100001
SHTS055040200005
1 Air breather 4 Gasket

2 Axle housing assembly 5 Oil drain plug
3 Oil filler plug 6 Differential carrier assembly

A 78.4-117.6 {800-1,200, 58-86} C 78.4-117.6 {800-1,200, 58-86}
B φ12: 84.5-107.5 {860-1,100, 63-79} D 9.8-19.6 {100-200, 7-14}
φ14: 113-147 {1,150-1,500, 83-108}
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧞㧥ಽ
SHTS055040200006
1 Lock nut 12 Adjusting nut

2 Flange yoke coupling 13 Differential case
3 Oil seal 14 Thrust washer
4 Taper roller bearing 15 Differential side gear
5 Bearing cage 16 Differential pinion gear
6 Adjusting shim 17 Spider
7 Spacer 18 Hypoid ring gear
8 Hypoid pinion 19 Bearing cap
9 Cylindrical roller bearing 20 Lock plate
10 Retainer ring 21 Differential case spacer
11 Differential carrier case 22 O-ring

A 63.9-85.3 {650-870, 48-62} D 374-500 {3,800-5,100, 276-368}
B 197-225 {2,000-2,300, 145-166} E 246-294 {2,500-3,000, 182-216}
C 19-25 {190-260, 14-18} F 246-294 {2,500-3,000, 182-216}
OVERHAUL
EN0550402H200001

NOTICE
Make aligning marks before disassembling.
SHTS055040200007
2. DISMOUNTING OF THE DIFFERENTIAL CARRIER ASSEMBLY

(1) Drain the gear oil and remove the axle shaft.
(2) Using a jack, dismount the differential carrier assembly.
SHTS055040200008
1. MOUNT THE DIFFERENTIAL CARRIER ASSEMBLY ON A

WORK STAND.
SHTS055040200009
2. DIFFERENTIAL CASE
(1) Remove the bearing cap.
NOTICE
(2) Using a puller, remove the taper roller bearing.
SHTS055040200010
(3) Dismounting the ring gear

a. Make aligning mark both the differential case and the ring
gear.
b. Using press, fix the differential gear assembly.
ALIGNING MARK c. Remove the bolts, nuts and then ring gear.
NOTICE
Be careful not to drop the ring gear.
SHTS055040200011
(4) Disassemble the differential case.

NOTICE
Be sure to check the aligning marks on the differential case before
disassembling. Remove the bolts so that the case separates.
SHTS055040200012
3. HYPOID PINION
ALIGNING (1) Remove the bolts and then dismount the hypoid pinion and the
MARK shims.
NOTICE
Make aligning mark the differential cage and differential carrier.
SHTS055040200013
(2) Remove the bolts, nuts, and washers.

(3) Using brass bar and hammer, knock through the cylindrical roller
bearing outer race.
SHTS055040200014
4. BEARING CAGE
(1) Uncaulk the lock nut and remove the nut.
SHTS055040200015
SHTS055040200016
(2) Using a puller, remove the cylindrical roller bearing inner race.
SHTS055040200017
(3) Using a press, remove the hypoid pinion.
SHTS055040200018
(4) Using a puller, remove the taper roller bearing inner race.
SHTS055040200019
(1) Measure the pinion backlash.
NOTICE
Be sure to set the chamfered side of the thrust washer for the side
gear face to the gear side.
• A: Pinion
• B: Side gear
• C: Thrust washer
SHTS055040200020
(2) If the backlash is more than service limit, replace the thrust
washer for side gear and/or pinion.
Assembly standard: 0.20-0.60 mm {0.0079-0.0236 in.}
SHTS055040200021
(3) Assemble the differential case.

NOTICE
• Align the aligning marks when assembling.
• Apply lock agent (ThreeBond 1360K or equivalent) on the
bolt threads.
SHTS055040200022
(4) Install the ring gear to the differential case and tighten it with bolts
and nuts.
NOTICE
Apply lock agent (ThreeBond 1360K or equivalent) on the bolt
threads.
SHTS055040200023
2. HYPOID PINION
(1) Installing the inner and outer taper roller bearing outer race
a. Apply gear oil to the inner and outer taper roller bearing outer
race.
b. Using wear plates and press, press into the differential cage
OUTER RACE the inner and outer taper roller bearing outer race.
SHTS055040200024
(2) Installing the cylindrical roller bearing inner race

a. Apply gear oil to the cylindrical roller bearing inner race.
b. Using press, press the cylindrical roller bearing inner race to
the end of the hypoid pinion.
c. Install a new retainer ring.
! CAUTION
SHTS055040200025
(3) Installing the inner taper roller bearing inner race

a. Apply gear oil to the inner taper roller bearing inner race.
b. Using wear plates and press, press into the shaft of hypoid
pinion the inner taper roller bearing inner race.
SHTS055040200026
c. Install the spacer.
SHTS055040200027
(4) Installing the differential cage and outer taper roller bearing inner
race
a. Apply gear oil to the outer taper roller bearing inner race.
pinion the differential cage and outer taper roller bearing inner
race.
SHTS055040200028
3. ADJUSTMENT OF THE PINION BEARING PRELOAD

(1) Assemble the hypoid pinion and bearing cage and then tighten
the flange yoke coupling provisionally.
NOTICE
The oil seal must be installed in the bearing cage after measure-
ment of the preload.
SHTS055040200029
(2) Use a torque wrench to measure the preload of the bearings and
if the preload is out of specific value shown below, adjust with
spacer.
Assembly Standard: Turning torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}
New bearing Re-used bearing
1.97-2.94 {20-30, 1.5-2.1} 1.47-2.45 {15-25, 1.1-1.8}
Adjusting spacer thickness:

20 kinds of thicknesses ranging from 13.900 to 14.375 mm
{0.5473 to 0.5659 in.} each differing 0.025 mm {0.001 in.}
SHTS055040200030
NOTICE
Measure the preload and record it for measuring the total preload
at the differential carrier bearings at a later time.
(3) After adjusting the preload, install the new oil seal.
NOTICE
Tap the oil seal in small steps and evenly to prevent it from being
at slant position.
SHTS055040200031
NOTICE
Apply wheel bearing grease on the oil seal lip part.
SHTS055040200032
(4) Install the flange yoke coupling and tighten the lock nut.
SHTS055040200029
(5) Using a chisel and a hammer, caulk the lock nut.

NOTICE
• Caulk the nut securely as shown.
• Make sure that there is no rift in the caulked position.
VIEW A
SHTS055040200033
4. INSTALLATION OF THE CYLINDRICAL ROLLER BEARING

OUTER RACE
(1) Apply gear oil to the cylindrical roller bearing outer race.
(2) Install the cylindrical roller bearing outer race by nuts, bolts, and
washers.
SHTS055040200014
5. ADJUSTMENT OF THE PINION FITTING HEIGHT

(CONICAL DISTANCE)
(1) Apply bearing grease to the O-ring installation groove of the differ-
ential carrier cage and to the new O-ring.
(2) Install the O-ring in the O-ring installation groove of the differential
carrier cage.
NOTICE
Always use a new O-ring.
(3) Install the Bearing cage assembly and adjust the height with
shims.
SST: Gauge Assembly (S0964-01022)
SHTS055040200034
A: 21.5 mm {0.846 in.}

B: Adjusting shim
Thickness: 0.30 mm {0.0118 in.}
0.40 mm {0.0157 in.}
0.45 mm {0.0177 in.}
0.50 mm {0.0197 in.}
SHTS055040200035
(4) How to use the pinion depth gauge: Set the pinion depth gauge.
A: 21.5 mm {0.846 in.}
SHTS055040200036
EXAMPLE:
In a case where the engraved value at the surface of the pinion
gear is -2 (-2 means -0.2 mm):
Standard pinion
height "A" Measuring part (A')
21.5 mm – 0.2 mm = 21.3 mm
The engraved value
"a"
SHTS055040200037
6. CYLINDRICAL ROLLER BEARING

(1) Stake the lock nut. securely as shown in the figure.
SHTS055040200038
7. ADJUSTMENT OF HYPOID RING GEAR BACKLASH

(1) Set the differential case assembly on the carrier case and install
the adjusting nut and bearing cap.
NOTICE
A
Align the aligning marks "A".
SHTS055040200039
(2) Adjust the preload of the side bearing provisionally.

1/4TURN a. Tighten the adjusting nut fully, then loosen the adjusting nut
by 1/4 turn + 1 notch.
SST: Adjuster Tool (S0966-51150)
SHTS055040200060
b. Hit the bearing cap with a copper hammer.
SHTS055040200041
(3) Measure the gear backlash at three or four points on the circum-
ference of the gear.
Assembly standard: 0.25-0. 33 mm {0.010-0.013 in.}
SHTS055040200042
(4) Adjust the backlash by turning the adjusting nuts. Turn the both
nuts by the same angle.
BACKLASH: "A"-Decrease "B"-Increase
SHTS055040200043
8. INSPECTION AND ADJUSTMENT OF GEAR MESHING

(1) Satisfactory gear meshing.
NOTICE
New gears are marked as shown to indicate proper gear meshing.
Make necessary adjustment so that gears mesh corresponds with
the factory's mark.
SHTS055040200044
(2) Example of the unsatisfactory engagement

a. Toe and flank contact
A: Toe contact - Unadjust, replace the pinion and ring

gear as a set.
B: Flank contact - Adjust
SHTS055040200045
b. Heel and face contact
A: Heel contact - Unadjust, replace the pinion and ring

gear as a set.
B: Face contact - Adjust
SHTS055040200040
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧞ಽ
9. MEASUREMENT AND ADJUSTMENT OF THE SIDE BEARING

(1) Measure the total preload using a torque wrench at the flange
coupling.
NOTICE
Total preload = Side bearing preload + Pinion bearing preload
(refer to item 3).
SHTS055040200046
Assembly standard: Side bearing preload turning torque

Gear ratio 3.636 3.900 4.333 4.625
0.54-0.81 0.51-0.75 0.46-0.67 0.43-0.63
New bearing
{5.5-8.2, 0.40-0.59} {5.2-7.3, 0.38-0.54} {4.7-6.9, 0.34-0.49} {4.4-6.4, 0.32-0.46}
0.40-0.67 0.38-0.62 0.34-0.56 0.32-0.52
Re-used bearing
{4.1-6.8, 0.30-0.49} {3.9-6.4, 0.29-0.46} {3.5-5.4, 0.24-0.39} {3.3-5.4, 0.24-0.39}
NOTICE
The gear ratio is indicated on the bearing cage.
(2) If necessary, adjust the side bearing preload with the adjusting
nut.
• A: Counterclockwise: Decrease preload
• B: Clockwise: Increase preload
SHTS055040200043
(3) Tighten the bearing cap and install the lock plate.
SHTS055040200047
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧞ಽ
1. MOUNTING
(1) Apply liquid gasket on the face of the housing flange.
NOTICE
• The liquid gasket should be applied continuously.
• Application should be approximately 3 mm {0.12 in.} width
and 4 mm {0.16 in.} away from the edge.
SHTS055040200048
(2) Using a jack, install the differential carrier assembly to the axle
housing.
NOTICE
Place the carrier assembly so that the ring gear teeth faces toward
the right-hand side of vehicle.
SHTS055040200008
(3) After applying the liquid gasket (ThreeBond #1215 or #1216 or

equivalent) round φ12 bolts (8 pieces), install the bolts and tighten
them regularly.
SHTS055040200049
(4) Connect the propeller shaft.

NOTICE
Tightening Torque:
61-91 N⋅m {623-927 kgf⋅cm, 45-67 lbf⋅ft}
(5) Fill the axle housing with specified gear oil up to the filler plug
hole.
Gear oil:
Refer to the owner's manual
SHTS055040200050

EN0550402H300001
Unit: mm {in.}
Pinion and ring gear: — — Replace, Visual check

Bearing and race: — — Replace, Visual check

Burns and pitting if necessary.
Differential case spider — — Replace, Visual check

holes: if necessary.
Wear and damage
Spider: — — Replace, Visual check

Differential side gear — — Replace, Visual check

and pinion: if necessary.
Wear and damage
Spider and pinion: A: 24 {0.945} 0.4 {0.016} Replace. Measure

Clearance B-A: 0.141-0.261
{0.0056-0.0103}
Thrust washers thick- Side gear: 1.7 {0.067} Replace. Measure

ness (Side gear and 1.9-2.1
pinion gear) {0.075-0.082}
Pinion gear: 1.3 {0.051}

1.5-1.7
{0.060-0.066}
Differential side gear 0.054-0.148 0.5 {0.0196} Replace. Measure

and axle shaft: {0.0021-0.0058}
Spline backlash
Flange coupling: — — Replace, Visual check

2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧝㧟ಽ

DF02
DF02-002

DESCRIPTION ................................................ DF02-2
SPECIAL TOOL ............................................... DF02-4
OVERHAUL ..................................................... DF02-7

EN0551402I200001
Gear ratios 5.125
Oil capacity 5.5 L {1.21 lmp gal. / 1.45 U.S gal.}
DESCRIPTION
EN0551402C100001
1
11
12
2
13
3
4 14
5
15
6
16
7
17
18
19
10
8 20
SHTS055140200001
1 Flange yoke coupling 8 Thrust washer 15 Spacer

2 Oil seal 9 Axle shaft 16 Cylindrical roller bearing
3 Hypoid ring gear 10 Bearing cap 17 Differential carrier case
4 Spider 11 Hypoid pinion 18 Adjusting nut
5 Differential pinion gear 12 Taper roller bearing 19 Axle housing
6 Differential side gear 13 Bearing cage 20 Oil filler plug
7 Differential case 14 Adjusting shim
TROUBLESHOOTING
EN0551402F300001

bearings
pinion gear
gears and pinions
and pinion gear
Abnormal noise (Oil system, etc.) Insufficient oil Add oil, check for leakage.
Abnormal propeller shaft noise Refer to the chapter "PROPELLER
SHAFT".
SPECIAL TOOL
EN0551402K100001

COMPONENT LOCATOR
EN0551402D100001
(EXAMPLE)
D
C
1
3
B 6
4
5
7 A
SHTS055140200006
1 Air breather 5 Oil drain plug

2 Axle housing assembly 6 O-ring
4 Gasket

A 39.2-117.6 {400-1200, 29-86} C 78.4-117.6 {800-1,200, 58-86}
B 113-147 {1,150-1,500, 83-108} D 9.8-19.6 {100-200, 7-14}
SHTS055140200007
1 Lock nut 8 Hypoid pinion 15 Differential side gear

2 Flange yoke coupling 9 Cylindrical roller bearing 16 Differential pinion gear
3 Oil seal 10 Retainer ring 17 Spider
4 Taper roller bearing 11 Differential carrier case 18 Hypoid ring gear
5 Bearing cage 12 Adjusting nut 19 Collar
6 Adjusting shim 13 Differential case 20 Bearing cap
7 Spacer 14 Thrust washer 21 Lock plate

A 108-148 {1,100-1,500, 80-108} E 19-25 {190-260, 14-18}
B 275-353 {2,800-3,600, 203-260} F 363-421 {3,700-4,300, 268-311}
C 19-25 {190-260, 14-18} G 167-215 {1,700-2,200, 123-159}
D 589-781 {6,000-8,000, 434-578}
OVERHAUL
EN0551402H200001

NOTICE
SHTS055140200008
2. DISMOUNT THE DIFFERENTIAL CARRIER ASSEMBLY.

SHTS055140200009

WORK STAND.
SHTS055140200010
NOTICE
ALIGNING MARK
SHTS055140200011

gear.
ALIGNING MARK b. Using press, fix the differential gear assembly.
c. Remove the bolts and then ring gear.
NOTICE
SHTS055140200012

NOTICE
SHTS055140200013
3. HYPOID PINION
(EXAMPLE) ALIGNING (1) Remove the bolts and then dismount the hypoid pinion and the
MARK shims.
NOTICE
SHTS055140200014

bearing outer race.
SHTS055140200015
4. BEARING CAGE
SHTS055140200016
SHTS055140200017
(2) Using a puller, remove the taper roller bearing outer race.
SHTS055140200018
SHTS055140200019
SHTS055140200020
NOTICE
• A: Pinion
• B: Side gear
SHTS055140200021
SHTS055140200022

NOTICE
bolt threads.
SHTS055140200023
(4) Install the ring gear to the differential case and tighten it with bolts.
NOTICE
threads.
SHTS055140200024
2. HYPOID PINION
race.
SHTS055140200025
(2) Installing the pilot bearing inner race

! CAUTION
SHTS055140200026

b. Using wear plates and press, press into the shaft of drive pin-
ion the inner taper roller bearing inner race.
SHTS055140200027
SHTS055140200028
race
race.
SHTS055140200029

NOTICE
SHTS055140200030
spacer.

1.97-2.45 {20-25, 1.5-1.8} 1.47-1.96 {15-20, 1.1-1.4}

SHTS055140200031
NOTICE
NOTICE
at slant position.
SHTS055140200032
NOTICE
SHTS055140200033
(5) Measure the preload and record it for measuring the total preload
SHTS055140200030

NOTICE
• Caulk the nut securely as shown in the figure.
• Make sure that there is no rift in the caulk position.
VIEW A
SHTS055140200034

OUTER RACE
washers.
NOTICE
threads.
SHTS055140200035
5. ADJUSTMENT OF PINION FITTING HEIGHT

(CONICAL DISTANCE)
(1) Install the pinion cage assembly and adjust the height with shims.
SHTS055140200036
A: 27 mm {1.063 in.}
B: Adjusting shim
0.40 mm {0.0157 in.}
0.45 mm {0.0177 in.}
0.50 mm {0.0197 in.}
SHTS055140200037
(2) How to use the pinion depth gauge: Set the pinion depth gauge.
A: 27 mm {1.063 in.}
SHTS055140200038
EXAMPLE:
In a case where the engraved value at the surface of the
pinion gear is -2 (-2 means -0.2 mm):
Standard pin-
ion height "A" Measuring part (A')
27.0 mm – 0.2 mm = 26.8 mm
The engraved
value "a"
NOTICE
Upon completing the adjustment, remove the bearing cage
SHTS055140200039
assembly and apply liquid gasket (ThreeBond #1215 or equiva-
lent) on the mounting surfaces of differential carrier case and
bearing cage.

NOTICE
A
SHTS055140200040

SHTS055140200041
SHTS055140200042
SHTS055140200043
SHTS055140200044
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧠ಽ

NOTICE
the factory's mark.
SHTS055140200045


gear as a set.
SHTS055140200046

gear as a set.
SHTS055140200047
8. MEASUREMENT AND ADJUSTMENT OF THE DIFFERENTIAL

CARRIER BEARING AND SIDE BEARING
(1) Measure and adjust the total preload at the differential carrier
bearings, using a torque wrench.
NOTICE
Total preload = side bearing preload + pinion bearing preload
(Refer to item 3).
Assembly standard:
Side bearing preload turning torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}
0.39-0.47
New bearing
SHTS055140200048 {4.0-4.8, 0.29-0.35}
0.29-0.38
Re-used bearing
{3.0-3.8, 0.22-0.28}
NOTICE
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧠ಽ
nut.
SHTS055140200044
SHTS055140200049
1. MOUNTING
(1) Using scraper, remove the rust on the joint surface between the
axle housing and the differential carrier assembly.
(2) Install a new O-ring.
SHTS055140200050

NOTICE
SHTS055140200051
housing.
NOTICE
SHTS055140200009

equivalent) round φ14 bolts (10 pieces), install the bolts and
tighten them regularly.
SHTS055140200052

NOTICE
Tightening Torque:
61-91 N⋅m {623-927 kgf⋅cm, 45-67 lbf⋅ft}
hole.
Gear oil:
SHTS055140200053

EN0551402H300001
Unit: mm {in.}



Wear and damage


Wear and damage
Spider and pinion: A: 26 {1.024} 0.4 Replace. Measure

Clearance {0.016}
B-A: 0.140-0.201
{0.0055-0.0079}
Thrust washers thick- Side gear: 1.7 Replace. Measure

ness (Side gear and 1.9-2.1 {0.067}
pinion gear) {0.075 – 0.082}
Pinion gear: 1.5

1.7-1.9 {0.059}
{0.067-0.074}
Differential side gear 0.054-0.148 0.5 Replace. Measure

and axle shaft: {0.0021-0.0058} {0.0196}
Spline backlash

2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧝㧠ಽ

DF02
DF02-003

DESCRIPTION ................................................ DF02-2
SPECIAL TOOL ............................................... DF02-4
OVERHAUL ..................................................... DF02-7

EN0551202I200001
Gear ratios 4.300, 4.625, 4.875, 5.857
Oil capacity 8 L {1.76 lmp gal. / 12.12 U.S gal.}
DESCRIPTION
EN0551202C100001
1
11
12
2
13
3
4 14
5
15
6
16
7
17
18
19
10
8 20
SHTS055120200001
1 Flange yoke coupling 8 Thrust washer 15 Spacer

2 Oil seal 9 Axle shaft 16 Cylindrical roller bearing
3 Hypoid ring gear 10 Bearing cap 17 Differential carrier case
4 Spider 11 Hypoid pinion 18 Adjusting nut
5 Differential pinion gear 12 Taper roller bearing 19 Axle housing
6 Differential side gear 13 Bearing cage 20 Oil filler plug
7 Differential case 14 Adjusting shim
TROUBLESHOOTING
EN0551202F300001

bearings
pinion gear
gears and pinions
and pinion gear
SHAFT".
SPECIAL TOOL
EN0551202K100001

COMPONENT LOCATOR
EN0551202D100001
(EXAMPLE)
D
C
1
3
B 6
4
5
7 A
SHTS055120200006

4 Gasket

A 39.2-68.6 {400-700, 29-50} C 78.4-117.6 {800-1,200, 58-86}
B 113-147 {1,150-1,500, 83-108} D 9.8-19.6 {100-200, 7-14}
SHTS055120200007
1 Lock nut 8 Hypoid pinion 15 Differential side gear

2 Flange yoke coupling 9 Cylindrical roller bearing 16 Differential pinion gear
3 Oil seal 10 Retainer ring 17 Spider
4 Taper roller bearing 11 Differential carrier case 18 Hypoid ring gear
5 Bearing cage 12 Adjusting nut 19 Collar
6 Adjusting shim 13 Differential case 20 Bearing cap
7 Spacer 14 Thrust washer 21 Lock plate

A 108-147 {1,100-1,500, 80-108} E 19-25 {190-260, 14-18}
B 275-353 {2,800-3,600, 203-260} F 363-421 {3,700-4,300, 268-311}
C 19-25 {190-260, 14-18} G 246-294 {2,500-3,000, 181-216}
D 589-781 {6,000-8,000, 434-578}
OVERHAUL
EN0551202H200001

NOTICE
SHTS055120200008
2. DISMOUNTING OF THE DIFFERENTIAL CARRIER ASSEMBLY

SHTS055120200009

WORK STAND.
SHTS055120200010
NOTICE
ALIGNING MARK
SHTS055120200011

gear.
ALIGNING MARK c. Remove the bolts and then ring gear.
NOTICE
SHTS055120200012

NOTICE
SHTS055120200013
3. HYPOID PINION
(EXAMPLE) ALIGNING (1) Remove the bolts and then dismount the hypoid pinion and the
MARK shims.
NOTICE
SHTS055120200014

bearing outer race.
SHTS055120200015
4. BEARING CAGE
SHTS055120200016
SHTS055120200017
SHTS055120200018
SHTS055120200019
SHTS055120200020
NOTICE
• A: Pinion
• B: Side gear
SHTS055120200021
SHTS055120200022

NOTICE
bolt threads.
SHTS055120200023
(4) Install the ring gear to the differential case and tighten it with bolts.
NOTICE
threads.
SHTS055120200024
2. HYPOID PINION
race.
SHTS055120200025
(2) Installing the cylindrical roller bearing inner race

! CAUTION
SHTS055120200026

pinion the inner taper roller bearing inner race.
SHTS055120200027
SHTS055120200028
race
race.
SHTS055120200029

NOTICE
SHTS055120200030
spacer.

1.97-2.94 {20-30, 1.5-2.1} 1.47-2.45 {15-25, 1.1-1.8}

SHTS055120200031
NOTICE
NOTICE
at slant position.
SHTS055120200032
NOTICE
• Apply the liquid gasket (ThreeBond#1207B or equivalent) on
the outer circumference of the oil seal.
• Apply wheel bearing grease on the oil seal lip part.
SHTS055120200033
SHTS055120200030

(EXAMPLE)
NOTICE
• Make sure that there is no rift in the caulked position.
VIEW A
SHTS055120200034

OUTER RACE
washers.
NOTICE
threads.
SHTS055120200015

(CONICAL DISTANCE)
(1) Install the bearing cage assembly and adjust the height with
shims.
SHTS055120200035
A: 33 mm {1.299 in.}
B: Adjusting shim
0.40 mm {0.0157 in.}
0.45 mm {0.0177 in.}
0.50 mm {0.0197 in.}
SHTS055120200036
(2) How to use the pinion depth gauge:

Set the pinion depth gauge.
A: 33 mm {1.299 in.}
SHTS055120200037
EXAMPLE:
Standard pin-
33.0 mm – 0.2 mm = 32.8 mm
The engraved
value "a"
NOTICE
SHTS055120200038
bearing cage.
6. ADJUSTMENT OF THE HYPOID RING GEAR BACKLASH

NOTICE
A
SHTS055120200039

SHTS055120200040
SHTS055120200041
Assembly standard:
Gear ratio Backlash
4.300, 5.857 0.25-0.33 mm {0.010-0.013 in.}
4.625, 4.875 0.30-0.41 mm {0.012-0.016 in.}
SHTS055120200042
SHTS055120200043

NOTICE
the factory's mark.
SHTS055120200044


gear as a set.
SHTS055120200045

gear as a set.
SHTS055120200046
8. MEASUREMENT AND ADJUSTMENT OF THE SIDE BEARING

(1) Measure the total preload using a torque wrench at the flange
coupling.
NOTICE
(Refer to item 3).
SHTS055120200047

Gear ratio 4.300 4.625 4.875 5.857
0.46-0.68 0.43-0.63 0.41-0.60 0.34-0.50
New bearing
{4.7-6.9, 0.34-0.50} {4.4-6.4, 0.32-0.46} {4.2-6.1, 0.30-0.44} {3.5-5.1, 0.25-0.37}
0.28-0.45 0.32-0.52 0.31-0.50 0.26-0.41
Re-used bearing
{2.8-4.6, 0.21-0.33} {3.3-5.4, 0.24-0.39} {3.1-5.1, 0.23-0.37} {2.6-4.2, 0.19-0.30}
NOTICE
nut.
SHTS055120200043
SHTS055120200048
1. MOUNTING
SHTS055120200049

NOTICE
SHTS055120200050
housing.
NOTICE
SHTS055120200009

SHTS055120200051

NOTICE
Tightening Torque:
61-91 N⋅m {623-927 kgf⋅cm, 45-67 lbf⋅ft}
hole.
Gear oil:
SHTS055120200052

EN0551202H300001
Unit: mm {in.}



Wear and damage


Wear and damage

Clearance {0.016}
B-A: 0.140-0.201
{0.0055-0.0079}

ness (Side gear and 1.9-2.1 {0.067}
pinion gear) {0.075 – 0.082}
Pinion gear: 1.5

1.7-1.9 {0.059}
{0.067-0.074}

and axle shaft: {0.0021-0.0058} {0.0196}
Spline backlash

2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧝㧣ಽ

DF02
DF02-004

DESCRIPTION ................................................ DF02-2
SPECIAL TOOL ............................................... DF02-4
OVERHAUL ..................................................... DF02-7

EN0551502I200001
Gear ratios 4.300, 4.625, 4.875, 5.250, 5.428, 5.857, 6.428
Oil capacity 11 L {2.42 lmp gal. / 2.91 U.S gal.}
DESCRIPTION
EN0551502C100001
SHTS055150200001
1 Taper roller bearing 8 Flange yoke coupling 15 Adjusting nut

2 Differential carrier case 9 Oil seal 16 Bearing cap
3 Hypoid pinion 10 Bearing cage 17 Axle housing
4 Hypoid ring gear 11 Adjusting shim 18 Spider
5 Cylindrical roller bearing 12 Spacer 19 Oil filler plug
6 Thrust washer 13 Differential case 20 Axle shaft
7 Differential side gear 14 Differential pinion gear
TROUBLESHOOTING
EN0551502F300001

bearings
pinion gear
gears and pinions
and pinion gear
SHAFT".
SPECIAL TOOL
EN0551502K100001

COMPONENT LOCATOR
EN0551502D100001
SHTS055150200006

4 Gasket

A 39.2-68.6 {400-700, 29-50} C 78.4-117.6 {800-1,200, 58-86}
B 167-213 {1,700-2,200, 123-159} D 9.8-19.6 {100-200, 7-14}
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧣ಽ
SHTS055150200007
1 Lock nut 9 Cylindrical roller bearing 17 Spider

2 Flange yoke coupling 10 Retainer ring 18 Hypoid ring gear
3 Oil seal 11 Differential carrier case 19 Collar
4 Taper roller bearing 12 Adjusting nut 20 Bearing cap
5 Bearing cage 13 Differential case 21 Lock plate
6 Adjusting shim 14 Thrust washer 22 Bolt (If so equipped)
7 Spacer 15 Differential side gear
8 Hypoid pinion 16 Differential pinion gear

A 167-223 {1,700-2,300, 123-166} E 19-25 {190-260, 14-18}
B 344-460 {3,500-4,700, 254-336} F 461-559 {4,700-5,700, 340-412}
C 19-25 {190-260, 14-18} G 246-294 {2,500-3,000, 181-216}
D 589-781 {6,000-8,000, 434-578}
OVERHAUL
EN0551502H200001

NOTICE
SHTS055150200008

SHTS055150200009

WORK STAND.
SHTS055150200010
NOTICE
SHTS055150200011

gear.
ALIGNING MARK c. Remove the bolts, nuts (Gear ratio 6.428: bolts only) and then
ring gear.
NOTICE
SHTS055150200012

NOTICE
disassembling. Remove the bolts and nuts so that the case sepa-
rates.
SHTS055150200013
3. HYPOID PINION
(1) Remove the bolts and then dismount the hypoid pinion and the
shims.
NOTICE
SHTS055150200014

bearing outer race.
SHTS055150200015
4. BEARING CAGE
SHTS055150200016
SHTS055150200017
SHTS055150200018
SHTS055150200019
SHTS055150200020
2A&(AA5*HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧤ಽ
NOTICE
• A: Pinion
• B: Side gear
SHTS055150200021
SHTS055150200022

NOTICE
bolt threads.
SHTS055150200023
(4) Install the ring gear to the differential case and tighten it with bolts
and nuts.
NOTICE
threads.
SHTS055150200024
2. HYPOID PINION
race.
SHTS055150200025
(2) Installing the pilot bearing inner race

! CAUTION
SHTS055150200026

b. Using wear plates and press, press into the shaft of drive pin-
ion the inner taper roller bearing inner race.
SHTS055150200027
SHTS055150200028
race
race.
SHTS055150200029

NOTICE
SHTS055150200030
spacer.
1.97-2.45 {20-25, 1.5-1.8} 1.47-1.96 {15-20, 1.1-1.4}

SHTS055150200031 NOTICE
NOTICE
at slant position.
SHTS055150200032
NOTICE
SHTS055150200033
SHTS055150200030

NOTICE
• Caulk the nut securely as shown.
VIEW A
SHTS055150200034

OUTER RACE
washers.
NOTICE
threads.
SHTS055150200035

(CONICAL DISTANCE)
(1) Install the pinion cage assembly and adjust the height with shims.
SHTS055150200036
A: 34 mm {1.339 in.}
B: Adjusting shim
0.40 mm {0.0157 in.}
0.45 mm {0.0177 in.}
0.50 mm {0.0197 in.}
SHTS055150200037

A: 34 mm {1.339 in.}
SHTS055150200038
EXAMPLE:
Standard pin-
34.0 mm – 0.2 mm = 33.8 mm
The engraved
value "a"
NOTICE
SHTS055150200039
bearing cage.

NOTICE
A
SHTS055150200040

SHTS055150200041
SHTS055150200042
Assembly standard:
Gear ratio Backlash
Except 6.428 0.30-0.41 mm {0.012-0.016 in.}
6.428 0.25-0.33 mm {0.010-0.013 in.}
SHTS055150200043
SHTS055150200044

NOTICE
the factory's mark.
SHTS055150200045


gear as a set.
SHTS055150200046

gear as a set.
SHTS055150200047

bearings, using a torque wrench.
NOTICE
(refer to item 3).
SHTS055150200048

Gear ratio 4.300 4.625 4.875 5.250 5.428 5.857 6.428
0.46-0.57 0.43-0.52 0.41-0.50 0.38-0.46 0.37-0.45 0.34-0.41 0.31-0.38
New bearing {4.7-5.8, {4.4-5.4, {4.2-5.1, {3.9-4.7, {3.7-4.6, {3.5-4.2, {3.2-3.8,
0.34-0.41} 0.32-0.39} 0.30-0.37} 0.28-0.34} 0.27-0.33} 0.25-0.30} 0.23-0.28}
0.35-0.45 0.32-0.42 0.31-0.40 0.29-0.37 0.28-0.36 0.26-0.33 0.23-0.30
Re-used
{3.6-4.6, {3.3-4.3, {3.1-4.0, {2.9-3.8, {2.8-3.6, {2.6-3.4, {2.4-3.1,
bearing
0.26-0.33} 0.24-0.31} 0.23-0.29} 0.21-0.27} 0.20-0.26} 0.19-0.24} 0.17-0.22}
NOTICE
nut.
SHTS055150200044
SHTS055150200049
1. MOUNTING
SHTS055150200050

NOTICE
SHTS055150200051
housing.
NOTICE
SHTS055150200009

SHTS055150200052

NOTICE
Tightening Torque:
φ14 bolt: 127.5-156.9 N⋅m {1,300-1,600 kgf⋅cm, 94-115 lbf⋅ft}
hole.
Gear oil:
SHTS055150200053 Refer to the owner's manual.

EN0551502H300001
Unit: mm {in.}



Wear and damage


Wear and damage
Spider and pinion: A: 32 {1.260} 0.4 {0.016} Replace. Measure

Clearance B-A: 0.145-0.190
{0.006-0.007}
Thrust washers thick- Side gear: 1.7 {0.067} Replace. Measure

ness (Side gear and 1.9-2.1
pinion gear) {0.075 – 0.082}
Pinion gear: 1.5 {0.059}

1.7-1.9
{0.067-0.074}
Differential side gear 0.054-0.148 0.5 {0.0196} Replace. Measure

and axle shaft: {0.0021-0.0058}
Spline backlash

2A&(AA6*&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧝㧤ಽ
DIFFERENTIAL CARRIER (THD17) DF02–1
DIFFERENTIAL CARRIER (THD17)

DF02
DF02-005
DIFFERENTIAL CARRIER (THD17)......... DF02-2

DESCRIPTION ................................................ DF02-2
SPECIAL TOOL ............................................... DF02-6
OVERHAUL ................................................... DF02-10
2A&(AA6*&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧟㧥ಽ
DF02–2 DIFFERENTIAL CARRIER (THD17)
DIFFERENTIAL CARRIER (THD17)

EN0551802I200001
Type Single-reduction, single-speed, by hypoid gearing with

Inter-axle differential and transfer gear, used for the
forward axle of tandem drive axles.
Gear ratios 5.428, 5.857, 6.428
Oil capacity 13 L {3.43 U.S.gal, 2.86 lmp.gal}
DESCRIPTION
EN0551802C100001
(EXAMPLE)
10
14 1
1 2 3 4 5 6 7 8 9 11 12 13 4
4
21
25
22
23
9 24
26
13
4
15
8
27 18
11 28
29 16 4 19 17 20
SHTS055180200001
1 Flange 16 Pinion drive gear

2 Oil seal 17 Cylindrical roller bearing
3 Shim 18 Differential carrier cover
4 Taper roller bearing 19 Pinion gear
5 Drive shaft 20 Rear axle housing
6 Shifter sleeve 21 Case cover
7 Drive gear 22 Shift fork
8 Washer 23 Return spring
9 Spider 24 Piston
10 Inter-axle differential case sub-assembly 25 Air shift unit
11 Differential pinion 26 Adjusting nut
12 Differential carrier 27 Lock plate
13 Side gear 28 Bearing cap
14 Through shaft 29 Ring gear
15 Differential carrier cage
OPERATION OF INTER-AXLE DIFFERENTIAL GEAR
SHTS055180200002
1 Fuse 10 Rearward axle drive gear

2 Inter-axle differential lock switch 11 Inter-axle differential pinion
3 Magnetic valve 12 Forward axle
4 Air shift unit 13 Rearward axle
5 Shift sleeve A From battery
6 Inter-axle differential gear B From air tank
7 Forward axle drive gear C Exhaust
8 Drive gear D From propeller shaft
9 Through shaft
SHTS055180200003
1 Fuse 10 Rearward axle drive gear

2 Inter-axle differential lock switch 11 Inter-axle differential pinion
3 Magnetic valve 12 Forward axle
4 Air shift unit 13 Rearward axle
5 Shift sleeve A From battery
6 Inter-axle differential gear B From air tank
7 Forward axle drive gear C Exhaust
8 Drive gear D From propeller shaft
9 Through shaft
TROUBLESHOOTING
EN0551802F300001

bearings
pinion gear
gears and pinions
and pinion gear
Worn or damaged inter-axle differen- Replace
tial gear
SHAFT".
SPECIAL TOOL
EN0551802K100001
S0983-95501
SOCKET WRENCH
S0983-96502

COMPONENT LOCATOR
EN0551802D100001
SHTS055180200009

4 Gasket

A 9.8-19.6 {100-200, 7.3-14.4} D 167-213 {1,700-2,200, 123-159}
B 78.4-117.6 {800-1,200, 58-86} E 64-84 {650-870, 47-63}
C 39.2-68.6 {400-700, 29-50}
M
L
23
24
22 38
42 13
17 16
9
X
A 13
8
42
10 21 18
6 38
38 5
4 22
7 Y 23
C 37 K
42
3
1 2 12
J
D 36
X 11
E W
35
33
P
Z
B 26
31 43 Y
19
I 25
34 O
F H
38
Z 15 42 44
18 Q
32 28 41
G 27 V
28
14 30
13 40
8
V
38
9
42
13
W 17 29
38
16 10 10
42 7
42
R
N
21
S
40
38
39
20
SHTS055180200010
1 Case cover 16 Spider 31 Oil filter shield

2 Piston seal 17 Differential pinion 32 Oil filter element set
3 Piston 18 Side gear 33 Seal ring
4 Differential carrier cover 19 Differential carrier 34 Oil strainer
5 Shift fork 20 Through shaft 35 Elbow
6 Return spring 21 Flange 36 Oil pump pipe
7 Oil seal 22 Adjusting nut 37 Oil pump gear
8 Differential carrier cage 23 Differential gear case 38 Taper roller bearing outer race
9 Shim 24 Ring gear 39 Bearing cage
10 Lock nut 25 Lock plate 40 Retainer ring
11 Drive shaft 26 Bearing cap 41 Cylindrical roller bearing inner
race
12 Shift sleeve 27 Pinion gear 42 Taper roller bearing inner race
13 Thrust washer 28 Lock washer 43 Joint
14 Drive gear 29 Pinion drive gear 44 Cylindrical roller bearing outer
race
15 Inter axle differential case 30 Spacer
sub-assembly

A 589-781 {6,000-8,000, 434-578} K 44.5-53.5 {450-550, 33-39}
B 44.5-53.5 {450-550, 33-39} L 246-294 {2,500-3,000, 181-216}
C 113-147 {1,100-1,500, 80-108} M 461-559 {4,700-5,700, 340-412}
D 113-147 {1,100-1,500, 80-108} N 589-781 {6,000-8,000, 434-578}
E 37.5-48.5 {380-500, 28-36} O 19-25 {190-260, 14-18}
F 78.5-117.5 {800-1,200, 58-86} P 344-456 {3,500-4,700, 254-339}
G 12.0-15.5 {120-160, 9-11} Q 19-25 {190-260, 14-18}
H 49-61 {500-630, 37-45} R 589-781 {6,000-8,000, 434-578}
I 34.5-43.5 {350-450, 26-32} S 167-223 {1,700-2,300, 123-166}
J 44.5-53.5 {450-550, 33-39}
OVERHAUL
EN0551802H200001

NOTICE
SHTS055180200011

(2) Disconnect the air hose.
SHTS055180200012
(3) Remove the through shaft.
SHTS055180200013
SHTS055180200014
1. THROUGH SHAFT
SHTS055180200015
2. MOUNT THE DIFFERENTIAL CARRIER ASSEMBLY ON THE

WORK STAND.
SHTS055180200016
3. DIFFERENTIAL CARRIER COVER ASSEMBLY

(1) Loosen the bolts and remove the differential carrier cover assem-
bly from the differential carrier.
NOTICE
Lift the assembly vertically with a wire and chain block, and be
careful not to drop the drive gear.
SHTS055180200017
(2) Loosen the bolts and remove the bearing cage with the drive shaft
from the carrier cover.
(3) Uncaulk the lock nut, and remove the nut.
NOTICE
Be careful not to drop the shift sleeve.
SHTS055180200018
(4) Loosen the bolts and remove the case cover from the carrier
cover, then remove the piston, shift fork and return spring.
NOTICE
Before removing the case make aligning mark on the case cover
and differential carrier cover.
SHTS055180200019
4. OIL PUMP
(1) Remove the oil strainer from the carrier cover.
SHTS055180200020
(2) Loosen the bolts and remove the oil pump assembly and the oil
pipe from the carrier cover.
SHTS055180200021
5. INTER-AXLE DIFFERENTIAL GEAR

(1) Check for the aligning marks for the differential gear case then
loosen the bolts and separate it.
SHTS055180200022
6. DIFFERENTIAL CARRIER
(1) Remove the bearing cap, then remove the differential case
assembly with a wire and a chain block.
NOTICE
Make aligning mark before disassembling.
(2) Using a puller, remove the taper roller bearings.
ALIGNING MARK
SHTS055180200023

gear.
ALIGNING MARK c. Remove the bolts then ring gear.
NOTICE
SHTS055180200024
(4) Disassembly the differential case.

NOTICE
Be sure to check the matching marks on the differential case
before disassembly. Remove the bolts and nuts so that the case
separates.
SHTS055180200025
7. DIFFERENTIAL CARRIER CAGE

(1) Uncaulk the lock nut and remove the lock nut.
(2) Remove the pinion drive gear.

(3) Loosen the bolts, then remove the pinion assembly.
NOTICE
Fit the gear and lock nut back to remove the pinion assembly.
SHTS055180200026
(4) Loosen the bolt and nut then remove the cylindrical roller bearing
lock washer.
(5) Using a puller, remove the taper roller bearing inner race and the
cylindrical roller bearing inner race.
SHTS055180200027
1. ADJUSTMENT OF THE THROUGH SHAFT THRUST PLAY

(1) Install the through shaft with taper roller bearings and outer bear-
ing race then install the retainer ring and bearing cage.
NOTICE
• During installation, rotate (approx. 30 degrees) the retainer
ring to check for proper installation in the groove.
• Be sure to use a new retainer ring, and discard the previously
installed ring.
• Set the oil seal in the bearing cage after measurement of the
SHTS055180200028
thrust play.
(2) Select a retainer ring with appropriate thickness. Without the oil
THROUGH SHAFT seal in place, adjust the thrust play between the through shaft
FLANGE [E]
BEARING bearing and retainer ring. To measure the thrust play, place a dial
DIAL GAUGE gauge on the end surface of the flange and move the flange [E].
RETAINER RING Assembly Standard: 0.025-0.125 mm {0.0010-0.0049 in.}
NOTICE
Retainer rings are color-coded according to thickness.
THROUGH
SHAFT
SHTS055180200029
Thickness of retainer ring Color cord

COLOR CORD
2.8 mm {0.110 in.} Non color
2.9 mm {0.114 in.} Blue
3.0 mm {0.118 in.} Yellow
3.1 mm {0.122 in.} Red
3.2 mm {0.126 in.} Sky blue
3.3 mm {0.130 in.} Brown
3.4 mm {0.134 in.} Green
SHTS055180200030 3.5 mm {0.138 in.} White
3.6 mm {0.142 in.} Orange
(3) Remove the through shaft assembly from the housing, and
remove the flange and the bearing cage from the shaft.
(4) Install the oil seal to the bearing cage.
NOTICE
• Apply bearing grease on the oil seal lip part.
• Before installation of the flange, heat the flange to a tempera-
ture between 80-100°C {176-212°F} in hot water or oil. After
the flange is installed, leave it for approximately 10 minutes.
• Heating parts to a high temperature causes a substantial
decrease in strength and durability. Do not heat parts above
120°C {248°F}
SHTS055180200031
(5) After assembly, tighten it to the specified torque.

SHTS055180200032

OUTER RACE
washers.
NOTICE
Apply lock agent (Lock tight) which is equivalent to ThreeBond
1360K on the bolt threads.
SHTS055180200033
3. ADJUSTMENT OF THE PINION ASSEMBLY PRELOAD

(1) Assemble the differential carrier cage and initially tighten the pin-
ion drive gear.
NOTICE
Apply gear oil to the bearings.
SHTS055180200034
(2) Using the torque wrench, measure the preload of the bearing and
if the preload is not within the specific value shown below, adjust
with spacer.
1.97-2.45 {20-25, 1.4-1.8} 1.47-1.96 {15-20, 1.1-1.4}

SHTS055180200035
(3) After completing the adjustment, loosen the lock nut.

(4) Remove the lock nut and the pinion drive gear.
SHTS055180200036
(5) Install the pinion assembly and tighten the bolts.

(6) Install the pinion drive gear and tighten the lock nut with specified
torque.
SHTS055180200037
4. ADJUSTMENT OF PINION FITTING HEIGHT

(CONICAL DISTANCE)
(1) Adjust the pinion fitting height with the shims.
Standard Pinion Fitting height: 34 mm {1.339 in.}
Adjusting shims Thicknesses:
0.3 mm {0.0118 in.} 0.45 mm {0.0177 in.}
0.4 mm {0.0157 in.} 0.50 mm {0.0197 in.}
SHTS055180200038

A: 34 mm {1.339 in.}
SHTS055180200039
(3) Measure the pinion fitting height (Conical distance), adjust by

using the proper shim.
A: Measuring part (Pinion height)
B: Pinion depth gauge
C: Adjusting shim
SHTS055180200040
EXAMPLE:
Standard pin-
34.0 mm – 0.2 mm = 33.8 mm
The engraved
value "a"
SHTS055180200041
(4) Caulk the pinion drive gear lock nut.

NOTICE
A • Caulk the nut securely as shown in the figure.
VIEW A
SHTS055180200042
A
NOTICE
X X gear face to the gear side.
A A
A: Pinion
B B B B: Side gear
X' X'
C C: Thrust washer
SHTS055180200043
washer for the side gear and/or for the pinion.
SHTS055180200044

NOTICE
• Apply lock agent (Lock tight) which is equivalent to
ThreeBond 1360K on the bolt threads.
SHTS055180200045
NOTICE
When lock agent is not applied, stake the lock nut as shown in the
figure.
SHTS055180200046
(4) Install the ring gear to the differential case and tighten the bolts.
NOTICE
• Apply lock agent (Lock tight) which is equivalent to
ThreeBond 1360K on the bolt threads.
• When lock agent is not applied, stake the nut in the same
manner as step 3.
SHTS055180200047
6. ADJUSTMENT OF PINION DRIVE GEAR AND RING GEAR

BACKLASH
(1) Set the differential case assembly on the differential carrier and
install the adjusting nut and bearing cap.
NOTICE
Align the aligning marks.
ALIGNING MARKS
SHTS055180200048

1/4 TURN a. Tightening the adjusting nut fully then loosen the adjusting nut
by 1/4 turn +1 notch.
SHTS055180200049
SHTS055180200050
Assembly standard:
Gear ratio Backlash
Except 6.428 0.30-0.41 mm {0.012-0.016 in.}
6.428 0.25-0.33 mm {0.010-0.013 in.}
SHTS055180200051
BACKLASH: "A" - Decrease "B" - Increase
SHTS055180200052

NOTICE
the factory's mark.
SHTS055180200053
(2) Example of the unsatisfactory engagement.


gear as a set.
SHTS055180200054
b. Heel and face contact.

gear as a set.
SHTS055180200055

bearings using a torque wrench.
NOTICE
(refer to item 3).
Assembly standard:
Side bearing preload turning torque
SHTS055180200056 Gear ratio 5.428 5.857 6.428
0.37-0.45 0.34-0.41 0.31-0.38
New
{3.8-4.5, {3.5-4.2, {3.2-3.8,
bearing
0.28-0.32} 0.25-0.30} 0.23-0.28}
0.28-0.36 0.26-0.33 0.23-0.30
Re-used
{2.9-3.7, {2.6-3.4, {2.4-3.1,
bearing
0.20-0.26} 0.19-0.24} 0.17-0.22}
NOTICE
nut.
SHTS055180200057
SHTS055180200058
9. DRIVE GEAR AND PINION DRIVE GEAR

(1) Measure the drive gear and pinion drive gear backlash.
SHTS055180200059
10. INTER-AXLE DIFFERENTIAL GEAR

A
NOTICE
Apply molybdenum grease to the pinion gear and spider.
X X
A A
A: Pinion
B: Side gear
B B B C: Thrust washer
X' X'
C
SHTS055180200060
washer for the side gear and/or for the pinion.
SHTS055180200061

NOTICE
• Apply molybdenum grease on all inner parts.
(4) Tighten the bolts.
NOTICE
Apply lock agent (Lock tight) which is equivalent to ThreeBond
1360K on the bolt threads.
SHTS055180200062
(5) Place the inter-axle differential gear and the drive gear as shown
in figure.
NOTICE
The bolts of the differential case should point downward when
assembling.
SHTS055180200063
11. DIFFERENTIAL CARRIER COVER ASSEMBLY

(1) Set the piston seal as shown in the figure.
(2) Place the spring and the shift fork in the differential carrier cover,
then insert the piston.
NOTICE
• Coat the piston seal with silicon grease "a".
• Coat the piston and case cover inner surface with gear oil
"b".
SHTS055180200064
(3) Install the case cover on the differential carrier cover.

NOTICE
• Apply liquid gasket (ThreeBond #1215 or equivalent) to the
facing surfaces of the case cover and differential carrier
cover.
• Align the aligning marks on the case cover and the differen-
tial carrier cover.
SHTS055180200065
(4) Install the oil pipe and oil pump assembly to the differential carrier
cover.
NOTICE
Be careful not to damage the O-ring when installing the oil pipe.
SHTS055180200066
(5) Install the oil strainer to the differential carrier cover.
SHTS055180200067
(6) Install the bearing on the drive shaft.

BEARING
X
(7) Install the oil seal to the carrier cage and then install the carrier
OIL SEAL cage with the shim to the drive shaft.
NUT NOTICE
Apply bearing grease on the oil seal lip parts.
SHIM
CARRIER (8) Install the flange yoke coupling and tighten the nut.
CAGE SST: Socket Wrench (S0983-96502)
FLANGE
DRIVE
X
SHAFT
SHTS055180200068
(9) Place the shift sleeve in the shift fork, then install the drive shaft
and the carrier cage assembly to the differential carrier cover.
NOTICE
facing surfaces of carrier cage and carrier cover.
• Align the spline of the sleeve and the drive shaft.
SHTS055180200069
(10) Place the thrust washer on the drive gear.

NOTICE
Apply molybdenum grease to the both sides of the thrust washer.
SHTS055180200070
(11) Initially install the differential carrier cover assembly to the differ-
ential carrier.
NOTICE
• Apply molybdenum grease to the sliding surface.
facing surface of differential carrier cover and differential
carrier "a".
SHTS055180200071
(12) Measure the drive shaft axial play and adjust the side gear and
drive shaft axial play with shims.
Adjusting shims Thicknesses:
0.30 mm {0.0118 in.}, 0.45 mm {0.0177 in.}
0.40 mm {0.0157 in.}, 0.50 mm {0.0197 in.}
NOTICE
After adjusting shims, apply liquid gasket (ThreeBond #1215 or
equivalent) to the facing surface of differential carrier cover and
differential carrier cage.
SHTS055180200072

NOTICE
SHTS055180200073
1. DIFFERENTIAL CARRIER ASSEMBLY

NOTICE
SHTS055180200074
housing.
NOTICE
Fit the O-ring to the stud bolt.
SHTS055180200075
2. THROUGH SHAFT ASSEMBLY

DIAMETER: DIAMETER: (1) Apply liquid gasket on face of the housing flange and insert the
APPROX. 113 mm APPROX. 3 mm through shaft.
{4.449 in.} {0.1181 in.} NOTICE
SHTS055180200076

NOTICE
SHTS055180200077
3. GEAR OIL
(1) Fill the gear oil using plug hole to level "A" and tighten the plug.
Gear oil:
Refer to the owner's manual.
PLUG
HOLE
LEVEL "A"
SHTS055180200078
4. PROPELLER SHAFT
(1) Install the propeller shafts.
NOTICE
Align the aligning marks.
Tightening Torque:
SHTS055180200079

EN0551802H300001
Unit: mm {in.}
Shift fork and piston: — — Replace, Visual check

Shift fork and piston — — Replace, Visual check

case sliding surface: if necessary.
Wear and damage
Return spring: — — Replace, Visual check

Squareness if necessary.
Through shaft: — 0.1 Replace. Measure

Bend {0.0039}
Inter-axle side gear and 0.132-0.210 0.5 Replace. Measure

through shaft: {0.006-0.008} {0.020}
Spline backlash
Drive shaft and shift — — Replace, Visual check

sleeve: if necessary.
Wear and damage
Through shaft bearing — — Replace, Visual check

and race: if necessary.
Burns and pitting
Taper roller bearing: — — Replace, Visual check

Inter axle differential — — Replace, Visual check

gear teeth: if necessary.
Wear and damage
Inter axle differential — — Replace,

side gear spline: if necessary.
Wear and damage
Inter axle differential — — Replace,

spider: if necessary.
Wear and damage
Inter axle differential A: 28 {1.102} 0.4 Replace. Measure

spider and pinion: {0.016}
Clearance B-A:
0.140-0.261
{0.006-0.010}
Inter axle differential 1.7-1.9 1.3 Replace. Measure

thrust washers thick- {0.006-0.010} {0.051}
ness
Inter axle differential — — Replace, Visual check

drive shift sliding sur- if necessary.
face, spline;
Wear and damage
Drive gear: — — Replace, Visual check

Drive gear: 1.9-2.1 1.7 Replace. Measure

Thrust washer thick- {0.075-0.082} {0.067}
ness
Pinion drive gear: — — Replace, Visual check

Cylindrical roller bear- — — Replace, Visual check

ing: if necessary.
Burns and damage


Burns and damage if necessary.

Wear and damage


Clearance {0.016}
B-A:
0.145-0.190
{0.0058-0.0074}

Wear and damage

ness 1.9-2.1 {0.067}
{0.075-0.082}
Pinion gear: 1.3

1.7-1.9 {0.051}
{0.067-0.074}

and axle shaft: {0.0021-0.0058} {0.020}
Spline backlash
Flange coupling spline: — — Replace, Visual check

2A$4AA#KTQXGTA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧞㧞ಽ
BRAKE EQUIPMENT (MODELS: WITH AIR OVER HYDRAULIC BRAKE) BR01–1
BRAKE EQUIPMENT BR01
(MODELS: WITH AIR OVER HYDRAULIC BRAKE)

BR01-001
SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DIAGRAM ........................................................ BR01-3
TROUBLESHOOTING................................... BR01-17
AIR BLEEDING.............................................. BR01-19
BR01–2 BRAKE EQUIPMENT (MODELS: WITH AIR OVER HYDRAULIC BRAKE)
SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN0680101C100001
Type of service brake Air over hydraulic system with drum-shoe type wheel brake.
Air charging system Air charging is from piston type air compressor and air flow is directed and con-
trolled by a pressure regulator, the necessary valves, and lines as required.
Pressure sensor and air pressure warning switch are used for indicating the
pressure level in the system.
Service brake control system Two independent lines for front and rear wheels with air flow controlled by a
brake valve, and each line is separated into air line and hydraulic line by a
brake air booster.
Stop lights switch is used to operate the stop lights.
Wheel brake Drum brake with hydraulic actuated, internally expending two-leading shoes in
front and dual two-leading shoes in rear wheels.
NOTICE
See "DIAGRAM" of the following page the component parts
(Valves, Switches, etc.) used in easy system.
DIAGRAM
EN0680101J100001
MODELS: FC, FD, GD (FOR CHILE, TAIWAN AND THAILAND) (WITHOUT ABS)
4 5
D1 F1
9
A2
6 7 8
3
14
N1
13
2
A3
C2
A4
10 11 12
H1
F2
R D2
1 F C1 F5
E2
E1
M5
F3 N3
H2
15
F6
M1 A1
CAB SIDE CHASSIS SIDE 16
D3
N2
: AIR HOSE 14
: OIL HOSE 3
: AIR PIPE
: OIL PIPE
: NYLON TUBE
G1 K1 8
E3
4 17 A3
5 G1
C3 6 7 8 19
S2 S1 G1 M4
C2 E2
18 G2 20
EQUIPPED WITH EQUIPPED WITH EQUIPPED WITH
ES START AIR SUSPENSION SEAT EXHAUST BRAKE
A2 23
8
M5
A2
H2 22
8
M1 A1 21
15
16
EQUIPPED WITH EQUIPPED WITH EQUIPPED WITH
AIR DRYER TIRE INFLATOR POWER SHIFT
SHTS068010100001
1 Brake valve 9 Safety valve 17 ES start control valve

2 Stop light switch 10 Check valve 18 Air suspension seat
3 Wheel brake - Front 11 Pressure sensor 19 Exhaust brake magnetic valve
4 Brake air booster - Front 12 Air pressure warning switch 20 Exhaust brake
5 Brake air booster - Rear 13 Pressure governor 21 Tire inflator
6 Air tank - Front 14 Wheel brake - Rear 22 Power shift
7 Air tank - Rear 15 Clutch booster 23 Air dryer
8 Air tank-Water separator 16 Air compressor
MODEL: FD (FOR SINGAPORE)
4 5
D1 F1
C5 E4
18
18 19
A3
11
A2
9
3 6 7 8 10
2 14 F2
H1
D2 F5
C2
C1
1 E2
E1 F3 N3
M5
H2
15 12
F6
M1 A1
: AIR HOSE CAB CHASSIS 13
: OIL HOSE SIDE SIDE D3
: AIR PIPE
: OIL PIPE N2
11
: NYLON TUBE 3
J1
M5
17
M6 H2
J2
16 14 12
EQUIPPED EQUIPPED WITH

WITH P.T.O. POWER SHIFT
CAB CHASSIS
SIDE SIDE 19
P1 Q1 Q2
P2 P3
A2
20 21
8
P4
22
P5
EQUIPPED WITH EQUIPPED WITH 21

TIRE INFLATOR WHEEL PARKING
SHTS068010100002
1 Brake valve 12 Clutch booster

2 Stop light switch 13 Air compressor
3 Wheel brake - Front 14 Magnetic valve
4 Brake air booster-Front 15 Exhaust brake
5 Brake air booster-Rear 16 Power take - off (If so equipped)
6 Air tank - Front 17 Power shift (If so equipped)
7 Air tank - Rear 18 Quick release valve
8 Air tank - Water separator 19 4 - way protection valve
9 Safety valve 20 Parking brake control valve
10 Air dryer 21 Parking brake chamber
11 Wheel brake - Rear 22 Relay valve
MODEL: FD (FOR HONG KONG)
16
17
4 5
D0 F0
C3 D1
E3
D11
A3
18 15
F1
15 F11
H1
3
G1
A2 9
N1 A5
A4 6
2 7 8
13 10
D2
C2 F2
C1 F12 F5
E2
1 E1
M5
G2 N3
F3
F13
14 H2 19 N3
11 F6
CAB SIDE CHASSIS SIDE M1 A1

: AIR HOSE 12
: OIL HOSE D12
10
: AIR PIPE
: OIL PIPE N2
: NYLON TUBE
3
H2
19 A2
11 J1
13 8
J2
20
EQUIPPED EQUIPPED WITH
18 A3
WITH P.T.O. TIRE INFLATOR
H1
G1
A4 A5
M5
13
19 M7 S2 S1
G2
H2
CAB SIDE CHASSIS SIDE

11
EQUIPPED WITH EQUIPPED WITH
POWER SHIFT AIR SUSPENSION SEAT
SHTS068010100003

4 Brake air booster - Front 14 Exhaust brake
5 Brake air booster - Rear 15 Quick release valve
6 Air tank - Front 16 Brake fluid reservoir
7 Air tank - Rear 17 Brake control modulator
8 Air tank - Water separator 18 4 - way protection valve
9 Air dryer 19 Power shift (If so equipped)
10 Wheel brake - Rear 20 Power take - off (If so equipped)
MODEL: FD (FOR TAIWAN) (EQUIPPED WITH ABS)
16
17
4 5
D0 F0
C3 D1
E3
D11
A3
18 15
F1
15 F11
H1
3
G1
A2 9
N1 A5
A4 6
2 7 8
13 10
D2
C2 F2
C1 F12 F5
E2
1 E1
M5
G2 N3
F3
F13
14 H2 19 N3
11 F6
CAB SIDE CHASSIS SIDE M1 A1

: AIR HOSE 12
: OIL HOSE D12
10
: AIR PIPE
: OIL PIPE N2
: NYLON TUBE
3
18 A3
H1
G1
A4 A5
A2 H2
19 13
8 11 J1
J2
13 G2
S2 S1
20
EQUIPPED WITH EQUIPPED CAB SIDE CHASSIS SIDE
TIRE INFLATOR WITH P.T.O.
EQUIPPED WITH
AIR SUSPENSION SEAT
SHTS068010100004

4 Brake air booster - Front 14 Exhaust brake
5 Brake air booster - Rear 15 Quick release valve
6 Air tank - Front 16 Brake fluid reservoir
7 Air tank - Rear 17 Brake control modulator
8 Air tank - Water separator 18 4-way protection valve
9 Air dryer 19 Power shift (If so equipped)
10 Wheel brake - Rear 20 Power take - off (If so equipped)
MODEL: FG (FOR INDONESIA)

17
13 18
9
6 7
CAB CHASSIS 8
SIDE SIDE 11
12 14
2
3 10 10
19
1
4 5
14
15 M5 H1
: AIR HOSE
: OIL HOSE
: AIR PIPE
: OIL PIPE 3
: NYLON TUBE 16
20 H4
21
22
15 M5
23
EQUIPPED WITH TIRE INFLATOR EQUIPPED WITH POWER SHIFT EQUIPPED WITH P.T.O.
SHTS068010100005
1 Brake valve 13 Exhaust brake

2 Stop light switch 14 Wheel brake - Rear
3 Wheel brake - Front 15 Clutch booster
4 Brake air booster - Front 16 Air compressor
5 Brake air booster - Rear 17 Exhaust brake magnetic valve
6 Air tank - Front 18 Air dryer
7 Air tank - Rear 19 Brake fluid reservoir
8 Air tank - Water separator 20 Power shift
9 Safety valve 21 Tire inflator
10 Check valve 22 Power take-off magnetic valve
11 Pressure sensor 23 Power take-off
12 Air pressure warning switch
MODELS: FG, GH (FOR TAIWAN)

18 M4 G2
G1 E3
2 A2
A5 12
13
1 RR A4 11 14
FR
10
9 8 A1-1
6 7
E1 F5
C1
E2 5
F1 F2 F3 N2
C2
21
3 F6
N1 4
D2
D1 14
: AIR HOSE D3 15 M5 H1
: OIL HOSE
N1 M1 A1
: AIR PIPE
: OIL PIPE 3
: NYLON TUBE 16
WITHOUT ABS
9 H1
18 12 11
M4 G2 A4 8 A2
G1
19
A5
6 7
2 E1 10
C1 E4
E2
RR C2
1 FR 14
5
E6 A F1 F2
20 B
S
E5 A
B
F11 F12
S F5
3 5 21 F3
F13
N1 C4 N2
D2
17 4 N2
D1
F6
D3 15 M5 H1
N1
M1 A1
3 14
16
WITH ABS
SHTS068010100006
K1
G1
12 8
A4
6 7 8 6 7
E3
E2 E4
E2 E3
E K1
E
S H1 S
S
5
S C2 F6 A
B
F1
C2 22 S
E4 5
22 20 F5 F11
F1 A
B
S
C3 21
21 5
D1 C3 C4
4 17 4
EQUIPPED EUIPPED
WITH ES START WITH ES START
(WITHOUT ABS) (WITH ABS)
31 R4 31 R4
8 8 8
8 R3 R3
R1 R1
R2
30 R2
30
7
29 29
R5 R5
31 31
EQUIPPED
EQUIPPED
WITH AIR SUSPENSION
WITH AIR SUSPENSION
(WITH ABS)
(WITHOUT ABS)

H1 24 H1 24
H2 M10
S1
H3 H2
23 25
M6 J1 M6 J2
J2
M6 23 G2
G1
EQUIPPED EQUIPPED
WITH TRANSMISSION P.T.O. WITH TRANSMISSION P.T.O. EQUIPPED
(WITH MF06) (WITH EATON) WITH AIR SUSPENSION SEAT
28
26 27 H4
M10 28
8
M5 H2 H1 M5
8 7
15 15
WITH EATON WITH MF06 EQUIPPED EQUIPPED
WITH TIRE INFLATOR WITH TIRE INFLATOR
(WITHOUT ABS) (WITH ABS)
SHTS068010100007
1 Brake valve 17 ABS control valve

2 Stop light switch 18 Exhaust brake
3 Wheel brake - Front 19 Exhaust brake magnetic valve
4 Brake air booster - Front 20 Relay valve
5 Brake air booster - Rear 21 Brake fluid reservoir
6 Air tank - Front 22 ES start control valve
7 Air tank - Rear 23 Power take - off
8 Air tank - Water separator 24 Power take - off magnetic valve
9 Safety valve 25 Air suspension seat
10 Check valve 26 Range preselection magnetic valve
11 Pressure sensor 27 Power shift
12 Air pressure warning switch 28 Tire inflator
13 Air dryer 29 Protection valve
14 Wheel brake - Rear 30 Leveling valve
15 Clutch booster 31 Air spring
16 Air compressor
MODELS: FL, FM
4
A4 5 6 A2
CAB CHASSIS
H1
SIDE SIDE
E3 A5
2
1
RR 3 C3
FR
D1 F1
12 13
N1
7 8 F2
D2 D2-1 F6
E1
C1
C2 11 F4 F8
E2 M10
N2 N3
10 M5
F5 F9
9
14 F3
13
: AIR HOSE M1 A1
12
D3 F7
: OIL HOSE
N1
: AIR PIPE
: OIL PIPE
: NYLON TUBE A4 A5
3
CAB CHASSIS E3 C3
SIDE SIDE
2 Q1
RR
FR
1
E1
7 8
C1
C2
E2 E4
P1 C4
P2
16
15 P3
17
Q2 Q3
5
Q4 Q5
CIRCUIT OF TRAILER
H1
M5
18 M6 H1
H3 M10
10 20
R2 H4
19
M6 H5
EQUIPPED WITH MF06 TRANSMISSION

EQUIPPED WITH P.T.O. (FS8209)
H1
H2
M5
19 M6 H4
20 21
M6 H5
EQUIPPED WITH P.T.O. (MF06) EQUIPPED WITH TIRE INFLATOR
SHTS068010100008
M5
22 G2 M4
23
EQUIPPED WITH EXHAUST BRAKE

(MODEL: FL WITH MF06, FS8209 TRANSMISSION)
24 M7 G1 W1 W2
24 M7
W1 W2
G2
22 M4 23 22 23
M5 G2 M4
EQUIPPED WITH DIFFERENTIAL LOCK AND EQUIPPED WITH DIFFERENTIAL LOCK AND
EXHAUST BRAKE (MODEL: EXCEPT FM TRACTOR) EXHAUST BRAKE (MODEL: FM TRACTOR)
S1
25
EQUIPPED WITH AIR SUSPENSION SEAT
SHTS068010100009
1 Brake valve 14 Air dryer

2 Stop light switch 15 Trailer hand brake
3 Wheel brake - Front 16 Double check valve
4 Safety valve 17 Relay valve
5 Pressure switch 18 Transmission power shift
6 Pressure sensor 19 Power take-off
7 Brake air booster - Front 20 Power take-off magnetic valve
8 Brake air booster - Rear 21 Tire inflator
9 Air compressor 22 Exhaust brake magnetic valve
10 Clutch booster 23 Exhaust brake
11 Transmission high-low change 24 Differential lock magnetic valve
12 Wheel brake - Rear 25 Air suspension seat
13 Wheel brake - Rear
MODELS: FL, FM (FOR INDONESIA)
4
A4 5 6 A2
CAB CHASSIS
H1
SIDE SIDE
E3 A5
2
1
RR 3 C3
FR
D1 F1
12 13
N1
7 8 F2
D2 D2-1 F6
E1
C1
C2 11 F4 F8
E2 M10
N2 N3
10 M5
F5 F9
9
14 F3
13
: AIR HOSE M1 A1
12
D3 F7
: OIL HOSE
N1
: AIR PIPE
: OIL PIPE
: NYLON TUBE
3
H1
18 H4
M10
R2 H4
20
10 M5 19
M6 H5
EQUIPPED WITH TRANSMISSION POWER SHIFT EQUIPPED WITH P.T.O. (FS8209)

(MF06)
H1
20
19 M6 H5
M6 21
10 M5 H2 H4
EQUIPPED WITH P.T.O. (MF06) EQUIPPED WITH TIRE INFLATOR
SHTS068010100010
M5
15 G2 M4
16
EQUIPPED WITH EXHAUST BRAKE

(MODEL: FL)
CAB CHASSIS
SIDE SIDE
U1
U2
17 22
W1 W2 M7
1
M5
15 G2 M4 16
S1
EQUIPPED WITH DIFFERENTIAL LOCK AND EQUIPPED WITH BRAKE LOCK

EXHAUST BRAKE (MODEL: FM)
SHTS068010100011
1 Brake valve 12 Wheel brake - Rear

2 Stop light switch 13 Wheel brake - Rear
3 Wheel brake - Front 14 Air dryer
4 Safety valve 15 Exhaust brake magnetic valve
5 Pressure switch 16 Exhaust brake
6 Pressure sensor 17 Differential lock magnetic valve
7 Brake air booster - Front 18 Transmission power shift
8 Brake air booster - Rear 19 Power take-off
9 Air compressor 20 Power take-off magnetic valve
10 Clutch booster 21 Tire inflator
11 Transmission high-low change 22 Brake lock control valve
MODEL: FM2P
W1 W2
CAB SIDE CHASSIS SIDE G1
4 G2
A4 5 6 14
B1
24 H1 M7
A5
16
2 E3
25 26
RR 3 C3
FR
D1 F1
1
N1 7 8 F2
D2 D2-1 F6
E1 12 13
C1
C2
E2
15 F4 F8
N2 N3
G2 F5 F9
B2
M8
18 9 M1 A1
: AIR HOSE M5 F3
H1
: OIL HOSE
11
F7
H5 19
: AIR PIPE 20 12 13
H4 H3
: OIL PIPE D3
: NYLON TUBE N1
M14
10 H1
15
M13
23 21
H4 M5 H1 22
M6 H6
G3 G2
B5 B2 M5
M1 H2
A0 A1
9 10
WITH ZF9S109 TRANSMISSION EQUIPPED WITH POWER TAKE-OFF
A2
G1
M1 A1 17
B3 B1
B2
WITH AIR DRIER EQUIPPED WITH TIRE INFLATOR
SHTS068010100012
2A$4AA#KTQXGTA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧞ಽ
A4
A5

E3 C3
Q1
25 26
2
RR
FR
1
E1
7 8
C1
C2
E2 E4
P1 C4
P2
27 P3
29
Q2 Q3 28
Q4 Q5
CIRCUIT OF TRAILER
SHTS068010100013
1 Brake valve 16 Diff-lock magnetic valve

2 Stop light switch 17 Air drier (If so equipped)
3 Wheel brake-Front 18 Waste gate
4 Safety valve 19 Waste gate magnetic valve
5 Pressure switch 20 Limiting valve
6 Pressure sensor 21 Power take-off magnetic valve (If so equipped)
7 Brake air booster-Front 22 Power take-off (If so equipped)
8 Brake air booster-Rear 23 Transmission power shift
9 Air compressor 24 Air tank - Water separator
10 Clutch booster 25 Air tank - Rear
11 Pressure regulator 26 Air tank - Front
12 Wheel brake - Rear 27 Hand brake valve
13 Wheel brake - Rear 28 Relay valve
14 Exhaust brake magnetic valve 29 Double check valve
15 Exhaust brake
TROUBLESHOOTING
EN0680101F300001

Not enough braking Lining is wet with grease or fluid Replace the lining.
(Wheel brake and drum) Improper contact of drum and lining Correct.
Improper lining material or glazed lin- Correct.
ing
Deformation or hardening of drum Correct or replace.
Excessively worn lining Replace.
Improper adjustment of shoe Adjust hold-down nut.
Not enough braking Leakage of brake fluid from brake sys- Tighten further or replace gasket.
(Control system) tem
Leakage of compressed air from brake Tighten further or replace gasket.
system
Lack of brake fluid Supply brake fluid.
Lack of compressed air pressure due Use properly.
to excessive use.
Improper operation of air compressor Repair or replace.
Improper operation of brake valve Repair or replace.
Improper operation of air booster Repair or replace.
Clogging of brake system Replace pipe, hose, etc.
Vapor lock in brake system Bleed air from brake line.
Brake fluid decreases Leakage of brake fluid from brake pip- Tighten further or replace gasket.
ing
Leakage of brake fluid from cylinder Replace cup.
Leakage of brake fluid from push rod Replace oil seal.
oil seal of air booster.
Unequal or unstable braking Lining is wet with grease or fluid Replace lining.
Defective lining material (Improper Replace lining.
combination)
Non-uniform lining contact Correct.
Improper adjustment of brake shoe Adjust.
Non-uniform shoe clearance Adjust the clearance.
Distorted drums Correct or replace.
Excessive abrasion of drums Correct or replace.
Loose hub bearing Adjust or replace bearing.
Improper or unequal pneumatic pres- Adjust to proper pneumatic pressure.
sure of tire
Brake drags or does not release Improper adjustment of shoe clear- Adjust the clearance.
(Wheel brake and drum) ance
Improper adjustment of brake shoe Adjust hold-down nut.
Defective shoe return spring Replace.
Brake drags or does not release Lack of pedal play Adjust.
(Control system) Improper return of brake pedal Repair or replace.
Defective check valve of air booster Replace.
Improper operation of air booster Repair or replace.

Brake squeal Improper lining material or glazed lin- Replace lining.
ing
Loose lining rivets Replace or tighten the rivet further.
Lining rivet in contact with drum Replace lining and rivet.
Deformation or wear of drum Repair or replace.
Intrusion of foreign matter between Clean the surface of lining or replace
drum and lining
Impossible to bleed air completely. Oil hose between air booster and oil Correct the bend of feed pipe and let
reservoir bends and air trapped air out of the oil reservoir.
Improper tightness of joint of brake Tighten further or replace gasket.
system.
AIR BLEEDING
EN0680101H100001
1. PREPARATION
(EXAMPLE) (1) Replenish the reservoir with brake fluid up to MAX line.
(2) Start the engine and keep the engine revolution at idling speed
during replacing the brake fluid.
NOTICE
/#: Always first finish the replacement of either front or rear brake line
and then start the replacement of the other.
/+0
SHTS068010100014
2. AIR BLEEDING OF THE LINE FROM THE RESERVOIR TO THE

BRAKE BOOSTER
(1) Attach a vinyl tube to the bleeder screw of the brake booster.
NOTICE
Prepare a container box receiving brake fluid at the end of the
vinyl tube.
SHTS068010100015
(2) While depressing slowly the brake pedal, loosen the bleeder
screw and discharge the brake fluid with air or old brake fluid.
NOTICE
When replacing the brake fluid, the color of the fluid changes
paler. So, observe the color of the fluid passing through the tube.
SHTS068010100016
2A$4AA#KTQXGTA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧞ಽ
(3) While depressing the brake pedal, tighten the bleeder screw and
then release the brake pedal.
(4) Repeat the above procedure until no air is observed in the vinyl
tube or the replacement of the brake fluid is finished.
Tightening Torque:
7.0-12.0 N⋅m {71-122 kgf⋅cm, 5.2-8.8 lbf⋅ft}
NOTICE
Because the quantity of brake fluid will decrease, continue to
replenish the reservoir with brake fluid to avoid that the reservoir
becomes empty.
SHTS068010100017
3. AIR BLEEDING THE LINE FROM THE BRAKE BOOSTER TO

THE WHEEL CYLINDER
(1) Attach the vinyl tube to the bleeder screw of wheel cylinder and
carry out the air bleeding or replacement in the same manner as
that of the brake booster.
Tightening Torque:
7.5-11.5 N⋅m {76-117 kgf⋅cm, 5.5-8.4 lbf⋅ft}
NOTICE
Carry out the air bleeding starting from the wheel cylinder nearest
to the brake booster.
SHTS068010100018
(2) After having finished the air bleeding or replacement, replenish
the reservoir with brake fluid up to the MAX line.
2A$4AA(WNNCKTA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧞㧠ಽ
BRAKE EQUIPMENT (MODELS: WITH FULL AIR BRAKE) BR01–1
BRAKE EQUIPMENT BR01
(MODELS: WITH FULL AIR BRAKE) BR01-002
SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DIAGRAM ........................................................ BR01-3
TROUBLESHOOTING................................... BR01-10
BR01–2 BRAKE EQUIPMENT (MODELS: WITH FULL AIR BRAKE)
SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN0680201C100001
Type of service brake Drum shoe type wheel brake activated by compressed air.
Air charging system Air charging is from piston type air compressor and air flow is directed
and controlled by a pressure regulator, the necessary valves, and lines
as required.
Pressure sensor and air pressure warning switch are used for indicating
the pressure level in the system.
Service brake control system Two independent lines for front and rear wheels with air flow controlled
by a brake valve, and each line comprises a group of valves and brake
chambers (one/wheel).
Two stop light switches (one/line) are used to operate the stop lights.
Spring brake control system (If so equipped) Single line for all spring brake chambers or two lines for all spring brake
chambers on tractor and for trailer emergency circuit.
The line comprises a control valve which controls air flow, the other nec-
essary valve and spring brake chambers.
A stop light switch is used to turn ON the stop lights.
A parking brake switch is used to turn OFF the warning buzzer and to
turn ON the parking brake warning lights.
Trailer brake control system (If so equipped) Two lines for service and emergency circuits with a control valve which
controls air flow and the other necessary valve.
A stop light switch is used to operate the stop lights.
A trailer brake switch is used to operate the trailer brake indicator light.
Wheel brake Drum brake with internally expanding, leading-trailing shoes operation
by slack adjuster and cam shaft in all wheels.
NOTICE
See "DIAGRAM" of the following page the component parts
(Valves, Switches, etc.) used in easy system.
DIAGRAM
EN0680201J100001
MODELS: FG, GH
B1
2 CAB SIDE CHASSIS SIDE
21
4 A8 8
M4 7
R
3 A4
A5
C3
1 F G1
5 9 10
M7 G2 8
A3
15
C5
E1
C1
C2 E4
E2 11 E3
P1
P2 P3 P4
6
E21 M8
Q1
M9
14 E22 M8
16
13 M5 H1 P5
B2
12 M1 A1
C6
: AIR HOSE M7 15
: AIR PIPE
: NYLON TUBE 3
3
M7 15
C5
17
E4
E3 E5
16
P3 P4
18 19
Q1 E21 M8 E7
M9
E22 E6
14 M8
19
P5
17 C6
M7
15
3
EQUIPPED WITH ABS
SHTS068020100001
26
M10
25 H4
13 M5 H3 H1
13 M5
EQUIPPED WITH
EQUIPPED WITH TRANSMISSION POWER SHIFT EATON FS6109 TRANSMISSION
H1
H1 M10
H3 H2
24
H2
24
23
M6 J2
23 M6 J1
J2
M6
EQUIPPED WITH
EQUIPPED WITH TRANSMISSION P.T.O.
TRANSMISSION P. T.O. (MF06 TRANSMISSION) (EATON FS6109 TRANSMISSION)
B2
E2 22
E8 E3
A1 A2
C2
C4 8
K1
27
5 11
EQUIPPED WITH ES START EQUIPPED WITH AIR DRIER
8 7
S1
20
EQUIPPED WITH TIRE INFLATOR EQUIPPED WITH AIR SUSPENSION SEAT
SHTS068020100002
1 Brake valve 15 Brake chamber - Rear

2 Stop light switch 16 Relay valve - Rear
3 Brake chamber - Front 17 ABS control valve - Front
4 Exhaust brake 18 Quick release valve
5 Exhaust brake magnetic valve 19 ABS control valve - Rear
6 Parking brake valve 20 Air suspension seat
7 4-way protection valve 21 Pressure regulator
8 Air tank - Water separator 22 ES start control valve
9 Air tank - Front 23 Transmission P.T.O.
10 Air tank - Rear 24 P.T.O. magnetic valve
11 Relay valve - Front 25 Transmission power shift
12 Air compressor 26 Range preselection lever
13 Clutch booster 27 Air dryer
14 Relay valve - Wheel parking
MODEL: FM
7 8
A5
A4
A8 A3 12
10 G2
Q1
9 8 G1 11
2 CAB SIDE CHASSIS SIDE B1 W1 W2 M9
C0
E0 20
E0
4
M13 M11
E4
1 C10 C4 14
P5
E5
E1 13
C1
E6
C2
E2 E3
P1 P15
P2 19
3
18 M21
21 M15 E21
6 M5 M16 E22
M10 M17
M22
H2 H1
B2 18
M1 A1 C5 17
P4
5 C11 C6 16 P16
P6 Q3
19
M12
M14
: AIR HOSE 4
15
: AIR PIPE
: NYLON TUBE
A2
8 H1
B1 G1
10
B2 24 23
M1 A1 M6
M10 H5
15 H2 H4
B3 22
EQUIPPED WITH AIR DRIER EQUIPPED WITH P.T.O.
EQUIPPED WITH TIRE INFLATOR
SHTS068020100003
1 Brake valve 13 Relay valve - Front

2 Stop light switch 14 Relay valve - Rear
3 Parking brake valve 15 Pressure regulator
4 Spring brake chamber - Front 16 Spring brake valve - Front
5 Air compressor 17 Spring brake valve - Rear
6 Clutch booster 18 Spring brake chamber - Rear
7 Air tank - Rear 19 Brake chamber - Rear
8 Air tank - Water separator 20 Differential lock magnetic valve
9 Air tank - Front 21 Transmission High-Low change
10 4-way protection valve 22 P.T.O. magnetic valve
11 Exhaust brake magnetic valve 23 Transmission P.T.O.
12 Exhaust brake 24 Air dryer
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MODEL: SG (FOR INDONESIA)
23 22 21 5 4
G2
CHASSIS SIDE H1
CAB SIDE 6
G1
2 14
A2
A5 A1
A4
RR B2
FR
A3
Q1
1
3 7 8
M7
C3
E1
C1
C2 E0
E2 E3 12
P1
P2 P3
13
11 Q2
9 10
Q3 Q4 M11
E4
M11 18 17
M10
M8
16 M5 H3
E5
: AIR HOSE
: AIR PIPE B2
15 M1 A1
: NYLON YUBE
C6
M7
13
3
17
M10 20
J1
H3 H1 24
19
M6 J2
EQUIPPED WITH POWER TAKE-OFF EQUIPPED WITH TIRE INFLATOR
SHTS068020100004
2A$4AA(WNNCKTA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧡ಽ
1 Brake valve 13 Wheel brake - Rear

2 Stop light switch 14 Air dryer
3 Wheel brake - Front 15 Air compressor
4 Exhaust brake 16 Cluch booster
5 Exhaust brake magnetic valve 17 Transmission high - low change
6 Air tank - Water separator 18 Relay valve - Trailer
7 Air tank - Front 19 Power take - off
8 Air tank - Rear 20 Tire inflator
9 Double check valve 21 Safety valve
10 Quick release valve 22 Pressure switch
11 Trailer hand brake valve 23 Pressure sensor
12 Relay valve - Rear 24 Power take - off magnetic valve
TROUBLESHOOTING
EN0680201F300001

Not enough braking Lining is wet with grease or fluid Replace the lining.
(Wheel brake and drum) Improper contact of drum and lining Correct.
Improper lining material or glazed lin- Correct.
ing
Deformation or hardening of drum Correct or replace.
Excessively worn lining Replace.
Not enough braking Leakage of compressed air from brake Tighten further or replace gasket.
(Control system) system
Lack of compressed air pressure due Use properly.
to excessive use.
Improper operation of air compressor Repair or replace.
Improper operation of relay valve and Repair or replace.
quick release valve
Unequal or unstable braking Lining is wet with grease or fluid Replace lining.
Defective lining material (Improper Replace lining.
combination)
Non-uniform lining contact Correct.
Improper adjustment of brake shoe Adjust.
Non-uniform shoe clearance Adjust the clearance.
Distorted drums Correct or replace.
Excessive abrasion of drums Correct or replace.
Improper or unequal pneumatic pres- Adjust to proper pneumatic pressure.
sure of tire
Brake drags or does not release Improper adjustment of shoe clear- Adjust the clearance.
(Wheel brake and drum) ance
Defective shoe return spring Replace.
Brake drags or does not release Lack of pedal play Adjust.
(Control system) Improper return of brake pedal Repair or replace.
Improper operation of relay valve and Repair or replace.
quick release valve
Brake squeal Improper lining material or glazed lin- Replace lining.
ing
Loose lining rivets Replace or tighten the rivet further.
Lining rivet in contact with drum Replace lining and rivet.
Deformation or wear of drum Repair or replace.
Intrusion of foreign matter between Clean the surface of lining or replace.
drum and lining
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SERVICE BRAKE (MODELS: WITH AIR OVER HYDRAULIC BRAKE) BR02–1
SERVICE BRAKE BR02
BR02 (MODELS: WITH AIR OVER HYDRAULIC BRAKE)

BR02-001
PRESSURE REGULATOR........................BR02-4 PROTECTION VALVE

DATA AND SPECIFICATIONS........................ BR02-4 (WITH 4-WAY PROTECTION VALVE).....BR02-34
DESCRIPTION ................................................ BR02-4 DATA AND SPECIFICATIONS...................... BR02-34
COMPONENT LOCATOR ............................... BR02-5 DESCRIPTION .............................................. BR02-34
OVERHAUL ..................................................... BR02-6 COMPONENT LOCATOR ............................. BR02-35
INSPECTION AND REPAIR ............................ BR02-7 OVERHAUL ................................................... BR02-36
ADJUSTMENT............................................... BR02-37
AIR DRYER ...............................................BR02-8 INSPECTION AND REPAIR .......................... BR02-39
DATA AND SPECIFICATIONS........................ BR02-8
DESCRIPTION ................................................ BR02-8 PROTECTION VALVE .............................BR02-40
COMPONENT LOCATOR ............................... BR02-9 DATA AND SPECIFICATIONS...................... BR02-40
OVERHAUL ................................................... BR02-10 DESCRIPTION .............................................. BR02-40
INSPECTION AND REPAIR .......................... BR02-11 COMPONENT LOCATOR ............................. BR02-41
OVERHAUL ................................................... BR02-42
AIR DRYER (MODEL: FM2P) .................BR02-12 INSPECTION AND REPAIR .......................... BR02-42
DATA AND SPECIFICATIONS...................... BR02-12
DESCRIPTION .............................................. BR02-12 QUICK RELEASE VALVE .......................BR02-43
COMPONENT LOCATOR ............................. BR02-13 DATA AND SPECIFICATION ........................ BR02-43
OVERHAUL ................................................... BR02-45
DOUBLE CHECK VALVE INSPECTION AND REPAIR .......................... BR02-45
(MODEL: TRACTOR)..............................BR02-16
DATA AND SPECIFICATION ........................ BR02-16 BRAKE FLUID RESERVOIR
DESCRIPTION .............................................. BR02-16 (MODELS: FC, FD, GD, THAILAND FG)BR02-46
COMPONENT LOCATOR ............................. BR02-17 DATA AND SPECIFICATIONS...................... BR02-46
DISMOUNTING AND MOUNTING ................ BR02-47
CHECK VALVE........................................BR02-19 INSPECTION AND REPAIR .......................... BR02-48
DESCRIPTION .............................................. BR02-19 BRAKE FLUID RESERVOIR
COMPONENT LOCATOR ............................. BR02-20 (MODELS: FG, GH, FL, FM) ...................BR02-49
INSPECTION AND REPAIR .......................... BR02-20
DESCRIPTION .............................................. BR02-49
SAFETY VALVE ......................................BR02-21 COMPONENT LOCATOR ............................. BR02-50
DATA AND SPECIFICATIONS...................... BR02-21 DISMOUNTING AND MOUNTING ................ BR02-50
DESCRIPTION .............................................. BR02-21 INSPECTION AND REPAIR .......................... BR02-51
BRAKE VALVE........................................BR02-22
DESCRIPTION .............................................. BR02-22
COMPONENT LOCATOR ............................. BR02-23
OVERHAUL ................................................... BR02-25
BR02–2 SERVICE BRAKE (MODELS: WITH AIR OVER HYDRAULIC BRAKE)
BRAKE AIR BOOSTER (AIRMASTER)

WITHOUT ABS (MODELS: FC, FD, GD, RELAY VALVE
BR 02
THAILAND FG) ....................................... BR02-52 (FOR TRAILER BRAKE) ........................ BR02-99

DATA AND SPECIFICATIONS ......................BR02-52 DATA AND SPECIFICATIONS ......................BR02-99
DESCRIPTION...............................................BR02-52 DESCRIPTION...............................................BR02-99
SPECIAL TOOL .............................................BR02-53 COMPONENT LOCATOR............................BR02-100
COMPONENT LOCATOR..............................BR02-54 OVERHAUL..................................................BR02-101
OVERHAUL....................................................BR02-55 INSPECTION AND REPAIR ........................BR02-102
INSPECTION .................................................BR02-60
INSPECTION AND REPAIR ..........................BR02-62 SPRING BRAKE CHAMBER................BR02-103
DATA AND SPECIFICATIONS ....................BR02-103
BRAKE AIR BOOSTER (AIRMASTER) DESCRIPTION.............................................BR02-103
WITH ABS (MODEL: FD) ....................... BR02-63 COMPONENT LOCATOR............................BR02-104
DATA AND SPECIFICATIONS ......................BR02-63 OVERHAUL..................................................BR02-105
DESCRIPTION...............................................BR02-63 INSPECTION AND REPAIR ........................BR02-106
SPECIAL TOOL .............................................BR02-64
COMPONENT LOCATOR..............................BR02-65 TRAILER HAND BRAKE CONTROL VALVE
OVERHAUL....................................................BR02-67 (MODEL: FM2P) ................................... BR02-107
INSPECTION .................................................BR02-71
DATA AND SPECIFICATION.......................BR02-107
INSPECTION AND REPAIR ..........................BR02-73
DESCRIPTION.............................................BR02-107
COMPONENT LOCATOR............................BR02-108
BRAKE AIR BOOSTER (AIRMASTER) OVERHAUL..................................................BR02-109
(MODELS: FG, GH, FL, FM) .................. BR02-74 INSPECTION AND REPAIR ........................BR02-110
DATA AND SPECIFICATIONS ......................BR02-74
DESCRIPTION...............................................BR02-75 WHEEL BRAKE (MODELS: FC, FD) ...BR02-111
COMPONENT LOCATOR..............................BR02-77 DATA AND SPECIFICATIONS ....................BR02-111
OVERHAUL....................................................BR02-80 DESCRIPTION.............................................BR02-111
INSPECTION .................................................BR02-85 SPECIAL TOOL ...........................................BR02-113
INSPECTION AND REPAIR ..........................BR02-88 COMPONENT LOCATOR............................BR02-114
OVERHAUL..................................................BR02-116
SPRING BRAKE CONTROL VALVE ...... BR02-89 ADJUSTMENT .............................................BR02-120
DATA AND SPECIFICATIONS ......................BR02-89 INSPECTION AND REPAIR ........................BR02-121
DESCRIPTION...............................................BR02-89
COMPONENT LOCATOR..............................BR02-90 WHEEL BRAKE (MODELS: GD, THAILAND FG,
OVERHAUL....................................................BR02-91 INDONESIA FG) ................................... BR02-123
DATA AND SPECIFICATIONS ....................BR02-123
DESCRIPTION.............................................BR02-124
RELAY VALVE SPECIAL TOOL ...........................................BR02-126
(FOR SPRING BRAKE CHAMBER) ...... BR02-93 COMPONENT LOCATOR............................BR02-127
DATA AND SPECIFICATIONS ......................BR02-93 OVERHAUL..................................................BR02-129
DESCRIPTION...............................................BR02-93 ADJUSTMENT .............................................BR02-134
COMPONENT LOCATOR..............................BR02-94 INSPECTION AND REPAIR ........................BR02-136
OVERHAUL....................................................BR02-95
INSPECTION AND REPAIR ..........................BR02-95 WHEEL BRAKE
(MODELS: TAIWAN FG, GH) ............... BR02-138
RELAY VALVE (FOR WABCO ABS) ...... BR02-96 DATA AND SPECIFICATIONS ....................BR02-138
DATA AND SPECIFICATIONS ......................BR02-96 DESCRIPTION.............................................BR02-139
DESCRIPTION...............................................BR02-96 SPECIAL TOOL ...........................................BR02-141
COMPONENT LOCATOR..............................BR02-97 COMPONENT LOCATOR............................BR02-142
OVERHAUL....................................................BR02-98 OVERHAUL..................................................BR02-144
INSPECTION AND REPAIR ..........................BR02-98 ADJUSTMENT .............................................BR02-150
INSPECTION AND REPAIR ........................BR02-152
WHEEL BRAKE (MODELS: FL, FM) ...BR02-154

DATA AND SPECIFICATIONS.................... BR02-154
DESCRIPTION ............................................ BR02-155
SPECIAL TOOL ........................................... BR02-157
COMPONENT LOCATOR ........................... BR02-158
OVERHAUL ................................................. BR02-160
ADJUSTMENT............................................. BR02-164
INSPECTION AND REPAIR ........................ BR02-166
LIMITING VALVE (MODEL: FM2P) ......BR02-168

DESCRIPTION ............................................ BR02-168
OVERHAUL ................................................. BR02-170
TWO-WAY VALVE
(BRAKE LOCK CONTROL VALVE)
(MODEL: FM1JKPM) ............................BR02-171
DESCRIPTION ............................................ BR02-171
OVERHAUL ................................................. BR02-173
PRESSURE REGULATOR
EN0610602I200001
Spring type, regulates air pressure together with

Type
unloader valve on compressor
Regulating pressure:
780-880 kPa {8.0-9.0 kgf/cm2, 114-128 lbf/in2.}
Regulator No. 44530-1330
DESCRIPTION
EN0610602C100001
SHTS061060200001
1 Dust cover 7 Main spring 13 Valve spring

2 Retainer ring 8 Push rod 14 Filter
3 Set bolt 9 Rod spring 15 Piston
4 Lock nut 10 O-ring A To Unloader valve
5 Spring seat 11 Back up ring B From Air tank
6 Valve body 12 Valve C Exhaust
COMPONENT LOCATOR
EN0610602D100001
SHTS061060200002
1 Dust cover 6 Valve body 11 Back up ring

2 Retainer ring 7 Main spring 12 Valve
3 Set bolt 8 Push rod 13 Valve spring
4 Lock nut 9 Rod spring 14 Filter
5 Spring seat 10 O-ring 15 Piston

A 2.4-3.5 {24-36, 1.8-2.6} B 0.29-0.49 {3-5, 0.22-0.36}
OVERHAUL
EN0610602H200001
1. LUBRICATION
(1) When reassembling the pressure regulator, replace all rubber
parts with new ones.
(2) Apply adequate amount of silicone grease to the O-rings, and
sliding surface S of the piston and valve rod.
SHTS061060200003
1. ADJUSTMENT
(1) Loosen the adjusting screw until the rod spring tension is
released, and start and idle the engine to charge the air for the air
tank.
SHTS061060200005
(2) Stop the engine when the gauge indicates valve opening pres-
sure shown below.
Valve opening pressure Pressure kPa {kgf/cm2, lbf/in2.}

44530-1330 860-900 {8.8-9.2, 125-130}
SHTS061060200006
(3) Tighten the adjusting screw gradually till the air starts to leak from
the port to the unloader valve side.
(4) Tighten the adjusting screw lock nut.
SHTS061060200007
(5) Watch the pressure gauge needle and see that it stops at the
valve closing pressure shown below.
(6) Connect the pipe and pressure regulator.
Valve closing pressure Pressure kPa {kgf/cm2, lbf/in2.}

44530-1330 750-790 {7.7-8.1, 109-115}
SHTS061060200008

EN0610602H300001
Valve body 1, piston 2 and — — Replace, if nec- Visual check

valve rod 3. Sliding surface: essary.
Valve rod 4.
Valve contact surface:
Wear and any other dam-
ages
Main spring 5. rod spring 6. — — Replace, if nec-

and valve spring 7: essary.
Rust and damage
AIR DRYER
EN0610602I200002
Type Purge tank, desiccant, auto-purge valve.

Parts No. S4430-E0210 Approx. 30 sec.
Air and Water discharging time
(Reclamation cycle) Parts No. 44830-2900
Approx. 50 sec.
Parts No. 44830-2950
DESCRIPTION
EN0610602C100002
E 3 2
B
4 1
F 14
X X
3 8
15
9
A 16
C
18
10
5 11
17
12 G
13
SECTION X-X
D
SHTS061060200010
1 Chamber (Purge tank) 10 Valve body A Outlet (Dried air to air tank)
2 Case cover 11 Valve spring B Orifice
3 Check valve 12 Piston C Inlet (From air compressor)
4 Spring 13 Purge valve D Purged air
5 Body 14 Plug E Dehumidification
6 Desiccant case 15 Pressure regulator F Reclamation
7 Filter 16 Adjusting screw G To purge valve
8 Desiccant 17 Piston
9 Oil separator filter (If so 18 Piston spring
equipped)
COMPONENT LOCATOR
EN0610602D100002
SHTS061060200011
1 O-ring 16 Filter plate

2 Plate 17 Filter
3 Piston 18 Desiccant
4 Valve spring 19 Desiccant case
5 Valve body 20 Oil separator filter (If so equipped)
6 Purge valve 21 Body
7 Silencer case 22 Valve stopper
8 Silencer plate 23 Governor valve
9 Silencer 24 Piston assembly
10 Retainer ring 25 Exhaust stem spring
11 Exhaust cover 26 Exhaust stem
12 Chamber 27 Pressure regulator assembly
13 Check valve 28 Valve seat
14 Case cover 29 Plate
15 Set spring

A 2.0-3.9 {20-40, 1.5-2.9} D 6.9-7.8 {71-79, 5.2-5.7}
B 3.9-6.9 {40-70, 2.9-5.0} E 17.7-27.5 {180-280, 13-20}
C 4.9-5.9 {50-60, 3.7-4.3}
OVERHAUL
EN0610602H200002
1. LUBRICATION
C (1) When assembling the air dryer, use new O-ring, gasket and seal.
(2) Apply grease (lithium base) to each sliding surface of the compo-
nent parts and O-ring groove.
A • A: O-ring
• B: Sliding surface
2. BEFORE TIGHTEN THE BOLT WITH SPECIFIED TIGHTENING

A TORQUE, TAP ALL OVER THE OUTER SURFACE OF THE
DESICCANT CASE WITH A PLASTIC HAMMER.
• C: Bolt
A IMPORTANT POINTS - MOUNTING

A
B
1. INSPECTION
(1) Operate the engine and raise the air pressure until the air dis-
charge from the purge valve, then stop the engine.
(The pressure reaches the valve opening pressure of the air pres-
sure regulator).
a. Check to see that there is no air leakage from the purge valve.
SHTS061060200012
2. ADJUSTMENT
tank.
SHTS061060200013
(2) Tighten the adjusting screw gradually till the air pressure gauge
indicate valve opening pressure shown below and the air starts to
discharge from purge valve.
Governor valve opening pressure: 880kpa {9.0 kgf/cm2, 128
lbf/in2.}
SHTS061060200014
(4) Watch the air pressure gauge needle and see that it stops at the
Governor valve closing pressure: 780 kpa {8.0 kgf/cm2, 114
lbf/in.2}
SHTS061060200015

EN0610602H300002
Check valve and valve — — Replace, Visual check

seat surface: if necessary.
Wear and damage
Valve body sliding surface — — Replace, Visual check

and purge valve seat sur- if necessary.
face:
Wear and damage
Piston sliding surface: — — Replace, Visual check

Purge valve seat surface: — — Replace, Visual check

Desiccant: — Discolored, Replace. Visual check

Contamination and deteri- more than 1/5
oration of the quantity.
AIR DRYER (MODEL: FM2P)

EN0610602I200003
Type Purge tank, desiccant, auto-drain valve.

Air and Water discharging time (Reclamation cycle) Approx. 60 sec.
DESCRIPTION
EN0610602C100003
SHTS061060200021
1 Check valve 11 Piston

2 Spring 12 Purge valve
3 Filter A Inlet (from air compressor)
4 Chamber (Purge tank) B Orifice
5 Desiccant case C Outlet (dried air to air tank)
6 Desiccant D Inlet (from pressure regulator)
7 Oil Filter E Purged air
8 Body F Dehumidification
9 Valve body G Reclamation
10 Valve spring
COMPONENT LOCATOR
EN0610602D100003
SHTS061060200022
1 Bracket 8 Piston
2 Chamber (purge tank) 9 Valve spring
3 Check valve 10 Valve body
4 Desiccant case 11 Purge valve
5 O-ring 12 Exhaust body
6 Plate 13 Retainer ring
7 Body

A 14.7-22.6 {150-230, 10.9-16.6} C 6.9-8.8 {70-90, 5.1-6.5}
B 3.9-6.9 {40-70, 2.9-5.0}
OVERHAUL
EN0610602H200003
1. LUBRICATION
(1) When assembling the air dryer, use new O-ring.
• A: O-ring
2. BEFORE CLOSING THE CHAMBER, TAP ALL OVER THE

OUTER SURFACE OF THE DESICCANT CASE WITH A PLAS-
TIC HAMMER.
SHTS061060200023
1. INSPECTION
(1) Operate the engine and raise the air pressure until the air com-
pressor stops functioning.
sure regulator).
a. Check to see that there is no air leakage from the purge valve
while the compressor is functioning.
b. When the compressor stops functioning, check to see that the air
is discharged from the purge valve for a period of approx. 60 sec-
onds.

EN0610602H300003
Check valve, — — Replace, Visual check

Valve seat surface: if necessary.
Wear and damage
Valve body, — — Replace, Visual check

Sliding surface and if necessary.
purge valve seat surface:
Wear and damage
Piston, — — Replace, Visual check

Sliding surface: if necessary.
Wear and damage
Purge valve, — — Replace, Visual check

Seat surface: if necessary.
Wear and damage

Contamination, Deteriora- more than 1/5
tion of the quantity.
DOUBLE CHECK VALVE (MODEL: TRACTOR)

EN0610602I200004
Type Piston type
DESCRIPTION
EN0610602C100004
SHTS061060200029
1 Valve body 5 Plug

2 Valve A Outlet
3 Guide B Inlet
4 Gasket
COMPONENT LOCATOR
EN0610602D100004
SHTS061060200030
1 Valve body 4 Gasket

2 Valve 5 Plug
3 Guide

A 35-44 {350-450, 25.3-32.5}
OVERHAUL
EN0610602H200004
1. LUBRICATION
(1) When assembling the double check valve, apply the ThreeBond:
TB-1101 or equivalent to the gasket.
NOTICE
Check to see that there is no air leakage from "A", when air is
charged from "B", and no air leakage from "B", when air is
charged from "A".
SHTS061060200031

EN0610602H300004
Valve and guide: — — Clean or replace, Visual check

Rust, wear and damage if necessary.
Valve body and plug: — — Clean or replace, Visual check

CHECK VALVE
EN0610602I200005
Type Spring type

Valve opening pressure Outlet side pressure 14.7 kPa {0.15 kgf/cm2, 2.13 lbf/in.2}
DESCRIPTION
EN0610602C100005
SHTS061060200034
1 Connector 4 Valve spring

2 O-ring 5 Valve holder
3 Valve
COMPONENT LOCATOR
EN0610602D100005
SHTS061060200035

3 Valve

EN0610602H300005
Connector: — — Replace, Visual check

Valve: — — Replace, Visual check

Valve spring: 19.8 mm 18 mm Replace, Measure and visual check

Rust, damage and free {0.78 in.} {0.71 in.} if necessary.
length
SAFETY VALVE
EN0610602I200006
Type Spring type

Valve opening pressure 1,029-1,069 kPa {10.5-10.9 kgf/cm2, 149-155 lbf/in.2}
DESCRIPTION
EN0610602C100006
SHTS061060200039
1 Valve 5 Compression spring

2 Body A Exhaust
3 Nut B From air tank (Pressure air)
4 Bolt

EN0610602H300006
Unit: kPa {kgf/cm2, lbf/in.2}
Valve opening pressure 1,029-1,069 — Replace, Measure

{10.5-10.9, if necessary
149-155}
BRAKE VALVE
EN0610602I200007
Type Dual pistons and valves with a plunger type pedal
DESCRIPTION
EN0610602C100007
SHTS061060200040
1 Boot 17 Primary valve body

2 Plunger 18 Primary feed valve
3 Brake valve cover 19 Retainer
4 Retainer ring 20 Primary feed valve return spring
5 Guide ring 21 Primary feed valve retainer
6 Spring seat 22 Secondary piston
7 Sub spring 23 Secondary piston return spring
8 Shim 24 Secondary valve body
9 Stem 25 Secondary feed valve
10 Main spring 26 Retainer
11 Shim 27 Secondary feed valve return spring
12 Guide ring 28 Secondary feed valve retainer
13 O-ring 29 C-ring
14 Primary piston 30 Exhaust port
15 Guide 31 Piston (If so equipped)
16 Primary piston return spring
COMPONENT LOCATOR
EN0610602D100006
SHTS061060200041
1 Stop light switch 10 Push rod

2 Bushing 11 Seal
3 Bracket 12 Clip
4 Buffer 13 Shaft
5 Pin 14 Pedal bracket
6 R-pin 15 Brake valve
7 Pedal pad 16 Connector
8 Brake pedal 17 Clutch master cylinder
9 Return spring

A 9.5-18.5 {97-188, 7.1-13.5} C 24.4-34.5 {250-350, 18-25}
B 18-31 {184-316, 14-22}
SHTS061060200042
1 Boot 17 Primary valve body

2 Plunger 18 Primary feed valve
3 Brake valve cover 19 Retainer
4 Retainer ring 20 Primary feed valve return spring
5 Guide ring 21 Primary feed valve retainer
6 Spring seat 22 Secondary piston
7 Sub spring 23 Secondary piston return spring
8 Shim 24 Secondary valve body
9 Stem 25 Secondary feed valve
10 Main spring 26 Retainer
11 Shim 27 Secondary feed valve return spring
12 Guide ring 28 Secondary feed valve retainer
13 O-ring 29 C-ring
14 Primary piston 30 Exhaust port
15 Guide 31 Piston (If so equipped)
16 Primary piston return spring

A 2.9-4.9 {30-50, 2.2-3.6} B 5.9-7.4 {60-75, 4.3-5.4}
OVERHAUL
EN0610602H200005
1. REMOVE THE CLUTCH MASTER CYLINDER.

HINT
Even if without removing the clutch master cylinder, pedal bracket
can be removed only to the length of the clutch hose.
2. DISCONNECT THE NYLON TUBE.
SHTS061060200043
3. REMOVE THE PEDAL BRACKET ASSEMBLY.

(1) Loosen the bolt and nut to remove the pedal bracket assembly.
NOTICE
Before removing the pedal bracket, put the wiper link upward.
SHTS061060200044
4. REMOVE THE BRAKE PEDAL.

(1) Tap the shaft lightly using a brass rod and a hammer, remove the
brake pedal from the pedal bracket assembly.
NOTICE
Do not pull out the shaft because the brake pedal and the clutch
pedal are installed by one pedal shaft.
SHTS061060200045
5. REMOVE THE BRAKE VALVE ASSEMBLY.

ALIGNING MARK (1) Apply aligning marks on the brake valve assembly and pedal
bracket assembly.
SHTS061060200046

ALIGNING NOTICE
MARK
Before disassembling the brake valve, apply aligning marks on
the brake valve cover, primary valve body and secondary valve
body.
SHTS061060200047
ALIGNING MARK
SHTS061060200048
1. REMOVE THE PRIMARY PISTON ASSEMBLY.
2. REMOVE THE SECONDARY VALVE BODY.
3. REMOVE THE SECONDARY PISTON.

NOTICE
Pull out with hands to prevent the seat part of the secondary pis-
ton from being damaged by using a plier etc. If not with hands,
secondary piston should not be reused.
4. REMOVE THE PRIMARY FEED VALVE.

SHTS061060200049
5. REMOVE THE EXHAUST PORT.
6. REMOVE THE SECONDARY FEED VALVE


12
1. LUBRICATION
14 (1) When reassembling the brake valve, replace the O-rings and
13 retainer rings with new ones.
(2) Apply adequate amount of silicone grease on the grooves for the
10
O-ring and to the sliding surfaces of the component parts.
11 1. Secondary feed valve retainer O-ring
8 2. Secondary feed valve retainer
5 3. Secondary feed valve
7 4. Exhaust port O-ring
9
5. Primary feed valve retainer O-ring
6. Primary feed valve retainer
3 7. Secondary piston O-ring
6 2 8. Secondary piston
4 9. Primary valve body
1
10. Primary piston
SHTS061060200050
11. Primary piston O-ring
12. Plunger
13. Piston O-ring
14. Piston
2. ASSEMBLE THE STEM, SPRING, SPRING SEAT AND SHIM.

(1) Assemble the sub spring. At this time, adjust dimension "A" and
the spring compression "P" by means of the lock nut and the
shim.
NOTICE
In adjusting the spring compression, the axial play of the spring
DIMENSION
must be removed.
"A"
Dimension "A": 27.15-27.55 mm {1.0689-1.0846 in.}
Setting load: 0-9.8 N {0-1 kgf, 0-2.2 lbf}
SHTS061060200051
3. ALIGN THE VALVE COVER AND VALVE BODIES.

ALIGNING (1) When assemble the brake valve cover, primary body and second-
MARK ary body, align the marks which were applied at disassembly.
SHTS061060200047
ALIGNING MARK
SHTS061060200048
4. INSPECTION AND ADJUSTMENT

(1) Brake valve
a. Measure the secondary feed valve stroke (dimension A from
starting to release the plunger to completing to fully release
the plunger).
A dimension: 0.6 mm {0.0236 in.} or above
A DIMENSION
SHTS061060200052
b. Connect the brake valve, nylon tube, air pressure gauge, and
air tank as shown in the figure.
c. Set the air tank pressure at 830 kPa {8.5 kgf/cm2, 120.87 lbf/
in.2}.
PRIMARY d. Apply soap water to the exhaust port and check to see there
is no air leakage.
AIR TANK
SECONDARY
SHTS061060200053
e. Drive in slowly the plunger. Measure the plunger stroke and

supply pressure at the point where the primary and secondary
PLUNGER
air pressure gauges start to rise. If the measurements do not
match with the standard values, adjust by the shim of the
main spring.
PRIMARY
SUPPLY Parts No. 47160-3292
PRESSURE
AIR TANK Measurement item Standard value
Plunger stroke 0.8-1.6 mm {0.0315-0.0630 in.}
5-25 kPa
Supply pressure
SECONDARY {0.1-0.3 kgf/cm2, 1.43-3.55 lbf/in.2}
SHTS061060200054
Parts No. 47160-3311, 47160-3322

Measurement item Standard value
19-41 kPa
Supply pressure
{0.2-0.4 kgf/cm2, 2.84-5.60 lbf/in.2}
f. Drive in further the plunger. Measure the plunger stroke and

supply pressure at the point immediately before that the pri-
PLUNGER
mary and secondary pressure increases rapidly (bending
point). If the measurements do not match with the standard
values, replace each spring.
PRIMARY
PLUNGER
Supply pressure 195 kPa {2.0 kgf/cm2, 28.28 lbf/in.2}
SECONDARY
SHTS061060200055
Parts No. 47160-3311, 47160-3322
g. Drive in further the plunger. Measure the plunger stroke and

PLUNGER
pressures increase rapidly. If the measurements do not match
with the standard values, replace each spring.
PRIMARY Parts No. 47160-3292
SUPPLY
PLUNGER Measurement item Standard value
AIR TANK Plunger stroke 6.34-7.66 mm {0.2497-0.3015 in.}
SECONDARY
Parts No. 47160-3311, 47160-3322
SHTS061060200056
h. Drive in further the plunger. Measure the pedal stepping down

angle and supply pressure at the point where the primary and
PLUNGER
secondary pressure are maximum. If the measurements do
not match with the standard values, replace each spring.
SUPPLY
PLUNGER
Supply pressure Max. regulating pressure
SECONDARY
Parts No. 47160-3311, 47160-3322
SHTS061060200057
Supply pressure Max. regulating pressure
(2) Brake pedal

a. Make sure that the installing height of the brake pedal "C" and
the pedal play "B".
"B": 2-5 mm {0.0788-0.1968 in.}
"C": 149.6-159.6 mm {5.890-6.283 in.}
C
B
SHTS061060200058
b. If the pedal play is out of the standard value, loosen the lock
nut and turn the push rod to adjust the pedal play to the stan-
dard value.
LOCK NUT
PUSH ROD
BOOT
PLUNGER
SHTS061060200059
(3) Check the clearance between stop light switch and buffer.
"D": 0.5-1.5 mm {0.0197-0.0590 in.}
STOP LAMP SWITCH
BUSHING
BUFFER
SHTS061060200060

EN0610602H300007
Parts No. 47160-3292
Main spring: 29.1 mm {1.15 in.}/ 28.3 mm Replace. Visual check and measure
Free length/ 27.5 mm {1.08 in.}/ {1.11 in.}
setting length/ 147.1 N
setting load {15.0 kgf, 35.07 lbf}
Sub spring: 21.6 mm {0.85 in.}/ 20.5 mm PRIMARY

or more SECONDARY
Primary and Secondary Primary: 40.5 mm Replace. Visual check and measure
piston return spring: 43.2 mm {1.70 in.}/ {1.59 in.}
Free length/ 16.5 mm {0.65 in.}/
PRIMARY
Secondary: 43.2 mm
45.8 mm {1.80 in.}/ {1.70 in.}
16.0 mm {0.63 in.}/
49.0 N
{5.0 kgf, 11 lbf}
SECONDARY
Primary and secondary — — Replace, Visual check

piston: if necessary.
Wear and damage
SECONDARY PISTON PRIMARY PISTON

feed valve: if necessary.
Wear and damage
Primary and secondary Primary: 20.4 mm Replace. Visual check and measure
feed valve return spring: 21.4 mm {0.84 in.}/ {0.80 in.}
PRIMARY
Secondary: 21.8 mm
22.8 mm {0.90 in.}/ {1.13 in.}
13.0 mm {0.51 in.}/
49.0 N
{5.0 kgf, 11.02 lbf} SECONDARY
Secondary valve body: — — Replace, Visual check

Primary valve body: — — Replace, Visual check

Parts No. 47160-3311, 47160-3322
Main spring: 29.3 mm {1.15 in.}/ 28.5 mm Replace. Visual check and measure
Sub spring: 21.6 mm {0.85 in.}/ 21 mm PRIMARY

setting length/ 457 N
or more SECONDARY
Primary and Secondary Primary: 40.5 mm Replace. Visual check and measure
piston return spring: 43.2 mm {1.70 in.}/ {1.59 in.}
PRIMARY
Secondary: 23.5 mm
24.5 mm {0.96 in.}/ {0.93 in.}
12.0 mm {0.47 in.}/
11.8 N
{1.2 kgf, 2.6 lbf}
SECONDARY

Wear and damage

Wear and damage
Primary and secondary Primary: 20.4 mm Replace. Visual check and measure
feed valve return spring: 21.4 mm {0.84 in.}/ {0.80 in.}
PRIMARY
Secondary: 21.8 mm
22.8 mm {0.90 in.}/ {1.13 in.}
13.0 mm {0.51 in.}/
49.0 N


PROTECTION VALVE (WITH 4-WAY PROTECTION VALVE)

EN0610602I200008
Type Spring type (4-way protection)

opening pressure Open: Port 21, 22 620-660 kpa {6.3-6.7 kgf/cm2, 89.61-95.29 lbf/in.2}
Part No, 44570-1290 570-610 kpa {5.8-6.2 kgf/cm2, 82.49-88.18 lbf/in.2}
Port 23
Port 24 570-610 kpa {5.8-6.2 kgf/cm2, 82.49-88.18 lbf/in.2}
Close: Port 21, 22, 24 440-480 kpa {4.5-4.8 kgf/cm2, 64.01-68.27 lbf/in.2}
Port 23
DESCRIPTION
EN0610602C100008
SHTS061060200075
1 Compression spring A Port 21 (Outlet) G Center check valve

2 Dust cover B Port 22 (Outlet) H No.2 side
3 Check valve C Port 23 (Outlet)
4 Dust seal rubber D Port 24 (Outlet)
5 Piston E Inlet port
6 Valve spring F No.1 side
COMPONENT LOCATOR
EN0610602D100007
8 3
4
9
5
10
11 6
7
12
13
11
10
SHTS061060200076
1 Dust cover 6 Shim 11 Valve

2 Dust seal rubber 7 Spacer 12 Body
3 Retainer ring 8 Piston 13 Check valve
4 Dust seal plate 9 O-ring
5 Compression spring 10 Valve spring
OVERHAUL
EN0610602H200006
1. LUBRICATION
(1) When assembling the protection valve use the new O-rings and
valves.
(2) Apply the silicone grease on the each sliding surface of the com-
ponent parts and O-ring groove.
• A: O-ring
SHTS061060200077
ADJUSTMENT
EN0610602H300008
AIR LEAKAGE
1. CHECK VALVE
(1) By-pass check valve at No.1 side.
a. Confirm no leakage of air at inlet, No.1, when applying pres-
sure to air under 49 kpa {0.5 kgf/cm2, 7.11 lbf/in.2}, 392 kpa {4
kgf/cm2, 56.89 lbf/in.2} from outlet No.21 and No.22.
SHTS061060200078
(2) Center check valve

a. Confirm no leakage of air at the outlet No.21 and No.22, when
applying pressure to air under 49 kpa {0.5 kgf/cm2, 7.11 lbf/
in.2}, pressure A from the inspection port.
Unit: kPa {kgf/cm2, Ibf/in.2}
Part No. Pressure A
44570-1290 880 {9, 122}
44570-1330 980 {10, 142}
SHTS061060200079
(3) Check valve at No.2 side

a. Confirm no leakage of air at the inspection port, when apply-
ing pressure to air under 49 kpa {0.5 kgf/cm2, 7.11 lbf/in.2},
pressure B at the outlet No.23 and No.24.
Part No. Pressure B
44570-1290 880 {9, 128}
44570-1330 980 {10, 142}
2. OTHER AIR TIGHTNESS

SHTS061060200080 (1) When applying pressure to air under Pressure C, confirm that any
leakage of air should be 0 cm3/min.
Part No. Pressure C
44570-1290 0-880 {0-9, 0-128}
44570-1330 0-980 {0-10, 0-142}
PERFORMANCE CHRACTERISTIC
1. OPENING VALVE PRESSURE

(1) No.1 side
a. Releasing the compressed air at the outlet port No.21 and
No.22 to air, when applying the compressed air at the speed
specified below, confirm that air pressure of the compressed
air, saturated at the inlet should be of Opening valve pres-
sure, which should be 620-660 kpa {6.3-6.7 kgf/cm2, 89.61-
95.29 lbf/in.2}.
Charging speed: From 295 kpa {3.0 kgf/cm2, 42.66 lbf/in.2} to
490 kpa {5.0 kgf/cm2, 71.10 lbf/in.2} within 3-7 seconds.
(2) No.2 side
a. When applying air at charging speed specified below from the
inlet side under air pressure "0" at the outlet port No.23 and
No.24, confirm that a pressure at the inspection port when it
starting to go up at the outlet should be of Opening valve
pressure.
Part No. Opening valve pressure
44570-1290 570-610 {5.8-6.2, 82.49-88.18}
Port No. 23
44570-1330 620-660 {6.3-6.7, 82.49-88.18}
Port No. 24 570-610 {5.8-6.2, 82.49-88.18}
Charging speed: From 295 kpa {3.0 kgf/cm2, 42.66 lbf/in.2} to

490 kpa {5.0 kgf/cm2, 71.10 lbf/in.2} within 8-22 seconds.
2. CLOSING VALVE PRESSURE

(1) When discharging air through respective No.1 side and No.2 side
inlet under a pressure of pressure D at the inlet and the outlet, at
discharging speed specified below, confirm that a pressure when
the pressures saturated should be of Closing valve pressure.
Part No. Pressure D
44570-1290 880 {9, 128}
44570-1330 980 {10, 142}

Part No. Opening valve pressure
Port No. 21, 22, 24 440-480 {4.5-4.8, 64.01-68.27}
44570-1290 440-480 {4.5-4.8, 64.01-68.27}
Port No. 23
44570-1330 490-530 {5.0-5.4, 71.07-76.87}
Discharging speed: From 590 kpa {6.0 kgf/cm2, 85.32 lbf/in.2} to

295 kpa {3.0 kgf/cm2, 42.66 lbf/in.2} within less than seconds.
NOTICE
Perform test again by increasing sims, when the respective pres-
sures is low and by decreasing it when high in the above inspec-
tion.

EN0610602H300009
Unit: mm {in.}
Sliding surface and contact — — Replace, Visual check

surface of body: if necessary.
Wear and damage

surface of valve seat and if necessary.
piston:
Wear and damage
Main spring and valve Main spring 137.3 N Replace, Measure and Visual check
spring: (Port 21, 22, 24): {14.0 kgf, if necessary.
Free length/ 42.4 {1.67}/ 30.87 lbf}
Setting length/ 27.5 {1.08}/ (Setting load)
Setting load 158.9 N
Crack, rust and damage {16.2 kgf, 35.72 lbf}
MAIN
Main spring
(Port 23):
35.3 {1.39}/
27.5 {1.08}/
VALVE
169.7 N
{17.3 kgf, 38.15 lbf}
Valve spring: 0.69 N

20.0 {0.79}/ {0.07 kgf,
9.0 {0.35}/ 0.155 lbf}
0.78 N (Setting load)
{0.08 kgf, 0.175 lbf}
PROTECTION VALVE
EN0610602I200009
Type Spring type

Open 637 kPa {6.2 kgf/cm2, 88.16 lbf/in.2}
Operating pressure
Close 510 kPa {5.2 kgf/cm2, 73.94 lbf/in.2}
DESCRIPTION
EN0610602C100009
SHTS061060200084
1 Valve body 5 Dust seal plate

2 O-ring 6 Retainer ring
3 Valve A Inlet
4 Compression spring B Outlet
COMPONENT LOCATOR
EN0610602D100008
SHTS061060200085
1 Body 4 Spacer 7 Dust seal plate

2 O-ring 5 Shim 8 Retainer ring
3 Piston 6 Spring 9 Dust seal
OVERHAUL
EN0610602H200007
1. LUBRICATION
(1) When reassembling the protection valve, replace the O-rings and
valve with new ones.
(2) Apply adequate amount of silicone grease to the sliding surface of
the component parts.
SHTS061060200086

EN0610602H300010
Unit: mm {in.}
Valve contact surface of — — Clean or Visual check

Body cap 1: replace,
Sliding surface of valve — — Clean or

body 2: replace,
Valve spring: 60.0 {2.36} — Replace. Measure

Free length
QUICK RELEASE VALVE

EN0610602I200010
Type Diaphragm type
DESCRIPTION
EN0610602C100010
SHTS061060200089
1 Cover 6 Bolt
2 Filter A Inlet
3 Gasket B Outlet
4 Diaphragm C Exhaust
5 Valve body
COMPONENT LOCATOR
EN0610602D100009
SHTS061060200090
1 Cover 4 Diaphragm
2 Filter 5 Valve body
3 Gasket 6 Bolt
OVERHAUL
EN0610602H200008

NOTICE
Before disassemble the relay valve apply the aligning mark "A" for
the cover and valve body.
SHTS061060200091
1. ASSEMBLE THE RELAY VALVE

(1) When assembly the relay valve, use the new diaphragm and gas-
ket.
• A: Gasket
• B: Diaphragm
(2) Coincide the aligning mark "A" which were applied at disassem-
bly.
SHTS061060200092

EN0610602H300011
Valve body and cover — — Replace, Visual check

surface: if necessary.
Rust and damage
BRAKE FLUID RESERVOIR

(MODELS: FC, FD, GD, THAILAND FG)
EN0610602I200011
Type Dual chambers for service brake control lines

Models: FC, FD (Singapore, Taiwan without ABS), GD, Below 18-24 mm {0.709-0.945 in.}
Low fluid level FG (Thailand) (Dimension A)
warning switch
operating range Models: FD (Hong Kong, Taiwan with ABS) Below 18-24 mm {0.709-0.945 in.}
(Dimension A)
DESCRIPTION
EN0610602C100011
SHTS061060200094
1 Filler cap 5 Float

2 Diaphragm 6 Float stopper
3 Reservoir B To brake air booster
4 Fluid level warning switch
COMPONENT LOCATOR
EN0610602D100010
SHTS061060200095
1 Reservoir cap 4 Hose

2 Body 5 Tube
3 Clip

EN0610602H100001
1. REMOVAL OF RESERVOIR.
NOTICE
• Before removing the reservoir, drain the brake fluid from the
hydraulic lines.
• Place a small pan under the reservoir to receive the brake
fluid. Do not let fluid remain on a painted parts. Wash it off
immediately.

EN0610602H300012
NOTICE
Brake fluid or isopropyl alcohol should only be used to wash the
components.
Brake fluid reservoir: — — Replace, Visual check

Cracks, damages and if necessary.
leakage
Operation of fluid level The warning light — Replace reser- When the reservoir is filled,
warning switch and buzzer should be voir assembly, submerge the float
turned on, when the if necessary.
float is submerged
lower than the MIN.
level.
BRAKE FLUID RESERVOIR

(MODELS: FG, GH, FL, FM)
EN0610602I200012
Type Dual chambers for service brake control lines

Low fluid level warning switch operating range Below 19-25 mm {0.748-0.984 in.}
DESCRIPTION
EN0610602C100012
3 1
2
5
4
6
7
11
8
A
10
SHTS061060200098
1 Reservoir cap 7 Float stopper

2 Slide ring 8 Float
3 Diaphragm 9 Reservoir lower
4 Ring cover 10 Fluid level warning switch
5 Reservoir upper 11 Bracket
6 Retainer ring
COMPONENT LOCATOR
EN0610602D100011
1
3
4
7 10 11
8
12
10 13
11
SHTS061060200099
1 Reservoir cap 8 Float

2 Slide ring 9 Reservoir lower
3 Diaphragm 10 Clip
4 Ring cover 11 Tube
5 Reservoir upper 12 Fluid level warning switch
6 Retainer ring 13 Bracket
7 Float stopper

EN0610602H100002
1. REMOVAL OF RESERVOIR.
NOTICE
• Before removing the reservoir, drain the brake fluid from the
hydraulic lines.
• Place a small pan under the reservoir to receive the brake
fluid. Do not let fluid remain on a painted parts. Wash it off
immediately.

EN0610602H300013
NOTICE
components.
Brake fluid reservoir: — — Replace, Visual check

Cracks, damages and if necessary.
leakage
Operation of fluid level The warning light — Replace reser- When the reservoir is filled,
warning switch and buzzer should be voir assembly, submerge the float
turned on, when the if necessary.
float is submerged
lower than the MIN.
level.

WITHOUT ABS (MODELS: FC, FD, GD, THAILAND FG)
EN0610602I200013
Type AIRMASTER (Boosted air controlled by brake valve)

Power cylinder diameter 114.3 mm {4.50 in.}
Hydraulic cylinder diameter 22.2 mm {0.87 in.}
DESCRIPTION
EN0610602C100013
SHTS061060200102
1 Piston seal 8 Push rod

2 Power piston 9 Nut
3 Return spring 10 Stroke warning switch
4 Power cylinder shell 11 Piston stroke detector
5 Check valve A Boost air (From brake valve)
6 Hydraulic cylinder B To wheel cylinder
7 Hydraulic piston C At power piston over stroke
SPECIAL TOOL
EN0610602K100001
Prior to starting a brake air booster overhaul, it is necessary to have these special tools.
S0969-91410 POWER PISTON HOLDER
S0965-72060 PISTON CUP GUIDE
S0963-02340 STAND
S0965-11120 PULLER
S0960-71160 PRESS FIT BAR
S0969-91400 CONNECTER
COMPONENT LOCATOR
EN0610602D100012
19
A 9 21
8
7 22
6 20
10
5 24 25
23 Y
B
B
18
2
17
27 13 12
32
D
31
30
29 11
3
1 28
29
16
4 B
14
15
C
Y 26
SHTS061060200109
1 Clamp 17 Hydraulic cylinder

2 Holder 18 O-ring
3 Exhaust cover 19 Hydraulic piston assembly
4 Stroke warning switch 20 Pin
5 Retainer ring 21 Valve seal
6 Oil pipe joint 22 Hydraulic piston spring
7 Spring 23 Hydraulic piston cup
8 O-ring 24 Back up ring
9 Check valve 25 Hydraulic piston
10 Air bleeder screw 26 Push rod
11 Power cylinder shell 27 O-ring
12 O-ring 28 End plate assembly
13 Piston seal 29 Washer
14 Power piston 30 Oil seal
15 Return spring 31 Oil seal
16 Push rod pin 32 End plate

A 7-12 {70-130, 5.1-9.3} C 8-12 {80-120, 5.8-8.6}
B 11-15 {110-160, 8-11} D 20-29 {200-300, 15-21}
OVERHAUL
EN0610602H200009
1. HYDRAULIC CYLINDER AND POWER CYLINDER

(1) Remove the nut and then remove the clamp, holder, and exhaust
cover.
(2) Remove the stroke warning switch.
WARNING SWITCH
SHTS061060200110
(3) Remove the retainer ring, oil pipe joint with O-ring, spring and
check valve.
(4) Remove the cap and the bleeder screw.
SHTS061060200111
(5) Using the special tool, secure the brake booster.

SST: Stand (S0963-02340)
SPECIAL TOOL
NOTICE
ALIGNING MARK
Before disassembling the brake air booster, apply aligning mark
on the power cylinder shell and end plat
(6) Remove the nuts, then remove the power cylinder shell and O-
ring.
SHTS061060200112
(7) Using the special tool, secure the power piston, then remove the
nut.
SST: Power Piston Holder (S0969-91410)
NOTICE
• Keep the power piston pushed far enough toward the hydrau-
lic cylinder side while removing the nut. If the power piston is
not adequately pushed toward the hydraulic cylinder side,
the push rod pin will turn together with the nut.
• When removing the nut, take precautions, for there is a
spring that will jump out when the nut is removed.
SHTS061060200113
(8) Remove the O-ring, piston seal, power piston and return spring.
(9) Remove the bolts, then remove the hydraulic cylinder and O-ring.
SHTS061060200114
(10) Press and hold down the hydraulic piston spring and remove the
pin, and then remove the hydraulic piston assembly.
(11) Remove the push rod, pulling it in the direction away from the
push rod threaded part.
SHTS061060200115
(12) Remove the washer from the end plate.

(13) Using the special tool, remove the oil seal (2 pieces) from the end
plate.
SHTS061060200116

(1) Using the special tool, secure the end plate.
SST: Stand (S0963-02340)
SHTS061060200117
(2) Coat the oil seal and end plate bore with silicone grease. Then
SPECIAL TOOL using the special tool, press the oil seal on the end plate.
SST: Press Fit Bar (S0960-71160)
NOTICE
Make sure the oil seal is inserted in the proper direction.
(3) Soak the washers in brake fluid and then install the end plate.
SHTS061060200118
(4) Using the special tool, install the back up ring and hydraulic piston
cup to the hydraulic piston.
SST: Piston Cup Guide (S0965-72060)
SPECIAL
TOOL NOTICE
• Install the back up ring and hydraulic piston cup in the cor-
rect order and direction.
PISTON • Make sure the back up ring is not biting into the piston.
CUP
BACK UP
RING
(5) Coat the push rod surfaces and valve seal with silicone grease,
then install the push rod to the end plate, installing it in the direc-
SHTS061060200119 tion away from the threaded parts.
(6) Line up the push rod end pin, the valve seal hole and the hydrau-
lic piston hole, and then insert the pin.
PIN
NOTICE
Make sure that the hydraulic piston spring covers the pin, which is
not drawn out from the hydraulic piston.
SHTS061060200120
(7) Coat the hydraulic piston assembly exterior surfaces, the hydrau-
HYDRAULIC CYLINDER lic cylinder inner surfaces and the O-ring with brake fluid.
(8) Install the O-ring on the hydraulic cylinder, then install the hydrau-
lic cylinder on the end plate.
(9) Install the air bleeder screw.
END PLATE
SHTS061060200121
(10) Install the pin in the push rod threaded part hole.
PIN RETURN (11) Install the return spring on the end plate.
SPRING
END PLATE
SHTS061060200122
(12) Coat the piston seal groove of the power piston and piston seal
with mineral grease (Air Master Paste or equivalent), and then
install the piston seal to the power piston.
NOTICE
Make sure the piston seal is installed in the proper direction.
POWER PISTON PISTON SEAL
SHTS061060200123
(13) While pressing and holding down the compression spring, install
the O-ring and washer in that order, and then secure the hydraulic
piston and push rod in place with the nut.
SST:
Power Piston Holder (S0969-91410)
Stand (S0963-02340)
NOTICE
• Supply compressed air (about 0.1 MPa) through the hydraulic
cylinder discharge opening to prevent the push rod from fall-
ing down.
SHTS061060200124
• After fastening the nut, caulk the nut and the push rod
threaded parts with a punch.
(14) Match the aligning mark, install the power cylinder shell on the
end plate.
(15) When assembling the power cylinder shell and end plate, align
ALIGNING MARK the mark which were applied at disassembly.
SPECIAL TOOL
SHTS061060200125
(16) Install the check valve, spring and oil pipe joint with O-ring, then
secure the oil pipe joint with the retainer ring.
SHTS061060200126
(17) Install the stroke warning switch and tighten it with the specified
torque.
(18) Coat the exhaust cover insertion part and the end plate insertion
part with silicone grease, and assemble the exhaust cover on the
end plate and install the clamp.
WARNING SWITCH
SHTS061060200127
INSPECTION
EN0610602H300014
CHECKING OF BRAKE AIR BOOSTER FUNCTION

RESERVOIR
OIL PRESSURE 1. OPERATION CHECK OF BRAKE BOOSTER
AIR PRESSURE GAUGE
GAUGE (1) Remove the bleeder screw of hydraulic cylinder and attach an oil
pressure gauge scaling 24.5 MPa {250 kgf/cm2, 3.555 lbf/in.2} by
using a special tool (connecting portion: M12 x 1.5).
SST: Connector (S0969-91400)
SPECIAL TOOL
BRAKE VALVE
SHTS061060200128
(2) Remove the plug from the brake valve assembly and attach an air
pressure gauge to the brake valve assembly.
PLUG
SHTS061060200129
2. TEST OF OPERATION START PRESSURE

(1) Purge the air within the air tank completely and check to see that
RESERVOIR TANK the air pressure gauge indicates 0.
(2) Depress the brake pedal completely to the floor and hold it down
at that position.
(3) Start the engine and increase the air pressure.
(4) Check to see that the oil pressure increases before the air pres-
sure reaches 69 kPa {0.7 kgf/cm2, 9.95 lbf/in.2}
BRAKE VALVE
SHTS061060200130
3. OPERATION CHECK AT FULL LOAD

883 kPa (1) Increase the air pressure after the above test.
21.6 23.5 MPa
{9.0 kgf/cm2, (2) Depress the brake pedal completely to the floor.
{220 240 kgf/cm2,
127.98 lbf/in.2}
3,129 3,412 lbf/in.2} (3) Stop the engine when the air pressure reaches 883 kPa {9.0kgf/
RESERVOIR cm2, 127.98 lbf/in.2}.
TANK (4) Check to see that the oil pressure at that moment is between
21.6-23.5 MPa {220-240 kgf/cm2, 3.129-3.412 lbf/in.2}.
4. AIR SEALING TEST AT FULL LOAD

(1) Immediately after the above test, check to see for one minute that
BRAKE VALVE the air pressure does not drop down.
SHTS061060200131
5. RESIDUAL PRESSURE TEST (CHECK VALVE TEST)

(1) Replace an oil pressure gauge with one having the scale of 0- 690
150 200 kPa 59 156 kPa
kPa {0-7 kgf/cm2, 0-99.54 lbf/in.2}.
{1.5 2.0 kgf/cm2 {0.6 1.6 kgf/cm2
8.54 22.75 lbf/in.2} (2) Depress the brake pedal till the air pressure reaches 150-200 kPa
21.33 28.44 lbf/in.2}
{1.5-2.0 kgf/cm2, 21.33-28.44 lbf/in.2} and then release the pedal.
Check to see that the oil pressure at that moment is 59-156 kPa
{0.6-1.6 kgf/cm2, 8.54-22.75 lbf/in.2} in case of the vehicle
equipped with drum brake, and 0 in case of the vehicle equipped
with disk brake.
SHTS061060200132
6. OPERATION AFTER CHECK

(1) Remove the air pressure gauge from the brake valve assembly.
(2) Apply lock agent (LOCTITE 575 or equivalent) on the threaded
portion of the plug.
(3) Install the plug on the brake valve assembly.
(4) Remove the oil pressure gauge and install the bleeder screw of
the hydraulic cylinder.
PLUG
SHTS061060200129
7. CHECK OF THE STROKE WARNING SWITCH AND WARNING

BUZZER
(1) Attach a vinyl tube to the bleeder screw of hydraulic cylinder.
(2) Depress the brake pedal and loosen the bleeder screw of hydrau-
lic cylinder to allow the fluid flow out.
NOTICE
Do not have the fluid scattered.
(3) Check to see if the warning lamp lights up and the warning buzzer
beeps.
NOTICE
Warning buzzer beeps only when the parking brake is released.
(4) Attach the bleeder screw of hydraulic cylinder.
SHTS061060200133

EN0610602H300015
NOTICE
components.
Unit: mm {in.}
Hydraulic cylinder inner — — Clean or Visual check

surface: replace,
Corrosion and wear if necessary.
Hydraulic piston: — — Clean or Visual check

Corrosion and wear replace,
if necessary.
Hydraulic cylinder and 0.07-0.14 0.16 Replace, Measure

piston: {0.0028-0.0055} {0.0063} cylinder and/or
Clearance piston.
Power piston: — — Clean or Visual check

Rust, deformation and replace,
wear if necessary.
Power cylinder shell: — — Clean or Visual check

Rust on inner surface replace,
and deformation. if necessary.
NOTICE
If the cylinder shell has
a deformation in 0.45
mm {0.1772 in.} or more
depth, be sure to
replace it.
Return spring: 161 {6.34} 154 {6.06} Replace, Measure and visual check
Rust, damage and free if necessary.
length

WITH ABS (MODEL: FD)
EN0610602I200014

DESCRIPTION
EN0610602C100014
SHTS061060200140
1 Piston seal 10 Hydraulic cylinder

2 Power piston 11 Stroke warning switch
3 Return spring 12 Piston stroke detector
4 Power cylinder shell 13 Push rod
5 End plate 14 Nut
6 Exhaust connector
7 Spacer A Boost air (From brake valve)
8 Check valve B To wheel cylinder
9 Hydraulic piston C At power piston over stroke
SPECIAL TOOL
EN0610602K100002
Prior to starting a brake air booster overhaul, it is necessary to have these special tools.
S0963-02340 STAND
S0969-91410 POWER PISTON HOLDER
S0965-11120 PULLER
S0960-71160 PRESS FIT BAR
S0969-91400 CONNECTER
COMPONENT LOCATOR
EN0610602D100013
SHTS061060200146
1 Brake booster assembly 3 Stroke warning switch

2 Exhaust connector
SHTS061060200147
1 Repair kit 5 Check valve assembly

2 O-ring 6 Retainer ring
3 Oil seal 7 Air bleeder screw cap
4 Hydraulic piston assembly 8 Piston seal
OVERHAUL
EN0610602H200010

(1) Remove the nut and then remove the clamp, exhaust hose, and
exhaust connector.
(2) Remove the stroke warning switch.
WARNING SWITCH
SHTS061060200148
(3) Remove the retainer ring, oil pipe joint with O-ring, spring and
check valve.
(4) Remove the cap and the air bleeder screw.
SHTS061060200149
(5) Using the special tool, secure the brake booster.

SST: Stand (S0963-02340)
ALIGNING
SPECIAL TOOL
MARK NOTICE
Before disassembling the brake air booster, apply aligning mark
on the power cylinder shell and end plate.
(6) Remove the nuts, then remove the power cylinder shell and O-
ring.
SHTS061060200150
(7) Using the special tool, secure the power piston, then remove the
NUT nut.
SST: Power Piston Holder (S0969-91410)
WASHER
NOTICE
O-RING
lic cylinder side while removing the nut. If the power piston is
not adequately pushed toward the hydraulic cylinder side,
• When removing the nut, take precautions, for there is a
spring that will jump out when the nut is removed.
SPECIAL TOOL
(8) Remove the washers, O-ring, piston seal, power piston and return
PISTON
spring.
SHTS061060200151
(9) Remove the bolts, then remove the hydraulic cylinder and O-ring.
SHTS061060200152
(10) Press and hold down the hydraulic piston spring and remove the
pin by using a nose plier, and then remove the hydraulic piston
assembly.
PIN
NOTICE
Do not disassemble the hydraulic piston, if it has defects, replace
the hydraulic piston assembly.
(11) Remove the push rod, pulling it in the direction away from the
push rod threaded part.
(12) Remove the O-ring from the end plate.
SHTS061060200153
(13) Remove the washer from the end plate.

(14) Using the special tool, remove the oil seal (2 pieces) from the end
plate.
SPECIAL TOOL
SHTS061060200154

SPECIAL TOOL
(1) Using the special tool, secure the end plate.
SST: Stand (S0963-02340)
(2) Coat a new oil seal and the end plate bore with silicone grease.
Then using the special tool, press the oil seal on the end plate.
SST: Press Fit Bar (S0960-71160)
NOTICE
Make sure the oil seal is inserted in the proper direction.
SHTS061060200155
(3) Soak the washers in brake fluid and then install the end plate.
(4) Coat the push rod surfaces and valve seal with silicone grease,
then install the push rod to the end plate, installing it in the direc-
tion away from the threaded parts.
PIN
(5) Line up the push rod end pin, the valve seal hole and the hydrau-
lic piston hole, and then insert the pin.
NOTICE
Make sure that the hydraulic piston spring covers the pin, which is
not drawn out from the hydraulic piston.
SHTS061060200156
(6) Coat the hydraulic piston assembly exterior surfaces, the hydrau-
lic cylinder inner surfaces and a new O-ring with brake fluid.
(7) Install the O-ring on the hydraulic cylinder, then install the hydrau-
lic cylinder on the end plate.
Tightening Torque:
20-29 N⋅m {204-295 kgf⋅cm, 15-21 lbf⋅ft}
(8) Install the air bleeder screw.

Tightening Torque:
7-12 N⋅m {72-122 kgf⋅cm, 5.2-8.8 lbf⋅ft}
SHTS061060200157
(9) Install the pin in the push rod threaded part side hole.
PIN RETURN (10) Install the return spring on the end plate.
SPRING
END PLATE
SHTS061060200158
(11) Coat the piston seal groove of the power piston and piston seal
with mineral grease (Air Master Paste or equivalent), and then
install the piston seal to the power piston.
NOTICE
Make sure the piston seal is installed in the proper direction.
POWER PISTON PISTON SEAL
SHTS061060200159
(12) While pressing and holding down the return spring, install a new
O-ring and the washer in that order, and then secure the hydraulic
NUT
piston and push rod in place with the nut.
WASHER SST:
Power Piston Holder (S0969-91410)
Stand (S0963-02340)
O-RING
Tightening Torque:
11-15 N⋅m {113-153 kgf⋅cm, 8.2-11 lbf⋅ft}
NOTICE
• Supply compressed air (about 0.1 MPa) through the hydraulic
SPECIAL TOOL cylinder discharge opening to prevent the push rod from fall-
PISTON
ing down.
lic cylinder side while tightening the nut. If the power piston
is not adequately pushed toward the hydraulic cylinder side,
• After fastening the nut, caulk the nut and the push rod
SHTS061060200160 threaded parts with a punch.
(13) Coat the power cylinder shell inner surface with mineral grease
(Air Master Paste or equivalent).
(14) Match the aligning mark, install the power cylinder shell on the
ALIGNING MARK end plate.
SPECIAL TOOL (15) When assembling the power cylinder shell and end plate, align
the mark which were applied at disassembly.
Tightening Torque:
11-15 N⋅m {113-153 kgf⋅cm, 8.2-11 lbf⋅ft}
SHTS061060200161
(16) Install the check valve, spring and oil pipe joint with a new O-ring,
then secure the oil pipe joint with a new retainer ring.
SHTS061060200162
(17) Apply sealant (ThreeBond No.1213) on the threaded part of the

stroke warning switch.
NOTICE
Before applying, clean off used sealant completely.
(18) Install the stroke warning switch and tighten it with the specified
torque.
Tightening Torque:
8-12 N⋅m {82-122 kgf⋅cm, 5.9-8.8 lbf⋅ft}
WARNING SWITCH
SHTS061060200163
(19) Apply sealant (ThreeBond No.1213) on the threaded part of the

exhaust connector.
NOTICE
Before applying, clean off used sealant completely.
(20) Install the exhaust connector and tighten it with the specified
torque.
Tightening Torque:
5-6 N⋅m {51-61 kgf⋅cm, 3.7-4.4 lbf⋅ft}
SHTS061060200164
INSPECTION
EN0610602H300016

RESERVOIR
OIL PRESSURE 1. OPERATION CHECK OF BRAKE BOOSTER
AIR PRESSURE GAUGE
GAUGE (1) Remove the bleeder screw of hydraulic cylinder and attach an oil
pressure gauge scaling 24.5 MPa {250 kgf/cm2, 3.555 lbf/in.2} by
using a special tool (connecting portion: M12 x 1.5).
SST: Connector (S0969-91400)
SPECIAL TOOL
BRAKE VALVE
SHTS061060200165
(2) Remove the plug from the brake valve assembly and attach an air
pressure gauge to the brake valve assembly.
PLUG
SHTS061060200166
2. TEST OF OPERATION START PRESSURE

(1) Purge the air within the air tank completely and check to see that
RESERVOIR TANK the air pressure gauge indicates 0.
(2) Depress the brake pedal completely to the floor and hold it down
at that position.
(3) Start the engine and increase the air pressure.
(4) Check to see that the oil pressure increases before the air pres-
sure reaches 69 kPa {0.7 kgf/cm2, 9.95 lbf/in.2}
BRAKE VALVE
SHTS061060200167
3. OPERATION CHECK AT FULL LOAD

883 kPa (1) Increase the air pressure after the above test.
21.6 23.5 MPa
{9.0 kgf/cm2, (2) Depress the brake pedal completely to the floor.
{220 240 kgf/cm2,
127.98 lbf/in.2 }
3,129 3,412 lbf/in.2 } (3) Stop the engine when the air pressure reaches 883 kPa {9.0kgf/
RESERVOIR cm2, 127.98 lbf/in.2}.
TANK (4) Check to see that the oil pressure at that moment is between
21.6-23.5 MPa {220-240 kgf/cm2, 3.129-3.412 lbf/in.2}.
Treatment in abnormal condition:
Replace the hydraulic piston assembly (contents of the
repair kit).
BRAKE VALVE
SHTS061060200168 4. AIR SEALING TEST AT FULL LOAD
(1) Immediately after the above test, check to see for one minute that
the air pressure does not drop down.
• If the power piston has defects, replace the brake booster
assembly.
• If the piston seal has defects, replace it with a new one (con-
tent of the repair kit).
5. RESIDUAL PRESSURE TEST (CHECK VALVE TEST)

(1) Replace an oil pressure gauge with one having the scale of 0- 690
150 200 kPa 59 156 kPa
kPa {0-7 kgf/cm2, 0-99.54 lbf/in.2}.
{1.5 2.0 kgf/cm2 {0.6 1.6 kgf/cm2
8.54 22.75 lbf/in.2} (2) Depress the brake pedal till the air pressure reaches 150-200 kPa
21.33 28.44 lbf/in.2}
{1.5-2.0 kgf/cm2, 21.33-28.44 lbf/in.2} and then release the pedal.
Check to see that the oil pressure at that moment is 59-156 kPa
{0.6-1.6 kgf/cm2, 8.54-22.75 lbf/in.2}.
• If the check valve has defects, replace it with a new one (con-
tent of the repair kit).
• If the spring has defects, replace the brake booster assem-
SHTS061060200169
bly.
6. OPERATION AFTER CHECK

(1) Remove the air pressure gauge from the brake valve assembly.
(2) Apply lock agent (LOCTITE 575 or equivalent) on the threaded
portion of the plug.
(3) Install the plug on the brake valve assembly.
Tightening Torque:
20-30 N⋅m {204-305 kgf⋅cm, 15-22 lbf⋅ft}
(4) Remove the oil pressure gauge and install the bleeder screw of
the hydraulic cylinder.
Tightening Torque:
PLUG 7-12 N⋅m {72-122 kgf⋅cm, 5.2-8.8 lbf⋅ft}
SHTS061060200170
7. CHECK OF THE STROKE WARNING SWITCH AND WARNING

BUZZER
(1) Attach a vinyl tube to the bleeder screw of hydraulic cylinder.
(2) Depress the brake pedal and loosen the bleeder screw of hydrau-
lic cylinder to allow the fluid flow out.
NOTICE
Do not have the fluid scattered.
(3) Check to see if the warning lamp lights up and the warning buzzer
beeps.
NOTICE
Warning buzzer beeps only when the parking brake is released.
(4) Attach the bleeder screw of hydraulic cylinder.
SHTS061060200171

EN0610602H300017
NOTICE
components.
Unit: mm {in.}
Power cylinder shell: — — Replace brake Visual check

Rust on inner surface booster assembly,
and deformation. if necessary.
! WARNING
If the cylinder shell has
a deformation in 0.45
mm {0.1772 in.} or more
depth, be sure to
replace it.
Push rod: — — Visual check

Damage on sliding sur-
face, and bend
Return spring: 161.0 {6.34} 154.0 {6.06} Measure

Free length
Return spring: 132.0 {5.19} —

Setting length
Return spring: 78.5 N 58.8 N

Setting load {8.0 kgf, 17.54} {6.0 kgf, 13.22}

(MODELS: FG, GH, FL, FM)
EN06106022600001

DESCRIPTION
EN06106022900001
WITH RELAY VALVE
SHTS061060200175
1 Breather 10 Power piston plug

2 Cylinder shell 11 Hydraulic cylinder
3 Power piston 12 Check valve
4 Push rod 13 End plug
5 Return spring 14 Air bleeder screw
6 X-ring 15 Tilt valve
7 Piston guide 16 Valve plug
8 Casing 17 Relay valve
9 Oil seal cup
WITH ABS CONTROL VALVE
3
4
2
1
15
13
14
12
11
9 10
8
5
6 7
SHTS061060200176
1 ABS control valve 9 Power piston plug

2 Exhaust pipe 10 Hydraulic cylinder
3 Cylinder shell 11 Check valve
4 Power piston 12 End plug
5 Return spring 13 Air bleeder screw
6 X-ring 14 Tilt valve
7 Casing 15 Valve plug
8 Oil seal cup
COMPONENT LOCATOR
EN06106020600001
WITH RELAY VALVE
SHTS061060200177
1 End plug 15 Oil seal cup 29 Power piston ring

2 O-ring 16 Back up ring 30 Power piston
3 Check valve 17 Bushing 31 Power piston seal
4 Valve spring 18 X-ring 32 Stopper and clip ring
5 Air bleeder screw 19 Brake booster stroke switch 33 Cylinder shell
6 Cap 20 Lock plate 34 Breather
7 Valve plug 21 Spring 35 Valve body
8 Tilt valve 22 Plunger 36 Valve
9 Valve spring 23 Spring 37 Retainer
10 Spring seat 24 Seal ring 38 Spacer
11 Retainer ring 25 Piston guide 39 Valve cover
12 Oil connector 26 Exhaust pipe 40 Hydraulic cylinder
13 Power piston plug 27 Cylinder seal 41 Piston
14 Stopper ring 28 Return spring

A 78.5-98.1 {800-1,000, 58-72} E 24.5-29.4 {250-300, 18-21}
B 78.5-98.1 {800-1,000, 58-72} F 24.5-29.4 {250-300, 18-21}
C 6.9-11.8 {70-120, 5.1-8.6} G 24.5-29.4 {250-300, 18-21}
D 78.5-98.1 {800-1,000, 58-72}
WITH ABS CONTROL VALVE
SHTS061060200178
1 End plug 13 Power piston plug 25 Piston guide

2 O-ring 14 Stopper ring 26 Exhaust pipe
3 Check valve 15 Oil seal cup 27 Cylinder seal
4 Valve spring 16 Back up ring 28 Return spring
5 Air bleeder screw 17 Bushing 29 Power piston ring
6 Cap 18 X-ring 30 Power piston
7 Valve plug 19 Brake booster stroke switch 31 Power piston seal
8 Tilt valve 20 Lock plate 32 Stopper and clip ring
9 Valve spring 21 Spring 33 Cylinder shell
10 Spring seat 22 Plunger 34 ABS control valve
11 Retainer ring 23 Spring
12 Oil connector 24 Seal ring

A 78.5-98.1 {800-1,000, 58-72} E 24.5-29.4 {250-300, 18-21}
B 78.5-98.1 {800-1,000, 58-72} F 24.5-29.4 {250-300, 18-21}
C 6.9-11.8 {70-120, 5.1-8.6} G 24.5-29.4 {250-300, 18-21}
D 78.5-98.1 {800-1,000, 58-72}
OVERHAUL
EN06106022300001
1. HYDRAULIC CYLINDER AND CYLINDER SHELL

(1) Loosen the nut, and remove the relay valve or ABS control valve
and O-ring from the brake booster.
SHTS061060200179
(2) Turn the end plug on the oil cylinder and remove it. Then, remove
the check valve and valve spring from inside of the hydraulic cyl-
inder.
SHTS061060200180
(3) Turn the valve plug and remove the valve plug assembly, oil con-
nector and O-ring from the oil cylinder.
SHTS061060200181
(4) Remove the retainer ring from the valve plug assembly. Remove
the tilt valve, valve spring and spring seat from the valve plug.
SHTS061060200182
(5) Remove the bolts, and remove the hydraulic cylinder from the
casing.
SHTS061060200183
(6) Loosen the mounting bolts and nuts of the casing and cylinder
shell, and remove the cylinder shell. Remove the stopper and clip
ring from the cylinder shell.
NOTICE
• Be sure to mark the parts during disassembly so that the
parts can be reassembled in the original positions.
• Carefully disassemble the unit since it contains a high-ten-
sion return spring.
SHTS061060200184
(7) Push down the casing to contract the return spring. After placing a
wrench on the hexagonal part of the power piston, lift the casing
slowly.
(8) Turn the power piston plug, and remove the power piston plug
and O-ring. Push down the casing again, remove the wrench, and
lift the casing slowly. Remove the power piston and return spring
from the casing.
SHTS061060200185
(9) Remove the X-ring from the casing.
SHTS061060200186
(10) Remove the stopper ring, O-ring, oil seal cup, back up ring and
seal ring from the casing.
(11) Remove the exhaust connector and O-ring from the casing. (With
ABS control valve only.)
(12) Remove the power piston ring and power piston seal from the
power piston.
SHTS061060200187
2. STROKE SWITCH
(1) Straighten the lock washer that is bent towards the casing, then
turn the brake booster stroke switch and remove it.
(2) Remove the spring, plunger, holder and spring one by one from
inside of the casing.
SHTS061060200188

NOTICE
Use Variant Grease S-1 (manufactured by showa shell sekiyu)
when grease A is specified. Use Nigroove RX-2 (manufactured by
Nippon Grease) when grease B is specified.
1. HYDRAULIC CYLINDER AND CYLINDER SHELL

(1) Coat the bushing and X-ring of the casing with grease B.
(2) Install the X-ring, bushing and seal ring in the casing.
SHTS061060200186
(3) Apply CCI #20 anti-rust oil (manufactured by CCI) on the oil seal
cup, and install the oil seal cup and backup ring in the casing.
Install the O-ring coated with grease B, then install the stopper
ring.
(4) Install the O-ring and exhaust connector on the casing.
(With ABS control valve only.)
SHTS061060200187
(5) Coat the plunger part of the power piston with grease B. Install the
power piston, return spring and casing. Push down the casing to
contract the return spring. With the tip of the power piston protrud-
ing from the casing, place a wrench on the hexagonal part of the
power piston. Then, lift the casing slowly. Install the O-ring coated
with grease B on the power piston plug, and tighten the power pis-
ton plug.
SHTS061060200189
(6) Apply grease A on the groove around the power piston. Install the
power piston seal coated with grease A and the power piston ring
in the air piston. Coat the periphery of the piston with grease A.
SHTS061060200190
(7) Install the clip ring and stopper on the tip of the stud located on
the bottom surface inside the cylinder shell. Apply grease A on
the inner wall of the cylinder shell. Install the cylinder shell and
cylinder seal in the casing. Tighten the bolts and nut.
SHTS061060200191
(8) Check to make sure that the O-ring is securely installed. Install
the relay valve on the cylinder shell and tighten the nuts with
spring washers.
SHTS061060200192
(9) Install the hydraulic cylinder in the casing and tighten the bolts.
SHTS061060200193
(10) Install the valve spring and check valve in the hydraulic cylinder.
SHTS061060200194
(11) Install the O-ring coated with grease B on the end plug, then
install the end plug on the hydraulic cylinder and tighten it.
SHTS061060200195
(12) Install the O-ring on the air bleed screw, then install the screw-in
cap on the hydraulic cylinder.
SHTS061060200196
(13) Apply a thin coat of grease B on the O-ring, and install it on the
valve plug.
SHTS061060200197
(14) Install the tilt valve, valve spring and spring as shown in figure.
SHTS061060200198
(15) Install the valve plug with the tilt valve, and install the retainer ring
to secure it in position.
SHTS061060200199
(16) Install the oil connector on the valve plug. Install it on the hydrau-
lic cylinder and tighten it.
NOTICE
Install the oil cylinder to casing, and then install the oil connector
and the plug.
SHTS061060200200
2. STROKE SWITCH
(1) As shown in the stroke switch structural diagram, install the
spring, holder, plunger and spring in that order on the boss of the
brake booster stroke switch. Hook the bent section of the lock
washer on the indentation of the boss, mount and tighten the
switch case, then bend the lock washer towards the switch case
to look it in position.
3. OPERATION OF STROKE SWITCH

(1) Remove the stroke detection lever, and mount the stroke switch.
Supply air pressure of 196 kpa {2 kgf/cm2, 28.4 lbf/in.2} to the inlet
of the relay valve to discharge oil gradually from the air bleed
SHTS061060200201
screw. Move the air piston to make sure that the stroking opera-
tion of the stroke switch causes a current flow.
INSPECTION
EN06106022300002
1. HYDRAULIC PISTON CHECK VALVE AND PISTON CUP.

(1) The fluid level of the reservoir should be fallen, when the brake
pedal is depressed.
SHTS061060200202
SHTS061060200203
(2) The fluid level of the reservoir should not come up from the fallen
A B state unless the brake pedal is released.
• A: Normal
• B: Defect
SHTS061060200204
2. POWER PISTON SEALING AND RELAY VALVE.

(1) Depress the brake pedal and remain depressed, then apply
soapy water to the exhaust port of the relay valve.
(2) If the soapy water makes bubbles (air leaking), the power piston
seals and/or relay valve are defective.
SHTS061060200202
SHTS061060200205
AIR BRAKE BOOSTER PERFORMANCE CHARAC-

a TERISTIC
1. THE CHARACTERISTIC IS AS SHOWN FIGURE.

• A: Hydraulic pressure (To Wheel cylinder)
A
• B: Air pressure (From Brake valve)
a b c
Parts No. (MPa {kgf/cm2, (MPa {kgf/cm2, (MPa {kgf/cm2,
b c lbf/in.2}) lbf/in.2}) lbf/in.2})
B
16.7-18.3 13.8-45.7
SHTS061060200206 44640-
{171-186, {0.14-0.46,
3561
2,437-2,654} 1.99-6.63}
16.3-18.3 52.7-84.5
44640-
{166-186, {0.54-0.86,
3571
2,378-2,654} 7.68-12.23}
690 {7.0, 99.54}
16.7-18.3 13.8-45.7
44640-
{171-186, {0.14-0.46,
3581
2,437-2,654} 1.99-6.63}
16.7-18.7 32.7-64.7
44640-
{171-190, {0.33-0.66,
3591
2,437-2,728} 4.77-9.43}
Residual hydraulic pressure:

78-118 kPa {0.8-1.2 kgf/cm2, 11.38-17.11 lbf/in.2}
HINT
The Booster No. is labeled on the cylinder shell.

EN0610602H300018
NOTICE
components.
Cylinder plug (Valve — — Replace, Visual check

contact surface): if necessary.
Corrosion, wear and
damage
Hydraulic cylinder (Inner — — Replace, Visual check

surface): if necessary.
Corrosion, wear and
damage
Hydraulic piston (Outer — — Replace, Measure

surface and valve con- if necessary.
tact surface):
Corrosion, wear and
damage
Power piston (Outer cir- — — Replace, Visual check

cumference): if necessary.
Rust, wear and damage
Power cylinder (Inner — — Replace, Visual check

surface): if necessary.
SPRING BRAKE CONTROL VALVE

EN0610602I200015
Type Variable pressure control type

Outlet pressure difference between parking and releas-
Within 147 kPa {1.5 kgf/cm2, 21.33 lbf/in.2}
ing stroke at a specified lever angle
DESCRIPTION
EN0610602C100015
14
13 PARK
1 3 2 4 5 6 11
12
15
O
36
OFF
7 8 9 10
C A B
SHTS061060200212
1 Body cover 7 Piston spring 13 Grip

2 Feed valve spring 8 Valve seat spring 14 Compression spring
3 Piston 9 Cam 15 Release rod
4 Feed valve 10 Cam holder A Inlet
5 Valve seat 11 Return spring (If so equipped) B Outlet
6 Valve body 12 Pull rod C Exhaust (PARK)
COMPONENT LOCATOR
EN0610602D100014
SHTS061060200213
1 Body cover 10 Valve seat spring 19 Body cap

2 Shim 11 Lock pin 20 Return spring (If so equipped)
3 Piston spring 12 Release rod knob 21 Valve body
4 Feed valve spring 13 Grip 22 Cam holder
5 Retainer ring 14 Pull rod 23 Body pin
6 O-ring 15 Supporter 24 Cam holder pin
7 Piston 16 Cover 25 Cam
8 Feed valve 17 Stopper 26 Piston guide
9 Valve seat 18 Compression spring

A 5.4-7.4 {55-75, 4.0-5.4} B 3.4-4.9 {35-50, 2.6-3.6}
OVERHAUL
EN0610602H200011

a
1. LUBRICATION
(1) When assembling the spring brake control valve, replace the feed
valve, valve seats and O-rings.
(2) Apply silicone grease to each sliding surface of the assembly
parts, O-rings and O-ring grooves.
a. O-ring
b. Feed valve
c. Piston
b c d e f
d. Valve seat
SHTS061060200214
e. Cam
f. Cam holder
2. ASSEMBLE THE CAM ASSEMBLY.

(1) When assembling the cam and cam holder, make sure that the
cam holder pin and spiral groove of the cam are aligned.
(2) When installing the cam assembly to the valve body, the valve
body pin and straight groove of the cam must be aligned.
SHTS061060200215
(3) Adjust dimension "A" with the shim.

a Assembly standard: 33.8-34.2 mm {1.331-1.346 in.}
a. Cam
A b. Cam holder
c. Shim
b c
SHTS061060200216
3. SPRING BRAKE CONTROL VALVE PERFORMANCE TEST

SPRING BRAKE (1) First, connect the pressure gauge to the outlet line and apply an
AIR
CONTROL VALVE
PRESSURE air pressure of 834 kPa {8.5 kgf/cm2, 121 lbf/in.2} to the inlet line.
GAUGE
TANK
SHTS061060200217
(2) Move the spring brake control lever towards the OFF position,
gradually and confirm that the air pressure in the outlet line meets
the characteristic shown in figure.
Standard:
Lever angle: Outlet pressure: kPa {kgf/cm2, lbf/in.2}
6-12° 19.6-49 {0.2-0.5, 2.85-7.11}
Over 31° 686 {7.0, 99.54}
NOTICE
The characteristic shown is under the inlet pressure of 834 kPa
{8.5 kgf/cm2, 121 lbf/in.2}
SHTS061060200218
SHTS061060200219

EN0610602H300019
Unit: mm {in.}
Piston and valve body: — — Replace, Visual check

Cam, pin and cam — — Replace, Visual check

holder: if necessary.
Wear and damage
Piston spring: Free Length 25.0 Replace, Measure and visual check
Rust, damage and mea- 27.9 {1.098} {0.984} if necessary.
sure the spring free
length
Feed valve spring and — — Replace, Visual check

valve seat spring: if necessary.
Rust and damage
RELAY VALVE (FOR SPRING BRAKE CHAMBER)

EN0610602I200016
Type Diaphragm type

Pressure difference between signal and outlet pressure Less than 29 kPa {0.3 kgf/cm2, 4.26 lbf/in.2}
DESCRIPTION
EN0610602C100016
1
4
A
5
B
6
7 3
SHTS061060200224
1 Cover 6 Feed valve

2 Body 7 Return spring
3 Cap A Signal air
4 Diaphragm B Inlet air
5 Exhaust valve C Exhaust
COMPONENT LOCATOR
EN0610602D100015
SHTS061060200225
1 Cover 8 Filter
2 Retainer ring 9 Dust cover
3 Washer 10 Body
4 Diaphragm 11 Feed valve
5 Shim 12 Return spring
6 O-ring 13 Gasket
7 Exhaust valve 14 Cap

A 11.8-14.7 {120-150, 9-10} B 58.8-78.4 {600-799, 44-57}
OVERHAUL
EN0610602H200012

NOTICE
Before disassembling the relay valve, apply the aligning mark A to
the cover and body.
SHTS061060200226
1. LUBRICATION
O-RING
(1) When reassembling the relay valve, replace the O-rings, dia-
GROOVE
phragm, gasket and feed valve with new ones.
O-RING (2) Apply adequate amount of the silicone grease to the O-rings,
grease groove and sliding surfaces of the component parts.
(3) When installing the cover to the body, align the aligning marks
O-RING
GROOVE which were applied at disassembly.
SHTS061060200227

EN0610602H300020
Sliding surfaces and — — Replace, Visual check

valve contact surfaces if necessary.
of exhaust valve:
Wear and damage
Valve Body, — — Replace, Visual check

Sliding surfaces 1 and if necessary.
valve contact surfaces
2:
Wear and damage
1
Cap, — — Replace,
Sliding surfaces 3: if necessary.
1
Wear and damage
3
RELAY VALVE (FOR WABCO ABS)

EN0610602I200017
Type Piston type
DESCRIPTION
EN0610602C100017
SHTS061060200230
1 Cover 7 Check valve

2 Piston A Signal (From brake valve)
3 Spring B Inlet (From air tank)
4 Feed valve C Outlet (To ABS control valve)
5 Body valve D Exhaust
6 Dust seal
COMPONENT LOCATOR
EN0610602D100016
SHTS061060200231
1 Cover 8 Ring
2 O-ring 9 Washer
3 Piston 10 Dust seal
4 Spring 11 Valve body
5 Retainer ring 12 Check valve
6 Body valve 13 Connector
7 Feed valve 14 Pipe

A 5.9-7.4 {60-75, 4.4-5.4}
OVERHAUL
EN0610602H200013

NOTICE
Before disassembling the relay valve, apply the aligning mark to
1. LUBRICATION
(1) When reassembling the relay valve, replace the O-rings and feed
valve with new ones
(2) Apply adequate amount of the valiant grease S-1 (manufactured
by Showa Shell Sekiyu) or equivalent to the O-rings, grease
groove and sliding surfaces of the component parts.
1. O-ring
2. Sliding surface
SHTS061060200232
which were applied at disassembly.

EN0610602H300021
Sliding surfaces and valve — — Replace, Visual check

contact surfaces of feed if necessary.
valve 1:
Wear and damage
Piston, valve body, slid-

ing surfaces 2:
Wear and damage
RELAY VALVE (FOR TRAILER BRAKE)

EN0610602I200018
Type Diaphragm type with double check valve combined

Pressure difference between signal and outlet pressure 29.4 kPa {0.3 kgf/cm2, 4.26 lbf/in2.}
DESCRIPTION
EN0610602C100018
SHTS061060200234
1 Cover 8 Filter
2 Diaphragm 9 Valve
3 Valve body 10 Plug
4 Valve sub assembly A Signal
5 Valve cap B Outlet
6 Spring C Exhaust
7 Valve D Inlet
COMPONENT LOCATOR
EN0610602D100017
SHTS061060200235
1 Valve sub assembly 7 Filter

2 Cover 8 Valve body
3 Guide 9 Valve
4 Valve 10 O-ring
5 Gasket 11 Spring
6 Plug 12 Valve cap

A 11.8-14.7 {120-150, 9-10} C 58.8-78.4 {600-800, 44-57}
B 34.3-44.1 {350-450, 26-32}
OVERHAUL
EN0610602H200014

NOTICE
Before disassembling the relay valve, mark the aligning marks "A"
on the cover and valve body.
SHTS061060200236
1. LUBRICATION
(1) When assembling the relay valve, use new O-rings and valves.
(2) Apply the silicone grease to each sliding surface of the compo-
A: O-ring
B: Apply the silicone grease
SHTS061060200237

EN0610602H300022
Check valve: — — Replace, Visual check

Cover, guide and plug: — — Clean or Visual check

Damage, wear and rust Replace,
if necessary.
Spring: — — Replace, Visual check

Rust and damage if necessary.
Relay valve body and cap — — Clean or Visual check

sliding surface: Replace,
Damage, wear and rust if necessary.
SPRING BRAKE CHAMBER

EN0610602I200019
Type Diaphragm type
DESCRIPTION
EN0610602C100019
SHTS061060200242
1 Push rod 6 Clamp

2 Guide 7 Diaphragm
3 Dust boot 8 Pressure plate
4 Return spring A Inlet
5 Chamber B Drain hole
COMPONENT LOCATOR
EN0610602D100018
11
4 10
9
8
7
B
3
16
5
2
1
C
A 15
14
Z 13
12
SHTS061060200243
1 Pressure plate 9 Return spring

2 Clamp nut 10 Spring seat
3 Clamp bolt 11 Guide
4 Clamp 12 Chamber
5 Spacer 13 Boot retainer
6 Diaphragm 14 Rod holder
7 Push rod 15 Dust boot
8 Spring holder 16 Clevis

A 26.5-32.3 {270-330, 20-23} C 50-68 {510-693, 37-50}
B 50-68 {510-693, 37-50}
OVERHAUL
EN0610602H200015

A
1. DISMOUNTING OF THE SPRING BRAKE CHAMBER
(1) Before dismounting, apply an aligning mark A to chamber, clamp
and chamber cover.
(2) Apply a position mark R or L to make clear the side where the
chamber was installed.
SHTS061060200244
1. ASSEMBLING THE SPRING BRAKE CHAMBER

(1) Replace the diaphragm with new one.
(2) Coincide the aligning mark A of the chamber, clamp and chamber
cover.
(3) Insert the bolt from opposite side of drain hole and tighten the
bolts evenly with nut within specified torque.
SHTS061060200245
2. CHECKING FOR AIR LEAKAGE

(1) Apply soapy water for joint part of chamber and charge the com-
pressed air of 835 kPa {8.5 kgf/cm2, 121 lbf/in.2} from the inlet
port then check the leakage.
SHTS061060200246
3. INSTALLATION OF CLEVIS.
(1) Install the clevis to the push rod and adjust the dimension A for
A specified value.
Assembly standard: A
273.5 mm {10.768 in.}

The chamber should be installed for former side.
NOTICE
See the position mark (R or L) which was applied at dismounting.
SHTS061060200247

EN0610602H300023
Cover, clamp, push rod, — — Replace, Visual check

compression spring, if necessary. Z
retainer, dust seal, holder
and Chamber:
Wear and damage
Z
TRAILER HAND BRAKE CONTROL VALVE (MODEL: FM2P)

EN0610602I200020
DESCRIPTION
EN0610602C100020
SHTS061060200249
1 Cam 7 Feed valve 13 Steel ball

2 Spring 8 Piston 14 Holder
3 Handle 9 Inner spring A Inlet
4 Shim 10 Cover B Outlet
5 Conical spring 11 Outlet spring C Exhaust
6 Valve body 12 Exhaust valve
COMPONENT LOCATOR
EN0610602D100019
SHTS061060200250
1 Valve body 8 Cam 15 Retainer ring

2 O-ring 9 Holder 16 Valve seat
3 Exhaust valve 10 Spring 17 Feed valve
4 Conical spring 11 Cover 18 Piston
5 Spring seat 12 Pin 19 Inner spring
6 Shim 13 Handle 20 Outer spring
7 Steel ball 14 Connector

A 9.9-19.6 {100-200, 8-14} C 2.5-3.9 {25-40, 1.9-2.8}
B 5.4-7.3 {55-75, 4.0-5.4}
OVERHAUL
EN0610602H200016

NOTICE
Before disassembling the hand brake valve, mark the aligning
mark "A" on the holder and valve body.
SHTS061060200251
1. LUBRICATION
(1) When assembling the hand brake valve, use new O-ring and feed
valve.
(2) Apply silicone grease to each sliding surface of the component
parts and O-ring groove.
a. O-ring
b. Contact of steel ball
c. Sliding surface
(3) Align the aligning mark of the holder and valve body.
SHTS061060200252
IMPORTANT POINTS - ADJUSTMENT
1. EXHAUST VALVE FITTING HEIGHT

(1) Measure the exhaust valve fitting height "L" and adjust it.
! WARNING
Adjust this dimension with shims.
L: 38.3-38.7 mm {1.508-1.523 in.}
SHTS061060200253
2. HAND BRAKE VALVE PERFORMANCE CHARACTERISTIC

a. Air pressure at outlet port (kPa {kgf/cm2, lbf/in2})
b. Handle turning angle (°)
(a1) (a2)
a 19.6-68.6 460.6-558.6
{0.2-0.7, 2.8-9.9} {4.7-5.7, 66.8-81.0}
(b1) (b2)
b
7-13 37-43
NOTICE
SHTS061060200254 The characteristic shown in both diagrams are for inlet air pres-
sure of 690 kPa {7.0 kgf/cm2, 99.54 lbf/in2.}
The characteristic can be adjusted by changing the shim thick-
ness of the steel ball and of the outer spring.

EN0610602H300024
Unit: mm {in.}
Sliding surface of — — Replace, Visual check

exhaust valve: if necessary.
Wear and damage
Spring: 1. 28.5 {1.122} 27 {1.063} Replace, Measure and visual check

Rust and damage 35 {1.377} if necessary.
2. 38 {1.496}
Measure the spring 29 {1.142}
dimension. 3. 31 {1.220}
Piston and valve seat: — — Replace, Visual check

Cam and steel ball: — — Replace, Visual check

Valve body: — — Replace, Visual check

WHEEL BRAKE (MODELS: FC, FD)

EN0610602I200021
Drum brake with hydraulically actuated, internally

Type expanding, two-leading shoes in front wheels and dual
two-leading shoes in rear wheels.
Brake drum inside diameter 320.0 mm {12.59 in.} for both front and rear.
Brake lining Front 110 x 13 mm {4.33 x 0.51 in.}
(Width x Thickness) Rear 145 x 13 mm {5.71 x 0.51 in.}
Front 36.51 mm {1.437 in.}
Wheel cylinder bore diameter
Rear 38.10 mm {1.50 in.}
DESCRIPTION
EN0610602C100021
FRONT
SHTS061060200260
1 Brake shoe 10 Air bleeder screw

2 Brake lining 11 Bleeder cap
3 Wheel cylinder assembly 12 Backing plate
4 Shoe adjusting bolt 13 Hole plug
5 Boot 14 Shoe hold down washer
6 Piston 15 Shoe hold down nut
7 Piston cup 16 Retracting spring
8 Cylinder 17 Wheel sensor (If so equipped)
9 Adjuster lock spring A Front
REAR
SHTS061060200261
1 Wheel cylinder assembly 11 Piston cup

2 Brake shoe 12 Cylinder
3 Brake lining 13 Piston
4 Hole plug 14 Adjuster lock spring
5 Shoe adjusting screw 15 Adjusting bolt
6 Shoe retracting spring 16 Air bleeder screw
7 Shoe hold down nut 17 Bleeder cap
8 Shoe hold down washer 18 Wheel sensor (If so equipped)
9 Backing plate A Front
10 Boot
SPECIAL TOOL
EN0610602K100003
Prior to starting a wheel brake overhaul, it is necessary to have these special tools.
HOOK
S0965-31100
(USE WITH S0968-31010)
RETRACTING SPRING PULL

S0968-31010
BACK TOOL
BRAKE SHOE ADJUSTING

S0965-51250
TOOL
COMPONENT LOCATOR
EN0610602D100020
FRONT
SHTS061060200265
1 Oil pipe 14 Air bleeder screw

2 Hole plug 15 Bleeder cap
3 Backing plate 16 Adjust spring
4 Wheel cylinder assembly 17 Adjusting nut
5 Shoe retracting spring 18 Rivet
6 Spring cover 19 Brake lining
7 Adjuster lock spring 20 Brake shoe
8 Shoe adjusting bolt 21 Shoe hold down washer
9 Piston 22 Shoe hold down nut
10 Back-up ring 23 Cotter pin
11 Piston cup 24 Wheel sensor (If so equipped)
12 Boot 25 Clamping bushing (If so equipped)
13 Cylinder 26 Wheel sensor holder (If so equipped)

A 148-196 {1,500-2,000, 109-144} D 88.8-120.1 {905-1,225, 66-88}
B 12.7-17.7 {130-180, 10-13} E 7.5-11.5 {70-120, 5.1-8.6}
C 16.7-24.5 {170-250, 13-18} F 33.8-50.0 {350-510, 25-37}
REAR
SHTS061060200266
1 Oil pipe 14 Shoe retracting spring

2 Grommet 15 Shoe adjusting bolt
3 Hole plug 16 Piston
4 Backing plate 17 Back-up ring
5 Wheel cylinder assembly 18 Piston cup
6 Adjust spring 19 Boot
7 Adjusting nut 20 Cylinder
8 Rivet 21 Adjusting lock spring
9 Brake lining 22 Wheel sensor (If so equipped)
10 Brake shoe 23 Clamping busing (If so equipped)
11 Shoe hold down washer 24 Wheel sensor holder (If so equipped)
12 Shoe hold down nut 25 Clip
13 Cotter pin

A 148-196 {1,500-2,000, 109-144} D 34.5-51.5 {350-520, 25-38}
B 12.7-17.7 {130-180, 9.4-13} E 1.3-1.9 {13-19, 1.0-1.4}
C 98.1-137.3 {1,000-1,400, 73-101}
OVERHAUL
EN0610602H200017
1. REMOVE THE TIRE.

(1) Refer to the chapter "WHEEL & TIRE".
2. REMOVE THE BRAKE DRUM.

NOTICE
(In case of models equipped with ABS;)
SOCKET WRENCH When mounting or dismounting the brake drum without removing
the sensor ring, be careful not to damage the sensor ring by tools.
If tools hit the sensor ring and damage it, ABS operation may be
deteriorated.
ABS SENSOR RING
SHTS061060200267
3. REMOVE THE BRAKE SHOE RETRACTING SPRING.

(1) Remove the retracting spring by using the special tools.
SST:
Hook (S0965-31100)
Retracting spring pull back tool (S0968-31010)
SHTS061060200268
1. REPLACE THE BRAKE LINING.

(1) Drill the rivet caulking section with a drill smaller than the rivet
diameter.
NOTICE
At this time, be careful not to scratch the brake shoe.
SHTS061060200269
(2) After drilling, remove the remaining portion of the rivet with a fine
chisel or a riveting machine.
SHTS061060200270
(3) Set the lining with shoe and insert the rivets into all holes, then
hold them in place with adhesive tape A.
SHTS061060200271
(4) Caulk the rivets lightly in a circular pattern as shown B; repeat

several times to assure proper seating of the lining.
Recommended configuration of punch: Shown in C.
Recommended force of staking the Rivet: 2.4 tons
(5) Remove adhesive tape.
SHTS061060200272
2. ASSEMBLE THE WHEEL CYLINDER.

(1) Apply rustproof oil to the internal surface of the cylinder.
Rustproof oil (CCI NO.20): 04156-1010
(2) Apply rubber grease to the threads of adjusting bolt, inside of

boot, groove for boot, sliding surface of piston.
Rubber grease (RX-2): 04133-1080
NOTICE
The parts where the rubber grease shall be applied are shown in
SHTS061060200274
figure with arrows and oblique lines.
SHTS061060200273
(3) Be sure to install the back up ring with the chamfered face of the
ring a way of the cup.
SHTS061060200275
3. INSTALL THE BRAKE SHOE ASSEMBLY.

(1) Apply heat-resistant grease to both ends of the shoe web contact-
ing with the piston, and to the top surface of the shoe web con-
tacting the shoe hold washer.
SHTS061060200276
(2) Adjust the clearance between the hold down washer and the
shoe.
(3) Tighten the slotted nut and back off the nut by 1/3 turn, then
secure the nut with the cotter pin.
If the cotter pin cannot be inserted into the hole, loosen the slotted
nut (within 1/6 turn) to align it with the bolt hole.
SHTS061060200277
4. INSTALL THE BRAKE SHOE RETRACTING SPRING.

(1) Install the retracting spring using a screwdriver. After installing the
spring, check that the end of the shoe web is securely set in the
groove of the wheel cylinder piston. Also check that the hook of
the spring is securely hooked in the hole of the shoe.
SHTS061060200278
5. INSTALL THE WHEEL SENSOR.

(If so equipped)
(1) Push in the clamping bushing until the stopper makes contact with
the wheel sensor holder.
(2) Push the wheel sensor forcefully into the clamping bussing until
you feel that the wheel sensor has contact with the sensor ring.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer
or attempt to pry it into place using a screwdriver, or the like.
Doing so could damage the wheel sensor.
(3) Arrange the wire harness.
SHTS061060200279
6. ASSEMBLE THE BRAKE DRUM AND WHEEL HUB.

(FRONT WHEEL)
(1) See the mark located at 1 or 1' on the brake drum as shown in
Figure. Install the drum according to NOTICE.
NOTICE
1. The drums. Number with R or L.
With R: Install in right side.
With L: Install in left side.
2. The drums, with no R or L.
New drums: Install in any side.
Reused drums: Install in the side originally installed.
SHTS061060200280
(2) When assembling the brake drum and wheel hub, make sure that
their aligning marks are aligned as close to each other as possi-
ble.
NOTICE
Position of marks are located at 2. as shown in the figure. (Broken
line shows alternative position).
(3) Caulk the hub and nuts as shown in figure, after tightening the
brake drum and wheel hub.
Tightening Torque:
393-470 N⋅m {4,000-4,800 kgf⋅cm, 290-347 lbf⋅ft}
7. MOUNT THE WHEEL HUB WITH BRAKE DRUM.

(1) Refer to the chapter "FRONT AXLE" and "REAR AXLE".
8. MOUNT THE TIRE.

SHTS061060200281
ADJUSTMENT
EN0610602H300025
1. REMAINING THICKNESS OF THE BRAKE LINING

(1) Check remaining thickness of lining through the inspection hole of
the backing plate. If the lining has been worn to the limit marking
or if it is foreseen that the lining will be worn to the limit by the time
the next inspection is made replace the lining.
SHTS061060200282
2. AIR PRESSURE IN THE AIR TANK

(1) Operate the engine and obtain an air pressure of the 780-880 kPa
{8.0-9.0 kgf/cm2, 113-127 lbf/in.2}
NOTICE
The specified air pressure in the air tank should be maintained
when making the adjustment.
SHTS061060200283
3. CLEARANCE BETWEEN BRAKE LINING AND BRAKE DRUM

(1) Lift the wheel to be adjusted off the ground.
(2) While turning the wheel in the forward direction and step on the
brake pedal several times to make sure that the brake shoes are
correctly positioned.
SHTS061060200284
(3) Turn the adjusting screw with an adjusting tool in the arrow direc-
tion, (The arrows are marked near the holes on the backing
plate), and put the drum into a position as to turn slowly by hand.
SST: Brake shoe adjusting tool (S0966-51250)
SHTS061060200285
(4) Return the adjusting screw 5-7 notches in the reverse arrow direc-
tion.
SHTS061060200286
(5) While turning the wheel by hand in the forward direction, step on
the brake pedal several times to make sure that the brake shoes
are correctly positioned.
(6) See to it that there is no dragging, when turning the wheel by
hand. If there is any dragging, repeat the operation over again
from (2).
NOTICE
Using the same procedure as above, adjust the clearance for all
wheels.
SHTS061060200287

EN0610602H300026
NOTICE
wheel cylinder component.
Unit: mm {in.}
Brake drum inner surface: — — Regrind or Visual check

Crack, scoring and/or any replace,
other damage if necessary.
Brake drum inner diameter 320.0 322.0 Replace. Measure

{12.600} {12.677}
Brake drum runout 0-0.1 0.2 Regrind or Measure

{0-0.0039} {0.0079} replace.
Brake shoe with lining: — — Re-lining or Visual check

Crack, wear deformation replace,
and/or any other damages if necessary.
Remaining thickness of 13.0 4.0 Re-lining. Measure

brake lining {0.512} {0.1575}
Brake shoe retracting — — Replace, Visual check

spring: if necessary.
Elastic strength distortion
and/or any damage
Wheel cylinder and piston: — — Clean or Visual check

Corrosion and/or any dam- replace,
age if necessary.
Clearance between piston Front 0.25 Replace. Measure

and wheel cylinder 0.03-0.13 {0.0098}
{0.0012-0.0051}
Rear
0.08-0.18
{0.0032-0.0070}
Backing plate and stud — — Replace, Visual check

pins: if necessary.
Deformation, damage and
any other abnormality
WHEEL BRAKE
(MODELS: GD, THAILAND FG, INDONESIA FG)
EN0610602I200022

Type expanding, two-leading shoes in front wheels and dual
two-leading shoes in rear wheels.
Brake drum inside diameter 400 mm {15.75 in.} for both front and rear.
Front 34.93 mm {1.375 in.}
Rear 38.10 mm {1.50 in.}
DESCRIPTION
EN0610602C100022
FRONT
SHTS061060200297
1 Hole plug 11 Wheel sensor (If so equipped)

2 Backing plate 12 Air bleeder screw
3 Brake lining 13 Bleeder cap
4 Brake shoe 14 Boot
5 Shoe adjusting screw 15 Wheel cylinder
6 Wheel cylinder assembly 16 Back up ring
7 Shoe retracting spring 17 Piston cup
8 Shoe hold down washer 18 Piston
9 Shoe hold down nut 19 Adjusting bolt
10 Adjuster lock spring A Forward turning
REAR
SHTS061060200298
1 Hole plug 12 Piston

2 Backing plate 13 Boot
3 Wheel sensor (If so equipped) 14 Back up ring
4 Brake lining 15 Piston cup
5 Brake shoe 16 Plunger
6 Wheel cylinder assembly 17 Adjusting bolt
7 Shoe retracting spring 18 Roller
8 Shoe hold down washer 19 Cage
9 Shoe hold down nut 20 Wedge cover
10 Adjuster lock spring 21 Wedge
11 Wheel cylinder 22 Rod
SPECIAL TOOL
EN0610602K100004

S0960-61040
BACK TOOL
BRAKE SHOE ADJUSTING

S0966-51130
TOOL
COMPONENT LOCATOR
EN0610602D100021
FRONT
SHTS061060200301
1 Oil pipe 9 Wheel sensor (If so equipped) 17 Back up ring

2 Hole plug 10 Wheel sensor holder (If so 18 Piston cup
equipped)
3 Backing plate 11 Shoe retracting spring 19 Boot
4 Adjusting bolt 12 Shoe hold down washer 20 Shoe adjusting lever
5 Wheel cylinder assembly 13 Shoe hold down nut 21 Wheel cylinder
6 Rivet 14 Cotter pin 22 Air bleeder screw
7 Brake lining 15 Adjusting bolt 23 Bleeder cap
8 Brake shoe 16 Wheel cylinder adjuster

A 12.75-17.65 {130-180, 10-13} E 25.50-36.28 {260-370, 19-26}
B φ14 bolt: 122.58-166.71 {1,250-1,700, 91-122} F 13.73-22.56 {141-229, 11-16}
C φ10 bolt: 37.27-49.03 {380-500, 28-36} G 7.5-11.5 {76-117, 5.5-8.4}
D 148-196 {1,500-2,000, 109-144}
REAR
SHTS061060200302
1 Spring brake chamber 12 Shoe hold down washer 23 Cage

2 Oil pipe 13 Shoe hold down nut 24 Wedge cover
3 Hole plug 14 Cotter pin 25 Spring
4 Backing plate 15 Wheel cylinder assembly 26 Cylinder
5 Wheel sensor (If so equipped) 16 Shoe retracting spring 27 Air bleeder screw
6 Wheel sensor holder (If so 17 Boot 28 Plunger
equipped)
7 Wheel cylinder assembly 18 Piston 29 Back up ring
8 Adjusting bolt 19 Rod 30 Piston cup
9 Brake lining 20 Pin 31 Adjusting bolt
10 Rivet 21 Wedge 32 Clamping bushing
11 Brake shoe 22 Roller

A 109-147 {1,110-1,500, 81-108} E 34.5-51.5 {350-525, 25-37}
B 148-196 {1,500-2,000, 109-144} F 25.50-36.28 {260-370, 19-26}
C 12.75-17.65 {130-180, 10-13} G 148-196 {1,500-2,000, 109-144}
D φ16 bolt: 186.33-254.97 {1,900-2,600, 137-188} H 7.5-11.5 {76-117, 5.5-8.4}
φ14 bolt: 122.58-166.71 {1,250-1,700, 91-122}
φ12 bolt: 79.43-107.87 {810-1,100, 58-79}
OVERHAUL
EN0610602H200018
1. REMOVAL OF TIRE.
2. REMOVAL OF BRAKE DRUM WITH WHEEL HUB AND WHEEL

HUB BEARINGS.
SOCKET WRENCH NOTICE
(In case of models equipped with ABS;)
When mounting or dismounting the brake drum without removing
the sensor ring, be careful not to damage the sensor ring by tools.
ABS SENSOR RING
deteriorated.
SHTS061060200303
3. REMOVAL OF BRAKE SHOE RETRACTING SPRING.

SST: Retracting spring pull back tool (S0960-61040)
SHTS061060200304
1. REPLACEMENT OF THE BRAKE LINING.

diameter.
NOTICE
SHTS061060200305
SHTS061060200306
SHTS061060200307

SHTS061060200308
2. ASSEMBLY OF THE WHEEL CYLINDER.

Rustproof oil (CCI No. 20):

04156-1010
(2) Apply rubber grease to the threads of adjusting bolt, inside of

boot, groove for boot, sliding surface of piston.
Rubber grease (RX-2):

04133-1080
SHTS061060200309
NOTICE
figure with oblique lines.
SHTS061060200310
SHTS061060200311
NOTICE
When assembling the rear wheel cylinder with wedge, pay atten-
tion to following items.
• Install the piston so that the taper of the groove of the sliding
part of the roller is positioned to expand the piston when the
push rod operates (is pulled).
• At this time, confirm that the notch comes to the side of the
push rod at the time of piston installation.
• In case of wrong installation, it is feared that in the worst
case the parking brake will not be effective.
SHTS061060200312
SHTS061060200313
3. INSTALLATION OF BRAKE SHOE ASSEMBLY.

(1) Apply heat-resistant grease to both ends of the shoe web contact-
ing with the piston, and to the top surface of the shoe web con-
tacting the shoe hold washer.
SHTS061060200314
(2) Adjust the clearance between the hold down washer and the
shoe.
Tighten the slotted nut and back off the nut by 1/3 turn.
Then secure the nut with the cotter pin.
If the cotter pin cannot be inserted into the hole, loosen the slotted
nut (within 1/6 turn) to align it with the bolt hole.
SHTS061060200315
4. INSTALLATION OF BRAKE SHOE RETRACTING SPRING.

(1) Install the retracting spring using a screwdriver. After installing the
spring, check that the end of the shoe web is securely set in the
groove of the wheel cylinder piston. Also check that the hook of
the spring is securely hooked in the hole of the shoe.
SHTS061060200316
5. ASSEMBLY OF THE BRAKE DRUM AND WHEEL HUB.

(FRONT WHEEL)
Figure. Install the drum according to NOTE.
NOTICE
SHTS061060200317
ble.
NOTICE
Tightening Torque:
393-470 N⋅m {4,000-4,800 kgf⋅cm, 290-347 lbf⋅ft}
6. MOUNTING OF WHEEL HUB WITH BRAKE DRUM.

7. MOUNTING OF TIRE.
SHTS061060200318
8. ADJUSTMENT.
(1) Finally, adjust the clearance between the brake lining and the
brake drum as explained in the section "ADJUSTMENT".
ADJUSTMENT
EN0610602H300027
1. REMAINING THICKNESS OF THE BRAKE LINING.

the next inspection is made replace the lining.
SHTS061060200319
2. AIR PRESSURE IN THE AIR TANK.

{8.0-9.0 kgf/cm2, 114-128 lbf/in.2}
NOTICE
SHTS061060200320
3. CLEARANCE BETWEEN BRAKE LINING AND BRAKE DRUM.

NOTICE
When adjusting the clearance between brake lining and brake
drum, set spring brake control valve to the OFF position.
SHTS061060200321
(3) Adjust the clearance between brake lining and brake drum.
1. Turn the adjusting screw with an adjusting tool in the arrow direc-
tion (The arrows are marked near the holes on the backing plate),
and put the drum into a position as to turn slowly by hand.
SST: Brake shoe adjusting tool (S0966-51130)
SHTS061060200322
2. Return the adjusting screw 5-7 notches in the reverse arrow direc-
tion.
SHTS061060200323
from (2).
NOTICE
wheels.
SHTS061060200324

EN0610602H300028
NOTICE
Unit: mm {in.}

Brake drum inner diameter 400 403 Replace. Measure

{15.748} {15.866}

{0-0.0039} {0.0079} replace.


brake lining {0.590} {0.197}

and/or any damage

age if necessary.
Clearance between piston 0.03-0.13 0.25 Replace Measure

and wheel cylinder {0.0012-0.0051} {0.0098}
Backing plate and stud — — Replace, Visual check

pins: if necessary.
Deformation, damage and
any other abnormality
WHEEL BRAKE (MODELS: TAIWAN FG, GH)

EN0610602I200023

Type
expanding, leading-trailing shoes in all wheels.
Brake lining Front 127 x 15.5 mm {5 x 0.61 in.}
(Width x Thickness) Rear 203 x 15.5 mm {8 x 0.61 in.}
Front 50.8 mm {2.000 in.}
Rear 58.7 mm {2.311 in.}
DESCRIPTION
EN0610602C100023
FRONT
SHTS061060200334
1 Drum cover 10 Piston cup 19 Brake spider

2 Brake drum 11 Spring 20 Anchor pin
3 Wheel cylinder assembly 12 Air bleeder screw 21 Lock plate
4 Push rod 13 Cap 22 Retainer
5 Cylinder cover 14 Retracting spring 23 Wheel sensor (If so equipped)
6 Boot 15 Brake lining A Forward turning of the drum
7 Cylinder 16 Brake shoe B To move the shoe outward
8 Piston 17 Holder
9 Back up ring 18 Adjusting cam
REAR
SHTS061060200335
1 Drum cover 11 Spring 21 Bleeder cap

2 Brake drum 12 Retracting spring 22 Air bleeder
3 Wheel cylinder assembly 13 Brake lining 23 Wheel sensor (If so equipped)
4 Push rod 14 Brake shoe A Top
5 Cylinder cover 15 Holder B Forward turning of the drum
6 Boot 16 Adjusting cam C Front (Forward)
7 Cylinder 17 Brake spider D To move the shoe outward
8 Piston 18 Anchor pin
9 Back up ring 19 Lock plate
10 Piston cup 20 Retainer
SPECIAL TOOL
EN0610602K100005
S0968-31070 SPRING PULL BACK TOOL
S0942-01510 ANCHOR PIN PULLER
S0968-41010 ANCHOR PIN TOOL
S0965-71330 GUIDE
COMPONENT LOCATOR
EN0610602D100022
FRONT
SHTS061060200340
1 Hole plug 12 Wheel cylinder assembly 23 Retainer

2 Drum cover 13 Boot 24 Lock plate
3 Pin 14 Cylinder 25 Retracting spring
4 Collar 15 Push rod 26 Cover
5 Spring 16 Piston 27 Brake shoe assembly
6 Boot 17 Back up ring 28 Brake lining
7 Washer 18 Piston cup 29 Rivet
8 Brake spider 19 Spring 30 Bushing
9 Adjusting cam 20 Air bleeder screw 31 Brake shoe
10 Joint bolt 21 Cap 32 Brake drum
11 Cylinder cover 22 Anchor pin 33 Wheel sensor (If so equipped)

A 168-226 {1,700-2,300, 123-166} E 34.5-51.5 {350-527, 26-38}
B 61-91 {621-930, 45-67} F 13-19 {120-200, 9-14}
C 44-60 {450-610, 33-45} G 18-26 {180-270, 13-19}
D 34.5-51.5 {350-527, 26-38}
REAR
SHTS061060200341
1 Hole plug 14 Push rod 27 Brake lining

2 Drum cover 15 Piston 28 Rivet
3 Pin 16 Back up ring 29 Cotter pin
4 Collar 17 Piston cup 30 Brake shoe
5 Spring 18 Spring 31 Bushing
6 Boot 19 Air bleeder screw 32 Brake drum
7 Washer 20 Cap 33 Wheel sensor (If so equipped)
8 Brake spider 21 Anchor pin 34 Bushing (If so equipped)
9 Adjusting cam 22 Retainer 35 Clamping bushing (If so
equipped)
10 Cylinder cover 23 Lock plate 36 Lock plate (If so equipped)
11 Wheel cylinder assembly 24 Brake shoe assembly 37 Wheel sensor holder (If so
equipped)
12 Boot 25 Retracting spring
13 Cylinder 26 Spring cover

A 34.5-51.5 {350-527, 26-38} E 13-19 {120-200, 9-14}
B 99-147 {1,000-1,500, 73-108} F 34.5-51.5 {350-527, 26-38}
C 34.5-51.5 {350-527, 26-38} G 18-26 {180-270, 13-19}
D 168-226 {1,700-2,300, 123-166}
OVERHAUL
EN0610602H200019
1. REMOVE THE TIRE.

2. REMOVE THE BRAKE DRUM WITH WHEEL HUB AND WHEEL

HUB BEARINGS.
SOCKET WRENCH NOTICE
(If so equipped)
When mounting or dismounting the brake drum without removing
the sensor ring, pay attention not to damage the sensor ring by
tools.
ABS SENSOR RING
deteriorated.
SHTS061060200342
3. RETRACTING SPRING.
(1) Using the special tool, remove the brake shoe retracting
spring.(Front wheel and rear wheel)
SST: Pull back spring tool (S0968-31070)
SHTS061060200343
(2) Pull out the pin, and then remove the brake shoe inner retracting
spring. (Rear drive wheel)
SHTS061060200344
4. BRAKE SHOE
(1) Remove the holder A of wheel cylinder push rod from the brake
shoe, then keep holding the brake shoe and remove the drum
cover.
SHTS061060200345
SHTS061060200346
(2) Using the special tool, remove the anchor pin then take the brake
shoe out.
SST: Anchor pin puller (S0942-01510)
SHTS061060200347
5. OPERATING INSPECTION OF ADJUSTING CAM

(1) The cam should rotate smoothly but with enough resistance, if it is
defective disassemble it.
(2) When disassemble and assemble the adjusting cam, using a spe-
cial tool and hand vise.
SST: Guide (S0965-71330)
SHTS061060200348
6. REMOVAL WHEEL CYLINDER

(1) Disconnect the oil pipe and remove the wheel cylinder.
NOTICE
Place the drain pan under the wheel cylinder to catch the hydrau-
lic fluid.
SHTS061060200349
1. REPLACE THE BRAKE LINING.

diameter.
NOTICE
SHTS061060200350
SHTS061060200351
SHTS061060200352

SHTS061060200353
2. ASSEMBLY OF THE WHEEL CYLINDER

Rustproof oil (CCI No. 20):

04156-1010
(2) Apply rubber grease to the inside of boot, groove for boot, sliding
surface of piston.
Rubber grease (RX-2):

04133-1080
SHTS061060200354
NOTICE
SHTS061060200355
3. INSTALLATION OF BRAKE SHOE ASSEMBLY

(1) Install the wheel cylinder, and then connect the oil pipe.
(2) Set the brake shoe assembly in place, then insert the anchor pins.
NOTICE
Apply the heat resistant grease for the shoe bushing.
SHTS061060200356
(3) Using the special tool, set the grooves of the two anchor pin, par-
allel and then insert the retainer in the grooves so that the retainer
hole and brake spider hole are aligned.
SST: Anchor Pin Tool (S0968-41010)
SHTS061060200357
(4) Hook the holder A of the wheel cylinder push rod to the brake
shoe.
SHTS061060200358
4. INSTALL THE BRAKE SHOE RETRACTING SPRING.

(1) Install the rear side drum cover and brake shoe retracting inner
spring, then insert the pin. (Rear drive wheel)
SHTS061060200344
(2) Use the special tool to install the retracting spring. (Front and
Rear wheel)
SST: Pull Back Spring Tool (S0968-31070)
SHTS061060200359
5. INSTALL THE WHEEL SENSOR.

(If so equipped)
(2) Push the wheel sensor forcefully into the clamping bussing until
NOTICE
SHTS061060200360 (3) Arrange the wire harness.
SHTS061060200361
6. ASSEMBLE THE BRAKE DRUM AND WHEEL HUB.

(FRONT WHEEL)
NOTICE
SHTS061060200362
ble.
NOTICE
Tightening Torque:
393-508 N⋅m {4,000-5,180 kgf⋅cm, 289-374 lbf⋅ft}
7. MOUNT THE WHEEL HUB WITH BRAKE DRUM.

8. MOUNT THE TIRE.

SHTS061060200363
9. ADJUSTMENT
(1) Finally adjust the clearance between the brake lining and the
ADJUSTMENT
EN0610602H300029

the next inspection, the lining should be made replacement the
lining.
SHTS061060200364

{8.0-9.0 kgf/cm2, 113-127 lbf/in.2}
NOTICE
SHTS061060200365
3. CLEARANCE BETWEEN BRAKE LINING AND BRAKE DRUM

SHTS061060200366
(3) Insert a 0.45 mm {0.018 in.} thick of the gauge A between the
brake drum and the brake lining.
SHTS061060200367
(4) Turn the adjusting cam to obtain the correct clearance.

ARROW MARK A show the cam turning direction to reduce the
clearance. (The arrow are marked on the brake drum cover near
the adjusting cam.)
The figure shows for front wheel as a sample.
SHTS061060200368
from 2.
NOTICE
wheels.
SHTS061060200366

EN06106022600002
NOTICE
Unit: mm {in.}

Brake drum inner diameter 406.4 410.4 {16.16} Replace. Measure

{16.00}

{0-0.0039} {0.0079} replace.


brake lining {0.61} {0.215}
Clearance between bush- 0.02-0.07 0.25 Replace the Measure

ing and anchor pin {0.0008-0.0027} {0.00984} bushing and/
or anchor
pin.

and/or any damage

age if necessary.

Adjusting cam and related — — Replace, Visual check

parts: if necessary.
Wear and/or any damage
WHEEL BRAKE (MODELS: FL, FM)

EN0610602I200024

Type
expanding, leading-trailing shoes in all wheels.
Front 50.8 mm {2.0 in.}
Wheel cylinder bore diameter Rear, Front 55.56 mm {2.19 in.}
Rear, Rear 53.50 mm {2.11 in.}
DESCRIPTION
EN0610602C100024
FRONT
SHTS061060200379
1 Drum cover 12 Cap

2 Brake drum 13 Retracting spring
3 Wheel cylinder assembly 14 Brake lining
4 Push rod 15 Brake shoe
5 Boot 16 Adjusting cam
6 Cylinder 17 Brake spider
7 Piston 18 Anchor pin
8 Back up ring 19 Lock plate
9 Piston cup 20 Retainer
10 Spring A Forward turning
11 Air bleeder screw B To move the shoe outward
REAR
SHTS061060200380
1 Drum cover 13 Brake lining

2 Brake drum 14 Brake shoe
3 Wheel cylinder assembly 15 Adjusting cam
4 Push rod 16 Brake spider
5 Cylinder cover 17 Anchor pin
6 Boot 18 Lock plate
7 Cylinder 19 Retainer
8 Piston 20 Bleeder cap
9 Back up ring 21 Air bleeder
10 Piston cup A Forward turning
11 Spring B To move the shoe outward
12 Retracting spring
SPECIAL TOOL
EN0610602K100006

S0968-31090
BACK TOOL
S0942-02000 PULLER ASSEMBLY

COMPONENT LOCATOR
EN0610602D100023
FRONT
SHTS061060200383

4 Cover 15 Push rod 26 Cover
11 Cylinder cover 22 Anchor pin 33 Snap ring

A 168-226 {1,700-2,300, 123-166} D 20-34 {205-347, 15-25}
B 75-91 {765-930, 56-67} E 20-34 {205-347, 15-25}
C 44-60 {450-610, 33-45} F 18.7-25.5 {190-260, 14-19}
REAR
SHTS061060200384
1 Hole plug 12 Boot 23 Lock plate

2 Drum cover 13 Cylinder 24 Brake shoe assembly
3 Pin 14 Push rod 25 Retracting spring
4 Cover 15 Piston 26 Spring cover
5 Spring 16 Back up ring 27 Brake lining
6 Boot 17 Piston cup 28 Rivet
7 Washer 18 Spring 29 Snap ring
8 Brake spider 19 Air bleeder screw 30 Brake shoe
9 Adjusting cam 20 Cap 31 Bushing
10 Cylinder cover 21 Anchor pin 32 Brake drum
11 Wheel cylinder assembly 22 Retainer

A 20-34 {205-347, 15-25} D 148-196 {1,500-2,000, 111-147}
B 113-157 {1,150-1,600, 85-118} E 18.7-25.5 {190-260, 14-19}
C 20-34 {205-347, 15-25}
OVERHAUL
EN0610602H200020
1. REMOVAL OF TIRE.

HUB BEARINGS.
NOTICE
The brake drums for front axle are specified for left and right,
therefore put an identification mark on disassembling.
3. REMOVAL OF BRAKE SHOE RETRACTING SPRING.

SST: Retracting spring pull back tool (S0968-31090)
SHTS061060200385
4. REMOVAL OF BRAKE SHOE

(1) Using the special tool, remove the anchor pin then take the brake
shoe out.
SHTS061060200386
SHTS061060200387
5. REMOVAL WHEEL CYLINDER

(1) Disconnect the oil pipe and remove the wheel cylinder.
NOTICE
Place the drain pan under the wheel cylinder to catch the hydrau-
lic fluid.
SHTS061060200388
1. REPLACEMENT OF THE BRAKE LINING.

diameter.
NOTICE
SHTS061060200389
SHTS061060200390
SHTS061060200391

SHTS061060200392
2. ASSEMBLY OF THE WHEEL CYLINDER

(1) Apply rubber grease to the inside of boot, groove for boot, sliding
surface of piston.
Rubber grease (RG-4)
NOTICE
SHTS061060200393
SHTS061060200394

(1) Install the wheel cylinder, and then connect the oil pipe.
NOTICE
Apply the heat resistant grease for the shoe bushing.
SHTS061060200395
(3) Set the grooves of the two anchor pin, parallel and then insert the
retainer in the grooves so that the retainer hole and brake spider
hole are aligned.
SHTS061060200396
4. INSTALLATION OF BRAKE SHOE RETRACTING SPRING.

(1) Use the special tool to install the retracting spring. (Front and
Rear wheel)
SST: Pull Back Spring Tool (S0968-31090)
SHTS061060200385
5. ASSEMBLY OF THE BRAKE DRUM AND WHEEL HUB.

(FRONT WHEEL)
NOTICE
New drum: Install in any side.
SHTS061060200397
ble.
NOTICE
Tightening Torque:
393-470 N⋅m {4,000-4,800 kgf⋅cm, 290-347 lbf⋅ft}
6. MOUNTING OF WHEEL HUB WITH BRAKE DRUM.

7. MOUNTING OF TIRE.
SHTS061060200398
8. ADJUSTMENT.
(1) Finally, adjust the clearance between the brake lining and the
ADJUSTMENT
EN0610602H300030
1. REMAINING THICKNESS OF THE BRAKE LINING.

the brake drum cover. If the lining has been worn to the limit
marking or if it is foreseen that the lining will be worn to the limit by
the time the next inspection is made replace the lining.
SHTS061060200399
2. AIR PRESSURE IN THE AIR TANK.

{8.0-9.0 kgf/cm2, 114-128 lbf/in.2}
NOTICE
SHTS061060200400
3. CLEARANCE BETWEEN BRAKE LINING AND BRAKE DRUM.

SHTS061060200401
(3) Insert a 0.3 mm {0.012 in.} thick of the gauge A between the
brake drum and the brake lining.
SHTS061060200402
(4) Turn the adjusting cam to obtain the correct clearance.

ARROW MARK A show the cam turning direction to reduce the
clearance. (The arrow are marked on the brake drum cover near
the adjusting cam.)
The figure shows for rear wheel as a sample.
SHTS061060200403
from 2.
NOTICE
wheels.
SHTS061060200401

EN0610602H300031
NOTICE
Unit: mm {in.}

Brake drum inner diameter 410.0 414.0 Replace. Measure

{16.142} {16.299}
Brake drum run out 0-0.1 0.2 Regrind or Measure

{0-0.0039} {0.0079} replace.


brake lining {0.630} {0.236}
Clearance between bush- 0.06-0.14 0.3 Replace the Measure

ing and anchor pin {0.0024-0.0055} {0.0118} bushing and/
or anchor
pin.

and/or any damage

age if necessary.

Adjusting cam and related — — Replace, Visual check

parts: if necessary.
Wear and/or any damage
LIMITING VALVE (MODEL: FM2P)

EN0610602I200025
Type Diaphragm and piston type

Inlet side pressure 686 kPa {7.0 kgf/cm2, 99.54 lbf/in2.}
ID mark kPa {kgf/cm2, lbf/in2.}
216 196.4-235.6 {2.0-2.4, 28.49-34.09}
235 205.6-264.4 {2.1-2.7, 29.87-38.39}
Outlet side pressure
363 343.4-382.6 {3.5-3.9, 49.77-55.45}
373 343.6-402.4 {3.5-4.1, 49.77-58.30}
392 362.6-421.4 {3.7-4.3, 52.62-61.14}
DESCRIPTION
EN0610602C100025
SHTS061060200414
1 Adjusting bolt 5 Retainer

2 Valve body 6 Valve
3 Spring 7 O-ring
4 Diaphragm
COMPONENT LOCATOR
EN0610602D100024
SHTS061060200415
1 Adjusting bolt 7 Diaphragm

2 Valve body 8 O-ring
3 Spring seat 9 Retainer
4 Spring 10 O-ring
5 Cotter pin 11 Valve
6 Plate 12 ID mark

A 9.8-19.6 {100-200, 8-14} C 0.40-0.58 {4-6, 0.29-0.43}
B 0.99-1.47 {10-15, 0.73-1.08} D 40-59 {400-600, 29-43}
OVERHAUL
EN0610602H200021
1. LUBRICATION
(1) When assembling the limiting valve, replace the O-rings dia-
phragm and valve with new one.
(2) Apply adequate amount of silicone grease for the sliding surface
of the component parts and O-rings.
SHTS061060200416
1. ADJUSTMENT
(1) Turn the adjusting screw counterclockwise fully, then placed and
piped the limiting valve as shown in figure.
(2) Charge the inlet side air tank with compressed air for 686 kPa {7.0
kgf/cm2, 99.54 lbf/in2.}.
(3) Turn the adjusting screw clockwise gradually till outlet side air
pressure for specified below.
Then tighten the lock nut.
ID mark Outlet side pressure: kPa {kgf/cm2, lbf/in2.}
SHTS061060200417 216 196.4-235.6 {2.0-2.4, 28.49-34.09}
235 205.6-264.4 {2.1-2.7, 29.87-38.39}
363 343.4-382.6 {3.5-3.9, 49.77-55.45}
373 343.6-402.4 {3.5-4.1, 49.77-58.30}
392 362.6-421.4 {3.7-4.3, 52.62-61.14}

EN0610602H300032
Valve contact surface 1. — — Clean or Visual check and measure

and friction surface 2. of replace.
valve body:
Load at setting 270.7 N/35.5mm 243.2-298.2 N Replace,

216
length: {27.6 kgf/35.5 mm, {24.8-30.4 kgf, if necessary
235
Valve ID mark 60.85 lbf/1.39 in.} 54.67-67.00 lbf}
1,176.8 N/132.0
363 1,059.1-1,294.5 N
mm {120 kgf/32.0
373 {108-132 kgf,
mm, 264.6 lbf/1.26
392 238.06-290.95 lbf}
in.}
TWO-WAY VALVE (BRAKE LOCK CONTROL VALVE)

(MODEL: FM1JKPM)
EN0610602I200026
Type Push-Pull type, with locking mechanism
DESCRIPTION
EN0610602C100026
SHTS061060200419
1 Piston 10 O-ring 19 Filter

2 Valve 11 Valve sub assembly 20 Retainer
3 Plug 12 Plain washer 21 Switch assembly
4 O-ring 13 Retainer 22 Knob
5 Valve guide 14 Conical spring A From reducing valve
6 O-ring 15 Plunger B To double check valve
7 Valve seat 16 Solenoid assembly C Exhaust
8 Check bolt nut 17 Guide
9 Cover 18 Brake valve body
COMPONENT LOCATOR
EN0610602D100025
SHTS061060200420
1 Knob 11 Solenoid assembly

2 Lock nut 12 Guide
3 Piston 13 Valve
4 O-ring 14 Washer
5 Valve body 15 Valve seat
6 Plug 16 Plunger
7 Filter 17 Spring
8 Retainer ring 18 Cover
9 Check valve 19 Switch assembly
10 Valve guide 20 Check bolt nut

A 1.5-2.4 {15-25, 1.1-1.8} D 1.96-2.06 {20-21, 1.45-1.51}
B 3.4-4.9 {30-50, 2.6-3.6} E 19.6-29.4 {200-300, 14.5-21.6}
C 6.9-9.8 {70-100, 5.1-7.2}
OVERHAUL
EN0610602H200022
1. LUBRICATION
(1) When assembling the two-way valve, replace the O-rings. Check
valve and valve with new ones.
(2) Apply adequate amount of silicone grease to the sliding surfaces,
O-ring grooves of the components and O-rings.
(3) Apply sealing compound (LOCTITE 572 or equivalent) to thread
of the plug but no to first 1-2 pitch.
O: O-ring
P: Plug
S: Sliding surface
SHTS061060200421
2. SWITCH AND SOLENOID

(1) Check the followings.
• Switch: When the switch is free; OFF.

When the plunger of the switch is pushed in; ON.
• Solenoid: When electric power is applied, the pin moves in.
Refer to chapter ELECTRICAL EQUIPMENT for details.
SHTS061060200422
3. SWITCH INSTALLATION
(1) Screw the switch into the cover, so that the switch is turned ON
when the knob is pushed in and vice versa.
(2) Lock the switch with the lock nut.
NOTICE
Use a circuit tester.
SHTS061060200423
1. FUNCTION CHECK
(1) Air shall be flow from B to C when the knob is pulled out.
(2) Air shall be flow from A to B when the knob is pushed in.
SHTS061060200424
(3) The knob shall be locked at pulled when the solenoid is free from
electric power.
(4) The knob shall be released when electric power is applied for
solenoid.
SHTS061060200425

EN0610602H300033

Wear, corrosion and any if necessary.
other damages
Valve guide: — — Replace, Visual check

other damages
Valve seat and — — Replace, Visual check

valve contact surface: if necessary.
Wear, corrosion and any
other damages
Plunger sliding surface — — Replace, Visual check

other damages

Rust and damages if necessary.
Valve body — — Replace, Visual check

sliding surface 1 and if necessary.
valve contact surface 2:
Wear, corrosion and any
other damages
Cover sliding surface 1: — — Replace,

other damages
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SERVICE BRAKE (MODELS: WITH FULL AIR BRAKE) BR02–1
SERVICE BRAKE BR02

BR 02
BR02-002
PRESSURE REGULATOR........................BR02-3 PROTECTION VALVE

DATA AND SPECIFICATIONS........................ BR02-3 (WITH 4-WAY PROTECTION VALVE).....BR02-28
DESCRIPTION ................................................ BR02-3 DATA AND SPECIFICATIONS...................... BR02-28
OVERHAUL ..................................................... BR02-5 COMPONENT LOCATOR ............................. BR02-29
INSPECTION AND REPAIR ............................ BR02-6 OVERHAUL ................................................... BR02-30
ADJUSTMENT............................................... BR02-30
AIR DRYER [MODELS: FG, GH, SG INSPECTION AND REPAIR .......................... BR02-32
(WITHOUT ABS)]......................................BR02-7
DATA AND SPECIFICATIONS........................ BR02-7 QUICK RELEASE VALVE .......................BR02-33
DESCRIPTION ................................................ BR02-7 DATA AND SPECIFICATION ........................ BR02-33
OVERHAUL ..................................................... BR02-9 COMPONENT LOCATOR ............................ BR02-34
INSPECTION AND REPAIR .......................... BR02-10 OVERHAUL ................................................... BR02-34
AIR DRYER (MODEL: FM) .....................BR02-11
DATA AND SPECIFICATIONS...................... BR02-11 SPRING BRAKE CONTROL VALVE ......BR02-36
DESCRIPTION .............................................. BR02-11 DATA AND SPECIFICATIONS...................... BR02-36
COMPONENT LOCATOR ............................. BR02-12 DESCRIPTION .............................................. BR02-36
OVERHAUL ................................................... BR02-13 COMPONENT LOCATOR ............................. BR02-37
INSPECTION AND REPAIR .......................... BR02-14 OVERHAUL ................................................... BR02-38
CHECK VALVE........................................BR02-15
DATA AND SPECIFICATIONS...................... BR02-15 RELAY VALVE (FOR FRONT BRAKE AND
DESCRIPTION .............................................. BR02-15 TRAILER BRAKE) ..................................BR02-40
COMPONENT LOCATOR ............................. BR02-15 DATA AND SPECIFICATIONS...................... BR02-40
INSPECTION AND REPAIR .......................... BR02-16 DESCRIPTION .............................................. BR02-40
SAFETY VALVE ......................................BR02-17 OVERHAUL ................................................... BR02-42
DATA AND SPECIFICATIONS...................... BR02-17 INSPECTION AND REPAIR .......................... BR02-42
DESCRIPTION .............................................. BR02-17
INSPECTION AND REPAIR .......................... BR02-17 RELAY VALVE (FOR FRONT SPRING BRAKE
CHAMBER) .............................................BR02-43
BRAKE VALVE........................................BR02-18 DATA AND SPECIFICATIONS...................... BR02-43
DATA AND SPECIFICATION ........................ BR02-18 DESCRIPTION .............................................. BR02-43
DESCRIPTION .............................................. BR02-18 COMPONENT LOCATOR ............................. BR02-44
COMPONENT LOCATOR ............................. BR02-19 OVERHAUL ................................................... BR02-44
OVERHAUL ................................................... BR02-21 INSPECTION AND REPAIR .......................... BR02-45
RELAY VALVE (WITH CHECK VALVE,
FOR REAR BRAKE) ...............................BR02-46
DESCRIPTION .............................................. BR02-46
OVERHAUL ................................................... BR02-47
2A$4AA(WNNCKTA0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧝㧜ᤨ㧝ಽ
BR02–2 SERVICE BRAKE (MODELS: WITH FULL AIR BRAKE)
RELAY VALVE (FOR REAR SPRING BRAKE BRAKE CHAMBER

CHAMBER) ............................................. BR02-49 [FOR REAR (REARWARD) BRAKE] .....BR02-81
DATA AND SPECIFICATIONS ......................BR02-49 BR 02
DATA AND SPECIFICATION.........................BR02-81
COMPONENT LOCATOR..............................BR02-50 COMPONENT LOCATOR..............................BR02-82
OVERHAUL....................................................BR02-51 OVERHAUL....................................................BR02-82
INSPECTION AND REPAIR ..........................BR02-51 INSPECTION AND REPAIR ..........................BR02-83
RELAY VALVE (FOR REAR BRAKE) .... BR02-52 BRAKE CHAMBER (MODEL: SG)
DATA AND SPECIFICATIONS ......................BR02-52 [FOR REAR BRAKE (S-CAM TYPE)] .... BR02-84
DESCRIPTION...............................................BR02-52 DATA AND SPECIFICATION.........................BR02-84
COMPONENT LOCATOR..............................BR02-53 DESCRIPTION...............................................BR02-84
OVERHAUL....................................................BR02-54 COMPONENT LOCATOR..............................BR02-85
INSPECTION AND REPAIR ..........................BR02-54 OVERHAUL....................................................BR02-86
[FOR REAR BRAKE (WEDGE TYPE)] .. BR02-55 TRAILER HAND BRAKE
DATA AND SPECIFICATIONS ......................BR02-55 CONTROL VALVE................................... BR02-88
DESCRIPTION...............................................BR02-55 DATA AND SPECIFICATION.........................BR02-88
COMPONENT LOCATOR..............................BR02-56 DESCRIPTION...............................................BR02-88
OVERHAUL....................................................BR02-57 COMPONENT LOCATOR..............................BR02-89
INSPECTION AND REPAIR ..........................BR02-58 OVERHAUL....................................................BR02-90
[FOR FRONT BRAKE (S-CAM TYPE)].. BR02-59 WHEEL BRAKE (WEDGE TYPE) .......... BR02-92
DATA AND SPECIFICATIONS ......................BR02-59 DATA AND SPECIFICATIONS ......................BR02-92
SPECIAL TOOL .............................................BR02-60 SPECIAL TOOL .............................................BR02-96
COMPONENT LOCATOR..............................BR02-60 COMPONENT LOCATOR..............................BR02-97
[FOR REAR BRAKE (S-CAM TYPE)] .... BR02-66 WHEEL BRAKE (S-CAM TYPE) .......... BR02-109
DATA AND SPECIFICATION.........................BR02-66 DATA AND SPECIFICATIONS ....................BR02-109
DESCRIPTION...............................................BR02-66 DESCRIPTION.............................................BR02-110
SPECIAL TOOL .............................................BR02-67 SPECIAL TOOL ...........................................BR02-116
BRAKE CHAMBER (MODELS: FG, GH, SG)
[FOR FRONT BRAKE EXPANDER (MODELS WITH WEDGE TYPE
(WEDGE TYPE)] ..................................... BR02-74 BRAKE).................................................BR02-141
DATA AND SPECIFICATIONS ......................BR02-74 DESCRIPTION.............................................BR02-141
DESCRIPTION...............................................BR02-74 SPECIAL TOOL ...........................................BR02-142
INSPECTION AND REPAIR ..........................BR02-77 INSPECTION AND REPAIR ........................BR02-148
BRAKE CHAMBER (MODELS: FG, GH, SG) TRAILER HAND BRAKE CONTROL VALVE
[FOR FRONT BRAKE (S-CAM TYPE)].. BR02-78 (MODEL: FM TRACTOR)...................... BR02-149
DATA AND SPECIFICATION.........................BR02-78 DATA AND SPECIFICATION.......................BR02-149
DESCRIPTION...............................................BR02-78 DESCRIPTION.............................................BR02-149
INSPECTION AND REPAIR ..........................BR02-80 INSPECTION AND REPAIR ........................BR02-152
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PRESSURE REGULATOR
EN0680202I200001
Spring type, regulates air pressure together with

Type
unloader valve on compressor
Regulating pressure:
780-880 kPa {8.0-9.0 kgf/cm2, 114-128 lbf/in.2}
Regulator No. 44530-1330
DESCRIPTION
EN0680202C100001
SHTS068020200001
1 Dust cover 7 Main spring 13 Valve spring

2 Retainer ring 8 Push rod 14 Filter
3 Set bolt 9 Rod spring 15 Piston
4 Lock nut 10 O-ring A To Unloader valve
5 Spring seat 11 Back up ring B From Air tank
6 Valve body 12 Valve seat C Exhaust
COMPONENT LOCATOR
EN0680202D100001
SHTS068020200002
1 Dust cover 6 Valve body 11 Back up ring

2 Retainer ring 7 Main spring 12 Valve
3 Set bolt 8 Push rod 13 Valve spring
4 Lock nut 9 Rod spring 14 Filter
5 Spring seat 10 O-ring 15 Piston

A 2.4-3.5 {24-36, 1.8-2.6} B 0.29-0.49 {3-5, 0.22-0.36}
OVERHAUL
EN0680202H200001
1. LUBRICATION
(1) When reassembling the pressure regulator, replace all rubber
parts with new ones.
(2) Apply adequate amount of silicone grease to the O-rings, and
sliding surface S of the piston and valve rod.
SHTS068020200003
1. ADJUSTMENT
tank.
SHTS06Z070200001
(2) Stop the engine when the gauge indicates valve opening pres-
sure shown below.
Valve opening pressure Pressure kPa {kgf/cm2, lbf/in.2}

44530-1330 860-900 {8.8-9.2, 125-130}
SHTS06Z070200002
(3) Tighten the adjusting screw gradually till the air starts to leak from
the port to the unloader valve side.
SHTS06Z070200003
(5) Watch the pressure gauge needle and see that it stops at the
(6) Connect the pipe and pressure regulator.
Valve closing pressure Pressure kPa {kgf/cm2, lbf/in.2}

44530-1330 750-790 {7.7-8.1, 109-115}
SHTS06Z070200004

EN0680202H300001
Valve body 1, piston 2 and — — Replace, Visual check

valve rod 3. Sliding surface: if necessary.
Valve rod 4.
Valve contact surface:
Wear and any other dam-
ages
Main spring 5. rod spring 6. — — Replace,

and valve spring 7: if necessary.
Rust and damage
AIR DRYER [MODELS: FG, GH, SG (WITHOUT ABS)]

EN0680202I200002
Type Purge tank, desiccant, auto-purge valve.

DESCRIPTION
EN0680202C100002
B E 3 2
4 1
F 14
X X
3 8
15
9
19
A 16
C
18
10
5 11
17
12 G
13
SECTION X-X
D
SHTS068020200009
1 Chamber (Purge tank) 14 Plug

2 Case cover 15 Pressure regulator
3 Check valve 16 Adjusting screw
4 Spring 17 Piston
5 Body 18 Piston spring
6 Desiccant case 19 Heater (If so equipped)
7 Filter A Outlet (Dried air to air tank)
8 Desiccant B Orifice
9 Oil separator filter C Inlet (From air compressor)
10 Valve body D Purged air
11 Valve spring E Dehumidification
12 Piston F Reclamation
13 Purge valve G To purge valve
COMPONENT LOCATOR
EN0680202D100002
SHTS068020200010
1 O-ring 16 Filter plate

2 Cover 17 Filter
3 Piston 18 Desiccant
4 Valve spring 19 Desiccant case
5 Valve body 20 Oil separator filter
6 Purge valve 21 Body
7 Silencer case 22 Valve stopper
8 Silencer plate 23 Governor valve
9 Silencer 24 Piston assembly
10 Retainer ring 25 Exhaust stem spring
11 Exhaust cover 26 Exhaust stem
12 Chamber 27 Pressure regulator assembly
13 Check valve 28 Valve seat
14 Case cover 29 Plate
15 Set spring 30 Heater (If so equipped)

A 2.0-3.9 {20-40, 1.5-2.9} D 6.9-7.8 {71-79, 5.2-5.7}
B 3.9-6.9 {40-70, 2.9-5.0} E 17.7-27.5 {180-280, 13-20}
C 4.9-5.9 {50-60, 3.7-4.3}
OVERHAUL
EN0680202H200002
1. LUBRICATION
C (1) When assembling the air dryer, use new O-ring, gasket and seal.
A • A: O-ring
2. BEFORE TIGHTEN THE BOLT WITH SPECIFIED TIGHTENING

A TORQUE, TAP ALL OVER THE OUTER SURFACE OF THE
DESICCANT CASE WITH A PLASTIC HAMMER.
• C: Bolt
A IMPORTANT POINTS - MOUNTING

A
B
1. INSPECTION
(1) Operate the engine and raise the air pressure until the air dis-
charge from the purge valve, then stop the engine.
sure regulator).
a. Check to see that there is no air leakage from the purge valve.
SHTS068020200011
2. ADJUSTMENT
tank.
SHTS068020200012
(2) Tighten the adjusting screw gradually till the air pressure gauge
indicate valve opening pressure shown below and the air starts to
discharge from purge valve.
Governor valve opening pressure: 880kpa {9.0 kgf/cm2, 128
lbf/in.2}
SHTS06Z070200006
(4) Watch the air pressure gauge needle and see that it stops at the
Governor valve closing pressure: 780 kpa {8.0 kgf/cm2, 114
lbf/in.2}
SHTS06Z070200007

EN0680202H300002
Check valve and valve — — Replace, Visual check

seat surface: If necessary.
Wear and damage
Valve body sliding surface — — Replace, Visual check

and purge valve seat sur- If necessary.
face:
Wear and damage

Wear and damage If necessary.
Purge valve seat surface: — — Replace, Visual check

Wear and damage If necessary.

Contamination and deteri- more than 1/5
oration of the quantity.
AIR DRYER (MODEL: FM)

EN0680202I200003
Type Purge tank, desiccant, auto-drain valve.

DESCRIPTION
EN0680202C100003
SHTS068020200020
1 Check valve 11 Piston

2 Spring 12 Purge valve
3 Filter A Inlet (from air compressor)
4 Chamber (Purge tank) B Orifice
5 Desiccant case C Outlet (dried air to air tank)
6 Desiccant D Inlet (from pressure regulator)
7 Oil Filter E Purged air
8 Body F Dehumidification
9 Valve body G Reclamation
10 Valve spring
COMPONENT LOCATOR
EN0680202D100003
SHTS068020200021
1 Bracket 8 Piston
2 Chamber (purge tank) 9 Valve spring
3 Check valve 10 Valve body
4 Desiccant case 11 Purge valve
5 O-ring 12 Exhaust body
6 Plate 13 Retainer ring
7 Body

A 14.7-22.6 {150-230, 10.9-16.6} C 6.9-8.8 {70-90, 5.1-6.5}
B 3.9-6.9 {40-70, 2.9-5.0}
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OVERHAUL
EN0680202H200003
1. LUBRICATION
(1) When assembling the air dryer, use new O-ring.
• A: O-ring
2. BEFORE CLOSING THE CHAMBER, TAP ALL OVER THE

OUTER SURFACE OF THE DESICCANT CASE WITH A PLAS-
TIC HAMMER.
SHTS06Z070200013
1. INSPECTION
(1) Operate the engine and raise the air pressure until the air com-
pressor stops functioning.
sure regulator).
a. Check to see that there is no air leakage from the purge valve
while the compressor is functioning.
b. When the compressor stops functioning, check to see that the air
is discharged from the purge valve for a period of approx. 60 sec-
onds.

EN0680202H300003
Check valve, — — Replace, Visual check

Valve seat surface: if necessary.
Wear and damage
Valve body, — — Replace, Visual check

Sliding surface and if necessary.
purge valve seat surface:
Wear and damage
Piston, — — Replace, Visual check

Sliding surface: if necessary.
Wear and damage
Purge valve, — — Replace, Visual check

Seat surface: if necessary.
Wear and damage

Contamination, Deteriora- more than 1/5
tion of the quantity.
CHECK VALVE
EN0680202I200004
Type Spring type

Valve opening pressure Outlet side pressure 14.7 kPa {0.15 kgf/cm2, 2.13 lbf/in.2}
DESCRIPTION
EN0680202C100004
SHTS068020200028

3 Valve
COMPONENT LOCATOR
EN0680202D100004
SHTS068020200029

3 Valve

EN0680202H300004
Unit: mm {in.}
Connector: — — Replace, Visual check

Valve: — — Replace, Visual check

Valve spring: 19.8 {0.78} 18 {0.71} Replace, Measure and visual check
Rust, damage and free if necessary.
length
SAFETY VALVE
EN06802022600001
Type Spring type

Valve opening pressure 1,029-1,069 kPa {10.5-10.9 kgf/cm2, 150-155 lbf/in.2}
DESCRIPTION
EN0680202C100005
SHTS068020200033
1 Valve 5 Compression spring

2 Body A Exhaust
3 Nut B From air tank (Pressure air)
4 Bolt

EN0680202H300005
Unit: kPa {kgf/cm2, lbf/in.2}
Valve opening pressure 1,029-1,069 — Replace, Measure

{10.5-10.9, if necessary.
150-155}
BRAKE VALVE
EN0680202I200005
Type Dual pistons and valves with a plunger type pedal
DESCRIPTION
EN0680202C100006
SHTS068020200034
1 Boot 16 Primary piston return spring

2 Plunger 17 Primary valve body
3 Brake valve cover 18 Primary feed valve
4 Retainer ring 19 Retainer
5 Guide ring 20 Primary feed valve return spring
6 Spring seat 21 Primary feed valve retainer
7 Sub spring 22 Secondary piston
8 Shim 23 Secondary piston return spring
9 Stem 24 Secondary valve body
10 Main spring 25 Secondary feed valve
11 Shim 26 Retainer
12 Guide ring 27 Secondary feed valve return spring
13 O-ring 28 Secondary feed valve retainer
14 Primary piston 29 C-ring
15 Guide 30 Exhaust port
COMPONENT LOCATOR
EN0680202D100005
SHTS068020200035
1 Stop light switch 10 Push rod

2 Bushing 11 Seal
3 Bracket 12 Clip
4 Buffer 13 Shaft
5 Pin 14 Pedal bracket
6 R-pin 15 Brake valve
7 Pedal pad 16 Connector
8 Brake pedal 17 Clutch master cylinder
9 Return spring

A 9.5-18.5 {97-188, 7.1-13.5} C 24.4-34.5 {250-350, 18-25}
B 18-31 {184-316, 14-22}
SHTS068020200036
1 Boot 16 Primary piston return spring

2 Plunger 17 Primary valve body
3 Brake valve cover 18 Primary feed valve
4 Retainer ring 19 Retainer
5 Guide ring 20 Primary feed valve return spring
6 Spring seat 21 Primary feed valve retainer
7 Sub spring 22 Secondary piston
8 Shim 23 Secondary piston return spring
9 Stem 24 Secondary valve body
10 Main spring 25 Secondary feed valve
11 Shim 26 Retainer
12 Guide ring 27 Secondary feed valve return spring
13 O-ring 28 Secondary feed valve retainer
14 Primary piston 29 C-ring
15 Guide 30 Exhaust port

A 2.9-4.9 {30-50, 2.2-3.6} B 5.9-7.4 {60-75, 4.3-5.4}
OVERHAUL
EN0680202H200004
1. REMOVE THE CLUTCH MASTER CYLINDER.

HINT
Even if without removing the clutch master cylinder, pedal bracket
can be removed only to the length of the clutch hose.
2. DISCONNECT THE NYLON TUBE.
SHTS068020200037
3. REMOVE THE PEDAL BRACKET ASSEMBLY.

(1) Loosen the bolt and nut to remove the pedal bracket assembly.
NOTICE
Before removing the pedal bracket, put the wiper link upward.
SHTS068020200038
4. REMOVE THE BRAKE PEDAL.

(1) Tap the shaft lightly using a brass rod and a hammer, remove the
brake pedal from the pedal bracket assembly.
NOTICE
Do not pull out the shaft because the brake pedal and the clutch
pedal are installed by one shaft.
SHTS068020200039
5. REMOVE THE BRAKE VALVE ASSEMBLY.

ALIGNING MARK (1) Apply aligning marks on the brake valve assembly and pedal
bracket assembly.
SHTS068020200040

ALIGNING NOTICE
MARK
Before disassembling the brake valve, apply aligning marks on
the brake valve cover, primary valve body and secondary valve
body.
SHTS068020200041
ALIGNING MARK
SHTS06Z070200025
1. REMOVE THE PRIMARY PISTON ASSEMBLY.
2. REMOVE THE SECONDARY VALVE BODY.
3. REMOVE THE SECONDARY PISTON.

NOTICE
Pull out with hands to prevent the seat part of the secondary pis-
ton from being damaged by using a pryer etc. If not with hands,
secondary piston should not be reused.
4. REMOVE THE PRIMARY FEED VALVE.

SHTS068020200043
5. REMOVE THE EXHAUST PORT.
6. REMOVE THE SECONDARY FEED VALVE.

1. LUBRICATION
(1) When reassembling the brake valve, replace the O-rings and
retainer rings with new ones.
(2) Apply adequate amount of silicone grease on the grooves for the
O-ring and to the sliding surfaces of the component parts.
1. Secondary feed valve retainer O-ring
2. Secondary feed valve retainer
3. Secondary feed valve
4. Exhaust port O-ring
5. Primary feed valve retainer O-ring
6. Primary feed valve retainer
7. Secondary piston O-ring
8. Secondary piston
9. Primary valve body
10. Primary piston
11. Primary piston O-ring
12. Plunger
SHTS068020200044
2. ASSEMBLE THE STEM, SPRING, SPRING SEAT AND SHIM.

(1) Assemble the sub spring. At this time, adjust dimension "A" and
the spring compression "P" by means of the lock nut and the
shim.
NOTICE
In adjusting the spring compression, the axial play of the spring
DIMENSION
must be removed.
"A"
Dimension "A": 27.15-27.55 mm {1.0689-1.0846 in.}
Setting load: 0-9.8 N {0-1 kgf, 0-2.2 lbf}
SHTS06Z070200026
3. ALIGN THE VALVE COVER AND VALVE BODIES.

ALIGNING (1) When assemble the brake valve cover, primary body and second-
MARK ary body, align the marks which were applied at disassembly.
SHTS068020200041
ALIGNING MARK
SHTS06Z070200027
4. INSPECTION AND ADJUSTMENT

(1) Brake valve
a. Measure the secondary feed valve stroke (dimension A from
starting to release the plunger to completing to fully release
the plunger).
A dimension: 0.6 mm {0.0236 in.} or above
A DIMENSION
SHTS06Z070200028
b. Connect the brake valve, nylon tube, air pressure gauge, and
air tank as shown in the figure.
c. Set the air tank pressure at 830 kPa {8.5 kgf/cm2, 120.87 lbf/
in.2}.
PRIMARY
d. Apply soap water to the exhaust port and check to see there
is no air leakage.
AIR TANK
SECONDARY
SHTS06Z070200029
e. Drive in slowly the plunger. Measure the plunger stroke and

PLUNGER
air pressure gauges start to rise. If the measurements do not
match with the standard values, adjust by the shim of the
main spring.
PRIMARY
PRESSURE
19-41 kPa
Supply pressure
SECONDARY {0.2-0.4 kgf/cm2, 2.76-5.94 lbf/in.2}
SHTS068020200048
f. Drive in further the plunger. Measure the plunger stroke and

supply pressure at the point immediately before that the pri-
PLUNGER
mary and secondary pressure increases rapidly (bending
point). If the measurements do not match with the standard
values, replace each spring.
PRIMARY
PLUNGER
SECONDARY
SHTS068020200049
g. Drive in further the plunger. Measure the plunger stroke and

PLUNGER
pressures increase rapidly. If the measurements do not match
with the standard values, replace each spring.
SUPPLY
SECONDARY
SHTS068020200050
h. Drive in further the plunger. Measure the pedal stepping down

PLUNGER angle and supply pressure at the point where the primary and
secondary pressure are maximum. If the measurements do
not match with the standard values, replace each spring.
SUPPLY
AIR TANK
SECONDARY
SHTS06Z070200030
(2) Brake pedal

a. Make sure that the installing height of the brake pedal "C" and
the pedal play "B".
"B": 2-5 mm {0.0788-0.1968 in.}
"C": 149.6-159.6 mm {5.890-6.283 in.}
C
B
SHTS06Z070200031
b. If the pedal play is out of the standard value, loosen the lock
nut and turn the push rod to adjust the pedal play to the stan-
dard value.
LOCK NUT
PUSH ROD
BOOT
PLUNGER
SHTS06Z070200032
(3) Check the clearance between stop light switch and buffer.
STOP LAMP SWITCH "D": 0.5-1.5 mm {0.0197-0.0590 in.}
BUSHING
BUFFER
SHTS06Z070200033

EN0680202H300006
Main spring: 29.3 mm {1.15 in.}/ 28.5 mm Replace, Visual check and measure
Free length/ 27.5 mm {1.09 in.}/ {1.12 in.} if necessary.
setting load {18 kgf, 39.68 lbf}
Sub spring: 21.6 mm {0.85 in.}/ 21 mm PRIMARY

setting length/ 457 N
or more SECONDARY
Primary and Secondary Primary: 40.5 mm Replace, Visual check and measure
piston return spring: 43.2 mm {1.70 in.}/ {1.59 in.} if necessary.
PRIMARY
Secondary: 23.5 mm
24.5 mm {0.96 in.}/ {0.93 in.}
12.0 mm {0.47 in.}/
11.8 N
{1.2 kgf, 2.6 lbf}
SECONDARY

Wear and damage

Wear and damage
Primary and secondary Primary: 20.4 mm Replace, Visual check and measure
feed valve return spring: 21.4 mm {0.84 in.}/ {0.80 in.} if necessary.
PRIMARY
Secondary: 21.8 mm
22.8 mm {0.90 in.}/ {1.13 in.}
13.0 mm {0.51 in.}/
49.0 N


PROTECTION VALVE (WITH 4-WAY PROTECTION VALVE)

EN0680202I200006
Type Spring type (4-way protection)

Opening pressure Open: Port 21, 22 620-660 kpa {6.3-6.7 kgf/cm2, 89.61-95.29 lbf/in.2}
Port 23, 24 570-610 kpa {5.8-6.2 kgf/cm2, 82.49-88.18 lbf/in.2}
Close: Port 21, 22 440-480 kpa {4.5-4.8 kgf/cm2, 64.01-68.27 lbf/in.2}
Port 23, 24 440-480 kpa {4.5-4.8 kgf/cm2, 64.01-68.27 lbf/in.2}
DESCRIPTION
EN0680202C100007
SHTS068020200062
1 Compression spring A Port 21 (Outlet)

2 Dust cover B Port 22 (Outlet)
3 Check valve C Port 23 (Outlet)
4 Dust seal rubber D Port 24 (Outlet)
5 Piston E Inlet port
6 Valve spring F No.1 side
G Center check valve
H No.2 side
COMPONENT LOCATOR
EN0680202D100006
8 3
4
9
5
10
11 6
7
12
13
11
10
SHTS068020200063
1 Dust cover 6 Shim 11 Valve

2 Dust seal rubber 7 Spacer 12 Body
3 Retainer ring 8 Piston 13 Check valve
4 Dust seal plate 9 O-ring
5 Compression spring 10 Valve spring
OVERHAUL
EN0680202H200005
1. LUBRICATION
(1) When assembling the protection valve use the new O-rings and
valves.
(2) Apply the silicone grease on the each sliding surface of the com-
ponent parts and O-ring groove.
• A: O-ring
SHTS068020200064
ADJUSTMENT
EN0680202H300007
AIR LEAKAGE
1. CHECK VALVE
(1) By-pass Check valve at No.1 side.
a. Confirm no leakage of air at inlet, No.1, when applying pres-
sure to air under 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2}, 392 kPa
{4 kgf/cm2, 56.89 lbf/in.2} from outlet No.21 and No.22.
SHTS068020200065
(2) Center check valve

a. Confirm no leakage of air at the outlet No.21 and No.22, when
applying pressure to air under 49 kPa {0.5 kgf/cm2, 7.11 lbf/
in.2}, 880 kPa {9 kgf/cm2, 128 lbf/in.2} from the inspection
port.
SHTS068020200066
(3) Check valve at No.2 side

a. Confirm no leakage of air at the inspection port, when apply-
ing pressure to air under 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2},
880 kPa {9 kgf/cm2, 128 lbf/in.2} at the outlet No.23 and
No.24.
2. OTHER AIR TIGHTNESS

(1) When applying pressure to air under 0-880 kPa {0-9.0 kgf/cm2, 0-
128 lbf/in.2}, confirm that any leakage of air should be 0 cm3/min.
SHTS068020200067
PERFORMANCE CHRACTERISTIC
1. OPENING VALVE PRESSURE

(1) No.1 side
a. Releasing the compressed air at the outlet port No.21 and
No.22 to air, when applying the compressed air at the speed
specified below, confirm that air pressure of the compressed
air, saturated at the inlet should be of Opening valve pres-
sure, which should be 620-660 kPa {6.3-6.7 kgf/cm2, 89.61-
95.29 lbf/in.2}.
Charging speed: From 295 kPa {3.0 kgf/cm2, 42.66 lbf/in.2} to
490 kPa {5.0 kgf/cm2, 71.10 lbf/in.2} within 3-7 seconds.
(2) No.2 side
a. When applying air at charging speed specified below from the
inlet side under air pressure "0" at the outlet port No.23 and
No.24, confirm that a pressure at the inspection port when it
starting to go up at the outlet should be of Opening valve
pressure, which should be 570-610 kPa {5.8-6.2 kgf/cm2,
82.49-88.18 lbf/in.2}.
Charging speed: From 295 kPa {3.0 kgf/cm2, 42.66 lbf/in.2} to
490 kPa {5.0 kgf/cm2, 71.10 lbf/in.2} within 8-22 seconds.
2. CLOSING VALVE PRESSURE

(1) When discharging air through respective No.1 side and No.2 side
inlet under a pressure of 880 kpa {9 kgf/cm2, 128 lbf/in.2} at the
inlet and the outlet, at discharging speed specified below, confirm
that a pressure when the pressures saturated should be of Clos-
ing valve pressure, which should be 440-480 kPa {4.5-4.8 kgf/
cm2, 64.01-68.27 lbf/in.2}.
Discharging speed: From 590 kPa {6.0 kgf/cm2, 85.32 lbf/in.2} to
295 kPa {3.0 kgf/cm2, 42.66 lbf/in.2} within less than seconds.
NOTICE
Perform test again by increasing sims, when the respective pres-
sures is low and by decreasing it when high in the above inspec-
tion.

EN0680202H300008
Unit: mm {in.}

surface of body: if necessary.
Wear and damage

surface of valve seat and if necessary.
piston:
Wear and damage
Conical spring and compres- 1. 0.78 1. 0.69 Replace. Visual check

sion spring: {0.08} {0.07}
2. 158.9 2. 137.3
Free length
{16.2} {14.0}
QUICK RELEASE VALVE

EN0680202I200007
Type Diaphragm type
DESCRIPTION
EN0680202C100008
SHTS068020200071
1 Cover 6 Bolt
2 Filter A Inlet
3 Gasket B Outlet
5 Valve body
COMPONENT LOCATOR
EN0680202D100007
SHTS068020200072
1 Cover 4 Diaphragm
2 Filter 5 Valve body
3 Gasket 6 Bolt
OVERHAUL
EN0680202H200006

NOTICE
Before disassemble the relay valve apply the aligning mark "A" for
SHTS068020200073
1. ASSEMBLE THE RELAY VALVE

(1) When assembly the relay valve, use the new diaphragm and gas-
ket.
• A: Gasket
• B: Diaphragm
(2) Coincide the aligning mark "A" which were applied at disassem-
bly.
SHTS068020200074

EN0680202H300009
Valve body and cover — — Replace, Visual check

surface: if necessary.
Rust and damage
SPRING BRAKE CONTROL VALVE

EN0680202I200008

Outlet pressure difference between parking and releas-
Within 147 kPa {1.5 kgf/cm2, 21.33 lbf/in.2}
ing stroke at a specified lever angle
DESCRIPTION
EN0680202C100009
14
13 PARK
1 3 2 4 5 6 11
12
15
O
36
OFF
7 8 9 10
C A B
SHTS068020200076
1 Body cover 7 Piston spring 13 Grip

2 Feed valve spring 8 Valve seat spring 14 Compression spring
3 Piston 9 Cam 15 Release rod
4 Feed valve 10 Cam holder A Inlet
5 Valve seat 11 Return spring B Outlet
6 Valve body 12 Pull rod C Exhaust (PARK)
COMPONENT LOCATOR
EN0680202D100008
SHTS068020200077
1 Body cover 10 Valve seat spring 19 Body cap

2 Shim 11 Lock pin 20 Return spring
3 Piston spring 12 Release rod knob 21 Valve body
4 Feed valve spring 13 Grip 22 Cam holder
5 Retainer ring 14 Pull rod 23 Body pin
6 O-ring 15 Supporter 24 Cam holder pin
7 Piston 16 Cover 25 Cam
8 Feed valve 17 Stopper 26 Piston guide
9 Valve seat 18 Compression spring

A 5.4-7.4 {55-75, 4.0-5.4} B 3.4-4.9 {35-50, 2.6-3.6}
OVERHAUL
EN0680202H200007

a
1. LUBRICATION
(1) When assembling the spring brake control valve, replace the feed
valve, valve seats and O-rings.
(2) Apply silicone grease to each sliding surface of the assembly
parts, O-rings and O-ring grooves.
a. O-ring
b. Feed valve
c. Piston
b c d e f
d. Valve seat
SHTS068020200078
e. Cam
f. Cam holder
2. ASSEMBLE THE CAM ASSEMBLY.

(1) When assembling the cam and cam holder, make sure that the
cam holder pin and spiral groove of the cam are aligned.
(2) When installing the cam assembly to the valve body, the valve
body pin and straight groove of the cam must be aligned.
SHTS068020200079
(3) Adjust dimension "A" with the shim.

a Assembly standard: 33.8-34.2 mm {1.331-1.346 in.}
a. Cam
A b. Cam holder
c. Shim
b c
SHTS068020200080
3. SPRING BRAKE CONTROL VALVE PERFORMANCE TEST

SPRING BRAKE (1) First, connect the pressure gauge to the outlet line and apply an
AIR
CONTROL VALVE
PRESSURE air pressure of 834 kPa {8.5 kgf/cm2, 121 lbf/in.2} to the inlet line.
GAUGE
TANK
SHTS068020200081
(2) Move the spring brake control lever towards the OFF position,
gradually and confirm that the air pressure in the outlet line meets
the characteristic shown in figure.
Standard:
Lever angle: Outlet pressure: kPa {kgf/cm2, lbf/in.2}
6-12° 19.6-49 {0.2-0.5, 2.85-7.11}
Over 31° 686 {7.0, 99.54}
NOTICE
The characteristic shown is under the inlet pressure of 834 kPa
{8.5 kgf/cm2, 121 lbf/in.2}
SHTS068020200082
SHTS068020200083

EN0680202H300010
Unit: mm {in.}
Piston and valve body: — — Replace, Visual check

Cam, pin and cam — — Replace, Visual check

holder: if necessary.
Wear and damage
Piston spring: Free Length 25.0 Replace, Measure and visual check
Rust, damage and mea- 27.9 {1.098} {0.984} if necessary.
sure the spring free
length
Feed valve spring and — — Replace, Visual check

valve seat spring: if necessary.
Rust and damage
RELAY VALVE (FOR FRONT BRAKE AND TRAILER BRAKE)

EN0680202I200009
Type Diaphragm type

Pressure difference between signal and outlet pressure 10-29 kPa {0.1-0.3 kgf/cm2, 1.43-4.26 lbf/in.2}
DESCRIPTION
EN0680202C100010
SHTS068020200088
1 Cover 7 Return spring

2 Body A Signal air
3 Cap B Outlet air
5 Exhaust valve D Inlet air
6 Feed valve
COMPONENT LOCATOR
EN0680202D100009
1
A
8
2
10
3 6
5 11
6
12
7
B
13
SHTS068020200089
1 Cover 8 Filter
2 Retainer ring 9 Body
3 Washer 10 Feed valve
4 Diaphragm 11 Return spring
5 Shim 12 Gasket
6 O-ring 13 Cap
7 Exhaust valve

A 11.8-14.7 {120-150, 9-10} C 11.8-14.7 {120-150, 9-10}
B 59-78 {600-800, 44-57}
OVERHAUL
EN0680202H200008

NOTICE
the cover and body.
SHTS068020200090
1. LUBRICATION
(2) Apply adequate amount of the silicone grease to the O-rings,
SHTS068020200091

EN0680202H300011

valve contact surfaces of if necessary.
exhaust valve:
Wear and damage

valve contact surfaces 2:
Wear and damage
Wear and damage
RELAY VALVE (FOR FRONT SPRING BRAKE CHAMBER)

EN0680202I200010
Type Diaphragm type with double check valve combined

Pressure difference between signal and outlet pressure 29.4 kPa {0.3 kgf/cm2, 4.26 lbf/in.2}
DESCRIPTION
EN0680202C100011
SHTS068020200094
1 Cover 8 Filter
2 Diaphragm 9 Valve
3 Valve body 10 Plug
4 Valve sub assembly A Signal
5 Valve cap B Outlet
6 Spring C Exhaust
7 Valve D Inlet
COMPONENT LOCATOR
EN0680202D100010
SHTS068020200095
1 Valve sub assembly 7 Filter

2 Cover 8 Valve body
3 Guide 9 Valve
4 Valve 10 O-ring
5 Gasket 11 Spring
6 Plug 12 Valve cap

A 11.8-14.7 {120-150, 9-10} C 58.8-78.4 {600-800, 44-57}
B 34.3-44.1 {350-450, 26-32}
OVERHAUL
EN0680202H200009

NOTICE
Before disassembling the relay valve, mark the aligning marks "A"
on the cover and valve body.
SHTS068020200096
1. LUBRICATION
(1) When assembling the relay valve, use new O-rings and valves.
(2) Apply the silicone grease to each sliding surface of the compo-
A: O-ring
B: Apply the silicone grease
SHTS068020200097

EN0680202H300012
Check valve: — — Replace, Visual check

Cover, guide and plug: — — Clean or Visual check

Damage, wear and rust Replace,
if necessary.

Relay valve body and cap — — Clean or Visual check

sliding surface: Replace,
Damage, wear and rust if necessary.
RELAY VALVE (WITH CHECK VALVE, FOR REAR BRAKE)

EN0680202I200011
Type Diaphragm type (With a check valve combined)

Pressure difference between signal and outlet pressure 24.5-53.9 kPa {0.25-0.55 kgf/cm2, 3.56-7.82 lbf/in.2}
DESCRIPTION
EN0680202C100012
SHTS068020200102

2 Spring 9 Cap
3 Check valve 10 Filter
4 Plug A Signal (From brake valve)
5 Diaphragm B Inlet (From air tank)
6 Valve body C Outlet (To brake chamber)
7 Exhaust valve D Exhaust
COMPONENT LOCATOR
EN0680202D100011
SHTS068020200103
1 Cover 9 Check valve

2 Retainer ring 10 Gasket
3 Diaphragm washer 11 Plug
4 Diaphragm 12 Valve body
5 Shim 13 Filter
6 Exhaust valve 14 Feed valve
7 O-ring 15 Cap
8 Spring 16 Valve spring

A 11.8-14.7 {120-150, 9-10} C 59-78 {600-800, 44-57}
B 50-58 {500-600, 37-43}
OVERHAUL
EN0680202H200010

NOTICE
the cover and body.
SHTS068020200090
1. LUBRICATION
(1) When reassembling the relay valve, replace the check valve, O-
rings, diaphragm, gasket and feed valve with new ones.
SHTS068020200104

EN0680202H300013
Unit: mm {in.}

valve contact surfaces of if necessary.
exhaust valve:
Wear and damage
Valve contact surface of — — Replace, Visual check

plug 1: if necessary.
Wear and damage
Valve body, — — Replace,

Sliding surfaces 2, Valve if necessary.
contact surfaces 3:
Wear and damage
Wear and damage
Compression spring: 46.0 {1.81} — Replace, Measure and visual check

Rust, damage, if necessary.
Free length.
Valve spring: 31.8 {1.25} — Replace,

Rust, damage, if necessary.
Free length.
RELAY VALVE (FOR REAR SPRING BRAKE CHAMBER)

EN0680202I200012
Type Diaphragm type

Pressure difference between signal and outlet pressure Less than 29 kPa {0.3 kgf/cm2, 4.26 lbf/in.2}
DESCRIPTION
EN0680202C100013
1
4
A
5
B
6
7 3
SHTS068020200107

2 Body 7 Return spring
3 Cap A Signal air
4 Diaphragm B Inlet air
5 Exhaust valve C Exhaust
COMPONENT LOCATOR
EN0680202D100012
SHTS068020200108
1 Cover 8 Filter
2 Retainer ring 9 Dust cover
3 Washer 10 Body
4 Diaphragm 11 Feed valve
5 Shim 12 Return spring
6 O-ring 13 Gasket
7 Exhaust valve 14 Cap

A 11.8-14.7 {120-150, 9-10} B 58.8-78.4 {600-799, 44-57}
OVERHAUL
EN0680202H200011

NOTICE
the cover and body.
SHTS068020200109
1. LUBRICATION
GROOVE O-RING (1) When reassembling the relay valve, replace the O-rings, dia-
O-RING (2) Apply adequate amount of the silicone grease to the O-rings,
O-RING
GROOVE which were applied at disassembly.
SHTS068020200110

EN0680202H300014

valve contact surfaces if necessary.
of exhaust valve:
Wear and damage

valve contact surfaces
2:
Wear and damage
1
1
Wear and damage
3
RELAY VALVE (FOR REAR BRAKE)

EN0680202I200013
Type Piston type

Pressure difference between signal and outlet pressure Less than 29 kPa {0.3 kgf/cm2, 4.26 lbf/in2.}
DESCRIPTION
EN0680202C100014
SHTS068020200113
1 Return spring 8 Check valve

2 Exhaust valve 9 Feed valve return spring
3 Cover A Signal air
4 Piston B Inlet air
5 Valve body C Outlet air
6 Feed valve D Exhaust
7 Valve retainer
COMPONENT LOCATOR
EN0680202D100013
SHTS068020200114
1 Cover 10 Spring seat

2 Piston 11 Feed valve return spring
3 O-ring 12 Valve retainer
4 Piston return spring 13 Retainer ring
5 Exhaust valve 14 Nut
6 Dust seal 15 Dust cover
7 Exhaust valve 16 Check valve
8 Plug 17 Plate
9 Feed valve
OVERHAUL
EN0680202H200012

NOTICE
Before disassembling the relay valve, apply the aligning mark "A"
to the cover and body.
SHTS068020200115
1. LUBRICATION
SHTS068020200116

EN0680202H300015
Valve cover, sliding surface 1: — — Replace, Visual check

Piston assembly, sliding surface 2, — — Replace,

valve contact surface 3: if necessary.
Wear and damage
Valve body, valve contact surface 4: — — Replace,


[FOR REAR BRAKE (WEDGE TYPE)]
EN0680202I200014
Type Spring and piston type brake chamber combined with diaphragm type chamber
DESCRIPTION
EN0680202C100015
SHTS068020200118
1 Elbow 4 Diaphragm
2 Clamp 5 Push rod assembly
3 Piggyback 6 Bracket
COMPONENT LOCATOR
EN0680202D100014
11
10
6
7
9
8
3
1
A
2
12
: Apply grease (Dynamax No.2: COSMO OIL CO., LTD product or equivalent).
SHTS068020200119
1 Elbow 7 Pin
2 Clamp 8 Bushing
3 Piggyback 9 Push rod guide
4 Diaphragm 10 Push rod boot
5 Push rod assembly 11 Push rod
6 Ring 12 Bracket

A 14.7-20.0 {150-204, 11.0-14.8}
OVERHAUL
EN0680202H200013
1. DISASSEMBLY OF SPRING BRAKE CHAMBER

NOTICE
Piggyback is very dangerous because there is very strong spring
inside it. Never disassemble the piggyback.
SHTS068020200120
(1) Disconnect the breather tube from the service chamber side
ELBOW BREATHER TUBE elbow.
NOTICE
• Do not disconnect the breather tube from the piggyback side.
• Pulling the center of the elbow obliquely can easily discon-
nect the breather tube from the elbow.
SHTS068020200121
(2) Apply the aligning mark on the clamp, piggyback and bracket.
(3) Remove the clamp, the piggyback and diaphragm from the
bracket.
(4) Remove the ring and pin, then disassemble the push rod assem-
bly.
SHTS068020200122
1. ASSEMBLY OF THE PUSH ROD ASSEMBLY

(1) Before assembling, apply grease (Dynamax No.2: COSMO OIL.,
LTD. product or equivalent) to each component parts.
SHTS068020200123
2. ASSEMBLY OF THE SPRING BRAKE CHAMBER

(1) Apply grease to inside of the bracket, and install the push rod
assembly, new diaphragm, piggyback and clamp.
NOTICE
• Do not adhere grease to the diaphragm.
• Before assembling, align the aligning marks on the clamp,
piggyback and bracket.
SHTS068020200122
(2) After wiping the breather tube, apply lock agent (LOCTITE 414 or
equivalent) on the tube open end.
13 mm {0.512 in.} (3) Insert the breather tube in the elbow as shown in the figure.
ELBOW or MORE BREATHER TUBE
SHTS068020200124
3. INSPECTION FOR AIR LEAKAGE

(1) Apply compressed air of 690-880 kPa {7.0-9.0 kgf/cm2, 100-128
lbf/in.2} to both inlet ports marked E and S, and make sure that
there is no air leakage from the joints of the assembly.
SHTS068020200125
4. INSPECTION FOR PISTON MOVEMENT

lbf/in.2} to the inlet port marked E gradually and measure the ser-
vice chamber stroke.
Piston stroke: 58-61 mm {2.28-2.40 in.}

EN0680202H300016
Bracket, push rod, dia- — — Replace, Visual check

phragm and piggyback: if necessary
Wear and damage

[FOR FRONT BRAKE (S-CAM TYPE)]
EN0680202I200015
Spring and piston type brake chamber combined with diaphragm type chamber
Type
with breather tube
DESCRIPTION
EN0680202C100016
SHTS068020200127
1 Filter 11 Piston 21 Clevis

2 Retainer 12 Retainer ring 22 Breather tube
3 Release bolt 13 Bushing A Spring brake air port
4 Slotted nut 14 Piston follower (Emergency and parking) - for
releasing air
5 Spring pin 15 Bulkhead B Service brake air port (Ser-
vice) - for braking air
6 Dust cover 16 Clamp band C Spring brake portion
7 Spring brake chamber 17 Diaphragm D Service brake portion
8 Spring 18 Service brake chamber E Drain hole
9 Piston ring 19 Compression spring
10 O-ring 20 Push rod
SPECIAL TOOL
EN0680202K100001
Prior to starting a spring brake chamber overhaul, it is necessary to have this special tool.
SPRING BRAKE PISTON

S0968-31051
RELEASE BOLT
COMPONENT LOCATOR
EN0680202D100015
SHTS068020200129
1 Dust cover 10 Retainer 19 Push rod

2 Spring pin 11 Plain washer 20 Spring retainer
3 Slotted nut 12 Release bolt 21 Compression spring
4 Filter 13 Retainer ring 22 Clamp band
5 Spring brake chamber 14 Bushing 23 Spacer
6 Spring 15 Bulkhead 24 Clamp band bolt
7 Piston ring 16 Chamber cover bolt 25 Service brake chamber
8 Piston 17 Piston follower 26 Clevis
9 O-ring 18 Diaphragm 27 Breather tube

A 39.2-44.2 {400-450, 29-32} D 39.0-49.0 {400-500, 29-36}
B 9.8-17.6 {100-180, 7.3-13.0} E 26.5-32.3 {270-330, 20-23}
C 39.0-49.0 {400-500, 29-36}
OVERHAUL
EN0680202H200014
1. DISMOUNTING THE CHAMBER ASSEMBLY

(1) Before dismounting the chamber, turn the release bolt counter-
clockwise to release the spring brake.
SHTS068020200130

NOTICE
Before disassembling, put aligning marks to the clamp band, ser-
vice brake chamber, bulkhead and spring brake chamber.
SHTS068020200131
1. DISASSEMBLING THE SPRING BRAKE CHAMBER

(1) Remove the piston follower and then remove the dust cover,
spring pin and release bolt.
SHTS068020200132
(2) Use a press or special tool to hold the spring in compression then
remove the chamber cover bolt.
SST: Spring brake piston release bolt (S0968-31051)
SHTS068020200133
1. LUBRICATION
(1) When assembling the spring brake chamber, replace the piston
ring, bushing and O-ring with new ones.
(2) Apply grease or oil to each point.
• a Silicone grease: O-ring, Bushing, Piston ring and

Spring brake chamber inner side.
• b Bearing grease: Release bolt
• c Rust preventive oil: Spring
SHTS068020200134

(1) Attach guide bolts to align the holes.
NOTICE
Align the aligning marks of the spring brake chamber and bulk-
head.
SHTS068020200135
(2) Use a press or special tool to compress the spring then tighten
the chamber cover with the bolts.
SHTS068020200136
(3) Screw in the release bolt until its head contacts the piston flange,
then return the release bolt one or two turns, then install the slot-
ted nut and spring pin.
NOTICE
The spring pin should be installed as shown in the figure.
SHTS068020200137
(4) Install the piston follower on the piston.

NOTICE
Apply locking adhesive (LOCTITE 242 or equivalent) to the thread
of the piston follower.
SHTS068020200138
3. ASSEMBLING THE SERVICE BRAKE CHAMBER

(1) Turn the release bolt counterclockwise to compress the spring of
the spring brake chamber.
NOTICE
To make turning easy, apply compressed air to the spring brake
chamber.
SHTS068020200139
(2) When reassembling the chamber, replace the diaphragm with

new one.
NOTICE
Align the aligning marks of the chamber, clamp band and bulk-
head.
(3) Insert the clamp band bolts from opposite side of drain hole and
tighten the bolts evenly with nuts within specified torque.
SHTS068020200140
(4) Turn the release bolt clockwise to release the spring of the spring
brake chamber.
SHTS068020200141

(1) Apply compressed air of 834 kPa {8.5 kgf/cm2, 121 lbf/in.2} to
both inlet ports marked E and S, and make sure that there is no
air leakage from the joints of the assembly.
SHTS068020200142

(1) Apply compressed air of 490 kPa {5.0 kgf/cm2, 71 lbf/in.2} to the
inlet port with mark E gradually and make sure that the push rod
is completely returned.
Piston stroke: 52 mm {2.05 in.}
for spring brake chamber parts No.
47850-2920/ -2930/ -2940/ -2950/ -3030/ -3040
SHTS068020200143
6. SETTING THE CLEVIS TO PUSH ROD

(1) Screw the clevis into the push rod until the screw ends of both cle-
vis and push rod are flush.
SHTS068020200144
1. INSTALLING THE CHAMBER ASSEMBLY

(1) Before mounting, turn the release bolt counterclockwise to
release the spring brake.
NOTICE
• Note the position mark R or L on the chamber which mark
was applied when dismounting and install it to its former
side.
• When connecting the clevis with slack adjuster, lubricate cle-
vis pin-hole and clevis pin with sufficient chassis grease.
SHTS068020200130
(2) After mounting, the release bolt must be set at the specified
torque.

EN0680202H300017

Piston: — — Replace, Visual check
Chamber: — — Replace, Visual check

Spring and compression spring: — — Replace, Visual check


[FOR REAR BRAKE (S-CAM TYPE)]
EN0680202I200016
Spring and piston type brake chamber combined with diaphragm type chamber
Type
with breather tube
DESCRIPTION
EN0680202C100017
SHTS068020200148
1 Retainer 15 Clamp band

2 Release bolt 16 Diaphragm
3 Slotted nut 17 Service brake chamber
4 Spring pin 18 Compression spring
5 Dust cover 19 Push rod
6 Spring brake chamber 20 Clevis
7 Spring 21 Breather tube
8 Piston ring A Spring brake air port
9 O-ring (Emergency and parking) - for releasing air
10 Piston B Service brake air port (Service) - for braking air
11 Retainer ring C Spring brake portion
12 Bushing D Service brake portion
13 Piston follower E Drain hole
14 Bulkhead
SPECIAL TOOL
EN0680202K100002
Prior to starting a spring brake chamber overhaul, it is necessary to have this special tool.
SPRING BRAKE PISTON

S0968-31051
RELEASE BOLT
COMPONENT LOCATOR
EN0680202D100016
SHTS068020200150
1 Dust cover 10 Retainer 19 Push rod

2 Spring pin 11 Plain washer 20 Spring retainer
3 Slotted nut 12 Release bolt 21 Compression spring
4 Caution plate 13 Retainer ring 22 Clamp band
5 Spring brake chamber 14 Bushing 23 Spacer
6 Spring 15 Bulkhead 24 Clamp band bolt
7 Piston ring 16 Chamber cover bolt 25 Service brake chamber
8 Piston 17 Piston follower 26 Clevis
9 O-ring 18 Diaphragm 27 Breather tube

A 39.0-44.0 {400-450, 29-32} D 39.0-49.0 {400-500, 29-36}
B 9.8-17.6 {100-180, 7.3-13.0} E 26.5-32.3 {270-330, 20-23}
C 39.0-49.0 {400-500, 29-36}
OVERHAUL
EN0680202H200015
1. DISMOUNTING THE CHAMBER ASSEMBLY

(1) Before dismounting the chamber, turn the release bolt counter-
clockwise to release the spring brake.
SHTS068020200151

NOTICE
Before disassembling, put aligning marks to the clamp band, ser-
vice brake chamber, bulkhead and spring brake chamber.
SHTS068020200152
1. DISASSEMBLING THE SPRING BRAKE CHAMBER

(1) Remove the piston follower and then remove the dust cover,
spring pin and release bolt.
SHTS068020200153
(2) Use a press or special tool to hold the spring in compression then
remove the chamber cover bolt.
SHTS068020200154
1. LUBRICATION
(1) When assembling the spring brake chamber, replace the piston
ring, bushing and O-ring with new ones.
(2) Apply grease or oil to each point.
• a Silicone grease: O-ring, Bushing, Piston ring and

Spring brake chamber inner side.
• b Bearing grease: Release bolt
• c Rust preventive oil: Spring
SHTS068020200155

(1) Attach guide bolts to align the holes.
NOTICE
Align the aligning marks of the spring brake chamber and bulk-
head.
SHTS068020200156
(2) Use a press or special tool to compress the spring then tighten
the chamber cover with the bolts.
SHTS068020200157
(3) Screw in the release bolt until its head contacts the piston flange,
then return the release bolt one or two turns, then install the slot-
ted nut and spring pin.
NOTICE
The spring pin should be installed as shown in the figure.
SHTS068020200158
(4) Install the piston follower on the piston.

NOTICE
Apply locking adhesive (LOCTITE 242 or equivalent) to the thread
of the piston follower.
SHTS068020200159
3. ASSEMBLING THE SERVICE BRAKE CHAMBER

(1) Turn the release bolt counterclockwise to compress the spring of
the spring brake chamber.
NOTICE
To make turning easy, apply compressed air to the spring brake
chamber.
SHTS068020200160
(2) When reassembling the chamber, replace the diaphragm with

new one.
NOTICE
Align the aligning marks of the chamber, clamp band and bulk-
head.
(3) Insert the clamp band bolts from opposite side of drain hole and
tighten the bolts evenly with nuts within specified torque.
SHTS068020200161
(4) Turn the release bolt clockwise to release the spring of the spring
brake chamber.
SHTS068020200162

(1) Apply compressed air of 834 kPa {8.5 kgf/cm2, 121 lbf/in.2} to
both inlet ports marked E and S, and make sure that there is no
air leakage from the joints of the assembly.
SHTS068020200163

lbf/in.2} to the inlet port with mark E gradually and make sure that
the push rod is completely returned.
Piston stroke: 62 mm {2.44 in.}
47850 -1890/ -1900/ -1971/ -1981/ -2530/
-2540/ -2551/ -2561/ -2570/ -2580/
-2590/ -2600/ -2650/ -2660/ -2670/
-2680/ -2720/ -2730/ -2810/ -2820/
-2830/ -2840/ -2850/ -2860/ -2870/
SHTS068020200164 -2880/ -2890/ -2900/ -2990/ -3000/
-3230/ -3240
: 52 mm {2.05 in.}
47850 -2920/ -2930/ -2940
-2950/ -3030/ -3040
6. SETTING THE CLEVIS TO PUSH ROD

(1) Screw the clevis into the push rod until the screw ends of both cle-
vis and push rod are flush.
SHTS068020200165
1. INSTALLING THE CHAMBER ASSEMBLY

(1) Before mounting, turn the release bolt counterclockwise to
release the spring brake.
NOTICE
• Note the position mark R or L on the chamber which mark
was applied when dismounting and install it to its former
side.
• When connecting the clevis with slack adjuster, lubricate cle-
vis pin-hole and clevis pin with sufficient chassis grease.
SHTS068020200151
torque.

EN0680202H300018

Piston: — — Replace, Visual check
Chamber: — — Replace, Visual check

Spring and compression spring: — — Replace, Visual check


[FOR FRONT BRAKE (WEDGE TYPE)]
EN0680202I200017
Type Diaphragm type
Chamber inside diameter 124 mm {4.88 in.}
DESCRIPTION
EN0680202C100018
SHTS068020200169
1 Chamber cover 4 Push rod assembly

2 Clamp 5 Bracket
3 Diaphragm
COMPONENT LOCATOR
EN0680202D100017
11
10
6
2
7
9
8 1
A
3
: Apply grease (Dynamax No.2: COSMO OIL CO., LTD. product or equivalent).
SHTS068020200170
1 Clamp 7 Pin
2 Chamber cover 8 Bushing
3 Diaphragm 9 Push rod guide
4 Push rod assembly 10 Push rod boot
5 Bracket 11 Push rod
6 Ring

A 14.7-20.0 {150-204, 11.0-14.8}
OVERHAUL
EN0680202H200016
1. DISASSEMBLY OF THE BRAKE CHAMBER

(1) Before dismounting, apply aligning mark to the clamp, chamber
cover and bracket.
(2) Remove the clamp, diaphragm and chamber cover from the
bracket.
(3) Disassemble the push rod assembly.
SHTS068020200171
1. ASSEMBLY OF PUSH ROD ASSEMBLY

(1) Before assembling, apply grease (Dynamax NO.2: COSMO OIL
CO., LTD. product or equivalent) to each component parts.
SHTS068020200172
2. ASSEMBLY OF BRAKE CHAMBER

(1) Apply grease to inside of the bracket and install the push rod
assembly, new diaphragm, chamber cover and clamp.
NOTICE
• Do not adhere grease to the diaphragm.
SHTS068020200173
• Before assembling, align the aligning marks on the clamp,

chamber cover and bracket.
SHTS068020200171
3. CHECK OF AIR LEAKAGE

(1) Apply soapy water to the chamber as shown and charge with
compressed air of 690-880 kPa {7.0-9.0 kgf/cm2, 100-128 lbf/in.2}
from the inlet port A then check for leakage.
SHTS068020200174

EN0680202H300019
Chamber cover, clamp, — — Replace, Visual check

push rod, diaphragm and if necessary
bracket:
Wear and damage

[FOR FRONT BRAKE (S-CAM TYPE)]
EN0680202I200018
Type Diaphragm type
DESCRIPTION
EN0680202C100019
SHTS068020200176
1 Push rod 5 Diaphragm

2 Return spring 6 Chamber cover
3 Chamber A Inlet
4 Clamp B Drain hole
COMPONENT LOCATOR
EN0680202D100018
SHTS068020200177
1 Chamber cover 7 Push rod

2 Clamp nut 8 Return spring
3 Clamp bolt 9 Chamber
4 Clamp 10 Holder
5 Spacer 11 Retainer
6 Diaphragm

A 17.7-19.6 {180-200, 13.1-14.4}
OVERHAUL
EN0680202H200017
1. DISMOUNTING OF THE BRAKE CHAMBER

(1) Before dismounting, apply aligning mark A to the chamber, clamp
and chamber cover.
(2) Apply a position mark R or L to identify the side where the cham-
ber was installed.
SHTS068020200178
1. ASSEMBLING THE BRAKE CHAMBER

(2) Align the aligning mark A of the chamber, clamp and chamber
cover.
bolts evenly with nut within the specified torque.
SHTS068020200179

compressed air of 830 kPa {8.5 kgf/cm2, 121 lbf/in.2} from the
inlet port A then check for leakage.
SHTS068020200180
3. INSTALLING CLEVIS
(1) Install the clevis to the push rod and adjust dimension A to the
specified value.
Assembly Standard: 183 mm {7.205 in.}
1. INSTALLING THE BRAKE CHAMBER

(1) The chamber must be mounted on the side as marked when dis-
mounting.
SHTS068020200181
NOTICE
• See the position mark (R or L) which was applied when dis-
mounting.
• When connecting the clevis with the slack adjuster, lubricate
the clevis pin hole and clevis pin with sufficient chassis
grease.

EN0680202H300020

return spring and cham- if necessary.
ber:
Wear and damage
BRAKE CHAMBER [FOR REAR (REARWARD) BRAKE]

EN0680202I200019
Type Diaphragm type
DESCRIPTION
EN0680202C100020
SHTS068020200183

2 Holder 8 Chamber cover
3 Dust seal 9 Retainer
4 Return spring A Inlet
5 Chamber B Drain hole
6 Clamp
COMPONENT LOCATOR
EN0680202D100019
SHTS068020200184
1 Chamber cover 7 Push rod

2 Clamp nut 8 Retainer
3 Clamp bolt 9 Return spring
4 Clamp 10 Dust seal
5 Spacer 11 Holder
6 Diaphragm 12 Chamber

A 26.5-32.3 {270-330, 20-23}
OVERHAUL
EN0680202H200018

(1) Before dismounting, apply aligning mark to the chamber, clamp
and chamber cover.
(2) Apply a position mark R or L to identify the side where the cham-
ber was installed.
SHTS068020200185

(2) Align the aligning mark A of the chamber, clamp and chamber
cover.
SHTS068020200186

compressed air of 830 kPa {8.5 kgf/cm2, 121 lbf/in.2} from the
inlet port A then check for leakage.
SHTS068020200187
(1) Install the clevis to the push rod and adjust dimension A to the
specified value.
ID MARK
Assembly Standard: 85 mm {3.35 in.} -3100/ -3110
318 mm {12.52 in.} -3080/ -3090
330 mm {12.99 in.} -2910/ -2920

SHTS068020200188 1. INSTALLING THE BRAKE CHAMBER
mounting.
NOTICE
• See the position mark (R or L) which was applied when dis-
mounting.
grease.

EN0680202H300021

return spring, if necessary.
retainer, dust seal, holder
and chamber:
Wear and damage
BRAKE CHAMBER (MODEL: SG)

[FOR REAR BRAKE (S-CAM TYPE)]
EN0680202I200020
Type Diaphragm type
DESCRIPTION
EN0680202C100021
SHTS068020200190

2 Return spring 6 Chamber cover
3 Chamber A Inlet
4 Clamp B Drain hole
COMPONENT LOCATOR
EN0680202D100020
SHTS068020200191
1 Chamber cover 6 Diaphragm

2 Clamp nut 7 Push rod
3 Clamp bolt 8 Return spring
4 Clamp 9 Chamber
5 Spacer

A 17.7-19.6 {180-200, 13.1-14.4}
OVERHAUL
EN0680202H200019

(1) Before dismounting, apply aligning mark "A" to the chamber,
clamp and chamber cover.
(2) Apply a position mark "R" or "L" to identify the side where the
SHTS068020200192

(2) Align the aligning mark "A" of the chamber, clamp and chamber
cover.
SHTS068020200193

compressed air of 830 kPa {8.5 kgf/cm2, 121 lbf/in2.} from the
inlet port "A" then check for leakage.
SHTS068020200194
(1) Install the clevis to the push rod and adjust dimension "A" to the
specified value.
Assembly Standard: 65 mm {2.559 in.}
SHTS068020200195
1. INSTALLING THE BRAKE CHAMBER

mounting.
NOTICE
• See the position mark ("R" or "L") which was applied when
dismounting.
grease.

EN0680202H300022

return spring and if necessary.
chamber:
Wear and damage
TRAILER HAND BRAKE CONTROL VALVE

EN0680202I200021
DESCRIPTION
EN0680202C100022
SHTS068020200197

COMPONENT LOCATOR
EN0680202D100021
SHTS068020200198


A 9.9-19.6 {100-200, 8-14} C 2.5-3.9 {25-40, 1.9-2.8}
B 5.4-7.3 {55-75, 4.0-5.4}
OVERHAUL
EN0680202H200020

NOTICE
Before disassembling the hand brake valve, mark the aligning
mark "A" on the holder and valve body.
SHTS068020200199
1. LUBRICATION
valve.
a. O-ring
c. Sliding surface
SHTS068020200200

NOTICE
L: 38.3-38.7 mm {1.508-1.523 in.}
SHTS068020200201
2. HAND BRAKE VALVE PERFORMANCE CHARACTERISTIC

a. Air pressure at outlet port (kPa {kgf/cm2, lbf/in2})
(a1) (a2)
a 19.6-68.6 460.6-558.6
{0.2-0.7, 2.8-9.9} {4.7-5.7, 66.8-81.0}
(b1) (b2)
b
7-13 37-43
NOTICE
sure of 690 kPa {7.0 kgf/cm2, 99.54 lbf/in2.}

EN0680202H300023
Unit: mm {in.}

Wear and damage

2. 38 {1.496}
dimension. 3. 31 {1.220}



WHEEL BRAKE (WEDGE TYPE)

EN0680202I200022
Drum brake with internally expanding, leading-trailing shoes operating

Type
by expander in all wheels.

Width x Thickness Rear 200 x 16 mm {7.9 x 0.63 in.}
DESCRIPTION
EN0680202C100023
FRONT (MODEL: FG)
SHTS068020200208
1 Brake shoe return spring 8 Brake lining

2 Expander 9 Anchor pin retainer
3 Brake shoe 10 Lock plate
4 Anchor pin 11 Wheel sensor (If so equipped)
5 Brake spider 12 Sensor ring (If so equipped)
6 Brake drum A Front
7 Brake chamber
REAR (MODEL: FG)
SHTS068020200209

7 Spring brake chamber
FRONT (MODEL: GH)
SHTS068020200210

7 Brake chamber
REAR (MODEL: GH)
SHTS068020200211

7 Spring brake chamber
SPECIAL TOOL
EN0680202K100003

COMPONENT LOCATOR
EN0680202D100022
FRONT (MODEL: FG)
SHTS068020200214
1 Brake chamber 11 Brake shoe return spring

2 O-ring 12 Brake drum cover
3 Hole plug 13 Brake drum
4 Brake spider 14 Rivet
5 Anchor pin 15 Brake lining
6 Anchor pin retainer 16 Retainer spring
7 Lock plate 17 Return spring pin
8 Brake shoe assembly (Leading) 18 Bushing
9 Brake shoe assembly (Trailing) 19 Wheel sensor (If so equipped)
10 Expander 20 Clamping bushing

A 20.1-33.9 {205-345, 14.9-24.9} C 13.7-23.5 {140-240, 10.1-17.4}
B 36.3-51.9 {371-529, 26.9-38.2} D 20.1-33.9 {205-345, 14.9-24.9}
REAR (MODEL: FG)
SHTS068020200215
1 Brake chamber 10 Expander 19 Plate

2 O-ring 11 Brake shoe return spring 20 Pivot pin
3 Hole plug 12 Brake drum cover 21 Washer
4 Brake spider 13 Brake drum 22 Cotter pin
5 Anchor pin 14 Rivet 23 Return spring hanger
6 Anchor pin retainer 15 Brake lining 24 Wheel sensor (If so equipped)
7 Lock plate 16 Retainer spring 25 Sleeve (If so equipped)
8 Brake shoe assembly (Leading) 17 Return spring pin 26 Lock washer (If so equipped)
9 Brake shoe assembly (Trailing) 18 Bushing 27 Holder (If so equipped)

A 36.3-51.9 {371-529, 26.9-38.2} C 20.1-33.9 {205-345, 14.9-24.9}
B 13.7-23.5 {140-240, 10.1-17.4} D 34.5-51.5 {351-527, 26-38}
FRONT (MODEL: GH)
SHTS068020200216
1 Brake chamber 11 Brake shoe return spring

2 O-ring 12 Brake drum cover
3 Hole plug 13 Brake drum
4 Brake spider 14 Rivet
6 Anchor pin retainer 16 Retainer spring
7 Lock plate 17 Return spring pin
8 Brake shoe assembly (Leading) 18 Bushing
9 Brake shoe assembly (Trailing) 19 Wheel sensor (If so equipped)
10 Expander 20 Clamping bushing

A 20.1-33.9 {205-345, 14.9-24.9} D 20.1-33.9 {205-345, 14.9-24.9}
B 36.3-51.9 {371-529, 26.9-38.2} E 21-30 {214-398, 15.5-28.8}
C 13.7-23.5 {140-240, 10.1-17.4}
REAR (MODEL: GH)
SHTS068020200217
1 Brake chamber 10 Expander 19 Plate

2 O-ring 11 Brake shoe return spring 20 Pivot pin
3 Hole plug 12 Brake drum cover 21 Washer
4 Brake spider 13 Brake drum 22 Cotter pin
5 Anchor pin 14 Rivet 23 Return spring hanger
6 Anchor pin retainer 15 Brake lining 24 Wheel sensor (If so equipped)
7 Lock plate 16 Retainer spring 25 Sleeve (If so equipped)
8 Brake shoe assembly (Leading) 17 Return spring pin 26 Lock washer (If so equipped)
9 Brake shoe assembly (Trailing) 18 Bushing 27 Holder (If so equipped)

A 36.3-51.9 {371-529, 26.9-38.2} D 34.5-51.5 {351-527, 26-38}
B 13.7-23.5 {140-240, 10.1-17.4} E 21-30 {214-398, 15.5-28.8}
C 20.1-33.9 {205-345, 14.9-24.9}
OVERHAUL
EN0680202H200021
1. REMOVAL OF TIRE
2. REMOVAL OF BRAKE DRUM, WHEEL HUB AND WHEEL HUB

BEARINGS
3. COMPRESSION OF SPRING IN SPRING BRAKE CHAMBER

BY RELEASE BOLT
(1) Remove the release bolt, washer and release nut from the cham-
ber.
SHTS068020200218
(2) Remove the end cap. Insert the release bolt to the brake cham-
SPRING BRAKE CHAMBER ber, then turn the release bolt by 1/4.
NOTICE
2
1 • Make sure that the release bolt can not be pulled out.
• When the release bolt is pulled out, insert the release bolt
again and turn it by 1/4 similarly.
RELEASE BOLT
END CAP
SHTS068020200219
(3) Apply compressed air of 640 kPa {6.5 kgf/cm2, 92.5 lbf⋅in.2} to the
spring brake port.
NOTICE
When compressed air cannot be applying, coat grease to the
release bolt.
(4) Install the washer and release nut to the release bolt and pull out
the release bolt by 76 mm {2.992 in.}.
NOTICE
Do not turn the release nut at the strong torque (68.7 N⋅m {700
kgf⋅cm, 51 lbf⋅ft} or more).
SHTS068020200220
4. REMOVAL OF BRAKE SHOE RETURN SPRING

(1) Using the special tool, remove the return spring.
(FRONT WHEEL)
SST: Spring pull back tool (S0968-31070)
SHTS068020200221
(2) Using the special tool, remove the outer return spring.
(REAR WHEEL)
SHTS068020200222
(3) Turn the pivot pin and pull out the return spring pin then remove
the inner return spring (REAR WHEEL).
SHTS068020200223
5. REMOVAL OF ANCHOR PIN

(1) Remove the lock plate and anchor pin retainer.
(2) Using the special tool, remove the pin and brake shoe assembly.
SHTS068020200224
6. REMOVAL OF BRAKE CHAMBER AND EXPANDER

(1) Remove the air hose.
(2) Remove the brake chamber and O-ring from the brake spider.
(3) Using a hexagon wrench, remove the expander from the brake
spider.
SHTS068020200225
1. REPLACEMENT OF BRAKE LINING

(1) Remove the brake lining from the brake shoe.
a. Drill the rivet caulking section with a drill smaller than the rivet
diameter.
NOTICE
SHTS068020200226
b. After drilling, remove the remaining portion of the rivet with a

fine chisel or a riveting machine.
SHTS068020200227
(2) Install the brake lining to the brake shoe.

NOTICE
If a notched lining is used, the brake shoe and brake lining should
be installed as shown in figure.
SHTS068020200228
a. Set the lining on the shoe and insert the rivets into all holes,
then hold them in place with adhesive tape "A".
SHTS068020200229
b. Caulk the rivets lightly in a circular pattern as shown in figure

"B", repeat several times assure proper seating of the lining.
Recommended configuration of punch: shown in "C".
Recommended force of staking the rivet: 2.4 tons.
c. Remove adhesive tape.
SHTS068020200230
2. INSTALLATION OF EXPANDER AND BRAKE CHAMBER

(1) Apply grease (Darina Grease: Showa Shell Sekiyu K.K. product
or equivalent) to the expander as shown in the figure.
SHTS068020200231
(2) Using a hexagon wrench, install the expander to the brake spider.
NOTICE
Pay attention to assembling way.
SHTS068020200232
(3) Confirm the length of the expander rod.

NOTICE
Length from the chamber mounting area of spider to the edge of
the rod should be 100.5 mm {3.96 in.} as shown in the figure left.
Confirm it as that there is a possibility of a defective return of the
rod if it is shorter than the standard length.
(4) Install the new O-ring and brake chamber to the brake spider.
SHTS068020200233

(1) Apply adequate amount of heat resistance grease on the brake
shoe bushing, O-ring and anchor pin.
(3) Insert the anchor pin retainer in the grooves of the two anchor
pins.
(4) Place the lock plate on the anchor pin retainer so that its hole is
aligned with the lock plate hole, then insert the bolt and tighten it.
SHTS068020200234
4. INSTALLATION OF BRAKE SHOE RETURN SPRING

(1) Hook the inner spring to the clamp and turn the pivot pin to align
the holes, then insert the spring hanger.
(REAR WHEEL)
NOTICE
Painted part of the spring must be placed in the upper side.
SHTS068020200223
(2) Use the special tool to install the return spring.

(FRONT WHEEL, REAR WHEEL OUTER SPRING)
NOTICE
The folded part of the spring cover must be placed in the upper
side.
SHTS068020200221
NOTICE
• Do not operate the brake with the brake drum removed.
• The wedge type showed a returning failure because the
brake was applied the without the drum and shoe return
spring when brake maintenance was performed.
• The wedge becomes caught when the brake is operated and
return becomes defective due to the wedge exceeding the
cage.
SHTS068020200235
5. BRAKE DRUM AND WHEEL HUB

(1) When assembling the front brake drum and front wheel hub,
make sure that their aligning marks are aligned as close to each
other as possible.
NOTICE
Position of marks is shown in the figure.
SHTS068020200236

RELEASE
BOLT 1. REMOVAL OF THE RELEASE BOLT
FITTING
POSITION
(1) After mounting, turn the release bolt counterclockwise to release
the spring brake.
NOTICE
Note the position mark R or L on the chamber which mark was
applied when dismounting and install it to its former side.
torque.
Tightening Torque:
SHTS068020200237 13.7-15.7 N⋅m {140-160 kgf⋅cm, 10.2-11.5 lbf⋅in.}
2. MOUNTING OF WHEEL HUB AND BRAKE DRUM.

3. MOUNTING OF TIRE
4. ADJUSTMENT
(1) Finally, adjust the brake shoe clearance as explained in the sec-
tion "WHEEL BRAKE" .
ADJUSTMENT
EN0680202H300024

the time the next inspection is made replace the lining.
SHTS068020200238

{7.5-8.5 kgf/cm2, 107-121 lbf/in.2}
NOTICE
while making the adjustment.
3. INSPECTION OF THE CLEARANCE BETWEEN BRAKE LIN-

ING AND BRAKE DRUM
(1) Step on the brake pedal several times to make sure that the brake
shoes are correctly positioned.
SHTS068020200239
(2) Insert a thickness gauge from the inspection hole to inspect the
clearance between brake lining and brake drum. If the clearance
exceeds standard value, disassemble auto adjuster and perform
maintenance service because auto adjuster possibly may be out
of order.
STANDARD (mm {in.})

FRONT 0.2-1.0 {0.0079-0.0393}
REAR 0.2-1.0 {0.0079-0.0393}
4. ADJUSTMENT OF THE CLEARANCE BETWEEN BRAKE LIN-

ING AND BRAKE DRUM
NOTICE
As this brake has auto adjuster function, it is not necessary to
adjust the clearance between brake lining and brake drum. Adjust
the clearance in accordance with the following method, if the
brake lining is replaced and maintenance service is performed.
SHTS068020200240 NOTICE
When adjusting the clearance between brake lining and brake
drum, set spring brake control valve to the OFF position.
(3) Remove the brake drum cover.

(4) Insert the thickness gauge and turn the adjusting screw with
screwdriver so that brake shoe clearance come to the standard
value.
SHTS068020200241
from 2.
NOTICE
wheels.
SHTS068020200240

EN0680202H300025
Unit: mm {in.}
Brake drum: — — Regrind or Visual check

Cracks and damage replace,
if necessary.
Brake drum: 410 {16.142} 414 {16.299} Replace. Measure

Inside diameter
Brake drum: 0-0.1 {0-0.0039} 0.2 {0.0079} Regrind or Measure

Runout replace.
Brake shoe assembly: — — Replace, Visual check

Cracks and damage if necessary.
Brake lining: 16 {0.630} 5.0 {0.197} Replace. Measure

Thickness
Clearance between brake 0.05-0.14 0.30 {0.0118} Replace the Measure

shoe bushing and anchor {0.0020-0.0055} brake shoe
pin bushing and/
or anchor
pin.
Brake shoe return spring — — Replace, Visual check

and spring cover: if necessary.
Damage, lacking elastic
strength distortion
WHEEL BRAKE (S-CAM TYPE)

EN0680202I200023
Drum brake with internally expanding, leading-trailing shoes operating

Type
by cam shaft and slack adjuster in all wheels.
Models: FG, GH, Front 127 x 15.5 mm {5.0 x 0.61 in.}

Brake lining SG Rear 203 x 15.5 mm {8.0 x 0.61 in.}
Width x Thick-
ness Front 152 x 15.5 mm {6.0 x 0.61 in.}
Models: FL, FM
Rear 216 x 15.5 mm {8.5 x 0.61 in.}
DESCRIPTION
EN0680202C100024
FRONT (MODELS: FG, GH, SG)
SHTS068020200249
1 Brake shoe return spring 9 Brake chamber bracket

2 Lubrication fitting 10 Brake chamber
3 Slack adjuster 11 Hole plug
4 Cam shaft 12 Brake shoe
6 Brake spider 14 Wheel sensor (If so equipped)
7 Brake drum 15 Sensor ring (If so equipped)
8 Brake drum cover A Front
FRONT (MODEL: FM)
SHTS068020200250
1 Brake shoe return spring 9 Brake chamber bracket

2 Lubrication fitting 10 Spring brake chamber
3 Slack adjuster 11 Hole plug
6 Brake spider 14 Wheel sensor (If so equipped)
7 Brake drum 15 Sensor ring (If so equipped)
8 Brake drum cover A Front
REAR (MODELS: FG, GH)
SHTS068020200252
1 Anchor pin 9 Lubrication fitting

2 Brake spider 10 Brake shoe return spring (Inner)
3 Brake drum 11 Brake shoe return spring (Outer)
4 Brake drum cover 12 Brake lining
6 Slack adjuster 14 Wheel sensor (If so equipped)
7 Spring brake chamber 15 Sensor ring (If so equipped)
8 Brake chamber bracket A Front
REAR (Frontward) (MODEL: FM)
SHTS068020200253
1 Anchor pin 9 Lubrication fitting

2 Brake spider 10 Brake shoe return spring (Inner)
3 Brake drum 11 Brake shoe return spring (Outer)
4 Brake drum cover 12 Brake lining
6 Slack adjuster 14 Wheel sensor (If so equipped)
7 Spring brake chamber 15 Sensor ring (If so equipped)
8 Brake chamber bracket A Front
REAR (Rearward) (MODEL: FM)
SHTS068020200254
1 Brake shoe return spring (Outer) 8 Brake drum cover

2 Brake shoe return spring (Inner) 9 Brake drum
3 Lubrication fitting 10 Brake spider
4 Brake chamber bracket 11 Anchor pin
5 Brake chamber 12 Brake shoe
6 Cam shaft 13 Brake lining
7 Slack adjuster A Front
REAR (MODEL: SG)
SHTS068020200255
1 Brake shoe return spring 9 Lock plate

2 Lubrication fitting 10 Brake spider
3 Cam shaft 11 Brake drum
4 Slack adjuster 12 Brake drum cover
5 Brake chamber bracket 13 Brake chamber
6 Brake shoe 14 Brake lining
7 Anchor pin 15 Hole plug
8 Anchor pin retainer A Front
SPECIAL TOOL
EN0680202K100004
S0968-41010 ANCHOR PIN TOOL

COMPONENT LOCATOR
EN0680202D100023
FRONT (MODELS: FG, GH, SG)
SHTS068020200259
1 Retainer ring 15 Retainer 29 Brake lining

2 Slack adjuster 16 Lock plate 30 Spring hanger
3 Collar 17 Anchor pin 31 Retainer ring
4 Oil seal 18 Lubrication fitting 32 Seal
5 Bracket 19 Spring cover 33 Roller
6 Pin 20 Brake shoe assembly (Trailing) 34 Pin
7 Washer 21 Brake shoe assembly (Leading) 35 Brake shoe
8 Cotter pin 22 Brake drum 36 Bushing
9 Clevis 23 Brake shoe return spring 37 Thrust washer (If so equipped)
10 Brake chamber bracket 24 Cam shaft 38 Auto slack adjuster (If so
equipped)
11 Brake chamber 25 Collar 39 Spacer (If so equipped)
12 Hole plug 26 O-ring 40 O-ring (If so equipped)
13 Brake drum cover 27 Bushing 41 Wheel sensor (If so equipped)
14 Brake spider 28 Rivet 42 Sleeve (If so equipped)

A 64-86 {650-870, 47-63} E 168-226 {1,710-2,300, 124-166}
B 50-68 {510-690, 36-50} F 34.5-51.5 {351-527, 26-38}
C 109-147 {1,100-1,500, 80-108} G 20.5-31.5 {200-400, 15-28}
D 34.5-51.5 {351-527, 26-38}
FRONT (MODEL: FM)
SHTS068020200260
1 Retainer ring 16 Lock plate 31 Spring hanger

2 Thrust washer 17 Anchor pin 32 Retainer ring
3 Slack adjuster 18 Brake shoe assembly (Trailing) 33 Seal
4 Collar 19 Brake drum 34 Roller
5 Oil seal 20 Spring cover 35 Brake shoe
6 Brake chamber bracket 21 Brake shoe return spring 36 Bracket (If so equipped)
7 Pin 22 Brake shoe assembly (Leading) 37 Auto slack adjuster (If so
equipped)
8 Washer 23 Cam shaft 38 Pin (If so equipped)
9 Cotter pin 24 Collar 39 Spacer (If so equipped)
10 Clevis 25 O-ring 40 Plate (If so equipped)
11 Spring brake chamber 26 Bushing 41 Indicator (If so equipped)
12 Hole plug 27 Lubrication fitting 42 Lock washer (If so equipped)
13 Brake drum cover 28 Spacer 43 Wheel sensor (If so equipped)
14 Brake spider 29 Rivet 44 Sleeve (If so equipped)
15 Retainer 30 Brake lining

A 119-225 {1,200-2,300, 87-166} D 246-324 {2,500-3,300, 181-238}
B 109-147 {1,100-1,500, 80-108} E 34.5-51.5 {351-527, 26-38}
C 34.5-51.5 {351-527, 26-38} F 20.5-39.5 {200-400, 15-28}
FRONT (MODEL: SG)
SHTS068020200261
1 Retainer ring 13 Brake spider 25 O-ring

2 Slack adjuster 14 Retainer 26 Bushing
3 Collar 15 Lock plate 27 Rivet
4 Oil seal 16 Anchor pin 28 Brake lining
5 Pin 17 Lubrication fitting 29 Spring hanger
6 Washer 18 Spring cover 30 Retainer ring
7 Cotter pin 19 Brake shoe assembly (Trailing) 31 Seal
8 Clevis 20 Brake shoe assembly (Leading) 32 Roller
9 Brake chamber bracket 21 Brake drum 33 Pin
10 Brake chamber 22 Brake shoe return spring 34 Brake shoe
11 Hole plug 23 Cam shaft 35 Bushing
12 Brake drum cover 24 Collar

A 64-86 {650-870, 47-63} E 168-226 {1,710-2,300, 124-166}
B 50-68 {510-690, 36-50} F 34.5-51.5 {351-527, 26-38}
C 109-147 {1,100-1,500, 80-108} G 20.5-39.5 {210-400, 15-29} (With ISO hub bolt)
D 34.5-51.5 {351-527, 26-38}
REAR (MODELS: FG, GH)
SHTS068020200262
1 Retainer ring 20 Brake shoe assembly (Trailing) 39 Brake lining

2 Slack adjuster 21 Brake shoe return spring 40 O-ring
(Inner)
3 Thrust washer 22 Brake shoe return spring 41 Cotter pin
(Outer)
4 Collar 23 Spring cover 42 Pivot pin
5 Oil seal 24 Brake drum 43 Spring hanger
6 Bushing 25 Spring hanger 44 Retainer ring
7 Bracket 26 Brake shoe assembly (Leading) 45 Seal
8 Lubrication fitting 27 Cam shaft 46 Roller
9 Protector 28 Washer 47 Pin
10 Brake chamber bracket 29 O-ring 48 Brake shoe
11 Cotter pin 30 Bushing 49 Bushing
12 Washer 31 Brake spider 50 Lock washer (If so equipped)
13 Pin 32 Spacer 51 Indicator (If so equipped)
14 Spring brake chamber 33 Connector 52 Spacer (If so equipped)
15 Hole plug 34 Lubrication fitting 53 Pin (If so equipped)
16 Brake drum cover 35 Wheel sensor (If so equipped) 54 Plate (If so equipped)
17 Anchor pin 36 Sleeve (If so equipped) 55 Auto slack adjuster (If so
equipped)
18 Retainer 37 Holder (If so equipped) 56 Bracket (If so equipped)
19 Lock plate 38 Lock washer (If so equipped)

A 109-147 {1,100-1,500, 80-108} E 168-226 {1,710-2,300, 124-166}
B 119-225 {1,200-2,300, 81-166} F 34.5-51.5 {351-527, 26-38}
C 109-147 {1,100-1,500, 80-108} G 21-39 {200-400, 15-28}
D 34.5-51.5 {351-527, 26-38} H 21.5-31.5 {220-320, 15-23}
REAR (Frontward) (MODEL: FM)
SHTS068020200263
1 Retainer ring 19 Lock plate 37 Holder (If so equipped)

2 Slack adjuster 20 Brake shoe assembly (Trailing) 38 Lock washer (If so equipped)
3 Thrust washer 21 Brake shoe return spring 39 Brake lining
(Inner)
4 Collar 22 Brake shoe return spring 40 Rivet
(Outer)
5 Oil seal 23 Spring cover 41 Spring hanger
6 Bushing 24 Brake drum 42 Retainer ring
7 Bracket 25 Spring hanger 43 Seal
8 Cotter pin 26 Brake shoe assembly (Leading) 44 Roller
9 Washer 27 Cam shaft 45 Pin
10 Pin 28 Washer 46 Brake shoe
11 Spring brake chamber 29 O-ring 47 Bushing
12 Washer 30 Bushing 48 Lock washer (If so equipped)
13 Cotter pin 31 Brake spider 49 Indicator (If so equipped)
14 Pivot pin 32 Spacer 50 Spacer (If so equipped)
15 Hole plug 33 Connector 51 Pin (If so equipped)
16 Brake drum cover 34 Lubrication fitting 52 Plate (If so equipped)
17 Anchor pin 35 Wheel sensor (If so equipped) 53 Auto slack adjuster (If so
equipped)
18 Retainer 36 Sleeve (If so equipped) 54 Bracket (If so equipped)

A 109-147 {1,100-1,500, 80-108} E 34.5-51.5 {351-527, 26-38}
B 119-225 {1,200-2,300, 81-166} F 21-39 {200-400, 15-28}
C 34.5-51.5 {351-527, 26-38} G 21.5-31.5 {220-320, 15-23}
D 168-226 {1,710-2,300, 124-166}
REAR (Rearward) (MODEL: FM)
SHTS068020200264
1 Brake chamber 17 Lubrication fitting 33 Brake shoe

2 Pin 18 Anchor pin 34 Pivot pin
3 Washer 19 Brake spider 35 Rivet
4 Cotter pin 20 Cam shaft 36 Spring hanger
5 Brake chamber bracket 21 Retainer 37 Bushing
6 Retainer ring 22 Lock plate 38 Retainer ring
7 Slack adjuster 23 Brake shoe assembly (Leading) 39 Pin
8 Thrust washer 24 Brake shoe return spring 40 Seal
(Inner)
9 Collar 25 Brake shoe return spring 41 Roller
(Outer)
10 Oil seal 26 Brake shoe assembly (Trailing) 42 Lock washer (If so equipped)
11 Bushing 27 Spring hanger 43 Indicator (If so equipped)
12 O-ring 28 Brake drum 44 Spacer (If so equipped)
13 Spacer 29 Brake lining 45 Pin (If so equipped)
14 Hole plug 30 Cotter pin 46 Auto slack adjuster (If so
equipped)
15 Brake drum cover 31 Washer 47 Plate (If so equipped)
16 O-ring 32 Clamp 48 Bracket (If so equipped)

A 50-68 {510-690, 36-50} E 34.5-51.5 {351-527, 26-38}
B 119-225 {1,200-2,300, 81-166} F 168-226 {1,710-2,300, 124-166}
C 109-147 {1,100-1,500, 80-108} G 20.5-39.5 {200-400, 15-28}
D 34.5-51.5 {351-527, 26-38}
REAR (MODEL: SG)
SHTS068020200265
1 Retainer ring 14 Bushing 27 Brake shoe assembly (Leading)

2 Thrust washer 15 Oil seal 28 Cam shaft
3 Slack adjuster assembly 16 Plug hole 29 Cam shaft collar
4 Collar 17 Brake drum cover 30 O-ring
5 Seal 18 Anchor pin 31 Brake spider
6 Cotter pin 19 Anchor pin retainer 32 Connector
7 Washer 20 Lock plate 33 Brake lining
8 Clevis 21 Brake shoe assembly (Trailing) 34 Rivet
9 Clevis pin 22 Brake shoe return spring 35 Brake shoe
(Inner)
10 Brake chamber 23 Brake shoe return spring 36 Roller pin
(Outer)
11 Brake dust seal 24 Spring cover 37 Roller
12 Lubrication fitting 25 Brake drum 38 Pivot pin
13 Brake chamber bracket 26 Spring hanger 39 Brake shoe return spring

A 168-226 {1,700-2,300, 123-166} E 50-68 {500-700, 37-50}
B 109-147 {1,100-1,500, 80-108} F 34.5-51.5 {351-527, 26-38}
C 39-49 {380-500, 28-36} G 20.5-39.5 {210-400, 15-29} (With ISO hub bolt)
D 34.5-51.5 {351-527, 26-38}
OVERHAUL
EN0680202H200022
1. REMOVAL OF TIRE

HUB BEARINGS.
3. REMOVAL OF BRAKE SHOE RETURN SPRING

(1) Using the special tool. remove the return spring.
(FRONT WHEEL AND REAR WHEEL - OUTER SPRING).
SHTS068020200266
(2) Turn the pivot pin and pull out the spring hanger then remove the
return spring, inner (REAR WHEEL).
SHTS068020200267
4. REMOVAL OF ANCHOR PIN

(1) Using the special tool, remove the pin and the brake shoe assem-
bly.
SHTS068020200268
5. REMOVAL OF CAM SHAFT AND SLACK ADJUSTER

(1) If the vehicle is equipped with spring brake chamber, before
removing the cam shaft and slack adjuster, release the spring
brake.
NOTICE
Before removing the slack adjuster and cam shaft, apply a mark to
them to make clear the side (Left or Right) where they were
installed.
SHTS068020200269
1. INSPECTION OF SLACK ADJUSTER

(1) Measure the axial play and if the play exceed the limit, inspect the
spline of cam shaft and disassemble the adjuster.
Dimension A: 150 mm {5.9 in.}
Assembly Standard: 1.5 mm {0.06 in.}
SHTS068020200270
(2) Measure the circumference play and if the play exceed the limit,
inspect the spline of cam shaft and disassemble the adjuster.
Dimension A: 150 mm {5.9 in.}
Assembly Standard: 3.0 mm {0.12 in.}
SHTS068020200271
2. ASSEMBLY OF SLACK ADJUSTER

(1) Install the body cover.
(2) Use new rivets and caulk the rivet ends.
NOTICE
Apply enough chassis grease on the worm gear shaft before
installing the cover.
SHTS068020200272
(3) Tighten the worm gear shaft stopper fully then loose it by 1/12-1/6
turn.
NOTICE
• Replace the O-ring with new one.
• Apply enough chassis grease on the worm gear shaft before
installing the worm gear shaft.
SHTS068020200273
(4) Install the lock ball, spring and plug.

(5) After tighten the plug, caulk it to the body by a punch.
NOTICE
Apply enough chassis grease on the lock ball and spring.
SHTS068020200274
3. REPLACEMENT OF BRAKE LINING

(1) Remove the brake lining from the brake shoe.
a. Drill the rivet caulking section with a drill smaller than the rivet
diameter.
NOTICE
SHTS068020200275
b. After drilling, remove the remaining portion of the rivet with a

fine chisel or a riveting machine.
SHTS068020200276
(2) Install the brake lining to the brake shoe.

NOTICE
If a notched lining is used, the brake shoe and brake lining should
be installed as shown in figure.
SHTS068020200277
a. Set the lining on the shoe and insert the rivets into all holes,
then hold them in place with adhesive tape "A".
SHTS068020200278
b. Caulk the rivets lightly in a circular pattern as shown in figure

"B", repeat several times assure proper seating of the lining.
Recommended configuration of punch: shown in "C".
Recommended force of staking the rivet: 2.4 tons.
c. Remove adhesive tape.
SHTS068020200279
1. ASSEMBLY OF BRAKE SHOE

(1) Seals "A" for roller "B" should be replaced with new ones.
(2) Apply adequate amount of heat resistance grease on the roller
and seals.
SHTS068020200280
2. INSTALLATION OF O-RING AND OIL SEAL

(1) When assembling the wheel brake, replace the O-rings and oil
seals with new ones.
NOTICE
• The lip parts of the seal should always be facing outside.
• The seal should be caulked to the bracket (or bracket spider)
with a punch.
SHTS068020200281
3. INSTALLATION OF CAM SHAFT AND SLACK ADJUSTER

(1) Apply adequate amount of chassis grease on the O-ring, oil seal
and bushing before installing the cam shaft.
(2) If the clearance "A" between the retainer ring and slack adjuster
exceed 2.0 mm {0.078 in.}, install the washer between them.
NOTICE
Install the cam shaft and slack adjuster on the correct side (Left or
Right) according to the mark on them which were applied when
disassembling.
SHTS068020200282
NOTICE
• Make sure that the slack adjuster is installed, so that the
arrow on the adjuster points to the direction of the brake
chamber rod stroke as shown in figure.
• When connecting the slack adjuster with the brake chamber
and/or spring brake chamber, lubricate the clevis pin-hole
and the pin with sufficient chassis grease.
SHTS068020200283
(3) If the vehicle is equipped with a spring brake chamber, after con-
necting the slack adjuster with the brake chamber push rod, turn
the spring brake release bolt clockwise and securely tighten (with
mechanical released device).
SHTS068020200284
4. INSTALLATION OF CAM SHAFT AND AUTO SLACK

ADJUSTER (If so equipped)
(1) Apply adequate amount of chassis grease on the O-ring, oil seal
and bushing before installing the cam shaft.
(2) Make sure that the auto slack adjuster is installed so that the
arrow on the adjuster points in the direction of the brake chamber
rod stroke, as shown in figure.
NOTICE
Install the cam shaft and auto slack adjuster on the correct side
(Left or Right) according to the mark which was applied when dis-
assembly.
SHTS068020200285
(3) Make sure that clearance "A" between the spacer and auto slack
adjuster is 0.5-2.0 mm {0.020-0.078 in.}. Install or remove the
washer to maintain the required clearance.
SHTS068020200286
(4) When connection the auto slack adjuster with the brake chamber
and/or spring brake chamber, lubricate the clevis pin-hole and pin
with sufficient chassis grease.
(5) If the clevis pin-hole and auto slack adjuster pin-hole are mis-
aligned, turn the set screw of auto slack adjuster for clockwise.
SHTS068020200287
(6) Rotate by hand, the control arm as for as possible in the direction
of the arrow on the adjuster point.
(7) Make sure that clearance between set bolt and control arm is cor-
rect, and tighten the nut.
SHTS068020200288
(8) If the spring brake chamber is the equipped, after connecting the
auto slack adjuster with the brake chamber push rod, turn the
spring brake release bolt for clockwise fully (with mechanical
released device).
SHTS068020200284

(1) Apply adequate amount of heat resistance grease on the bushing
of the brake shoe.
SHTS068020200289
(3) Using the special tool, set the grooves of the two anchor pin paral-
lel and then insert the retainer in the grooves so that the retainer
hole and brake spider hole are aligned.
SST: Anchor pin tool (S0968-41010)
SHTS068020200290
(4) Place the lock plate on the retainer so that its hole is aligned with
the lock plate hole, then insert the bolt and tighten it.
SHTS068020200291
6. INSTALLATION OF BRAKE SHOE RETURN SPRING

(1) Hook the inner spring to the clamp and turn the pivot pin to align
the holes, then insert the spring hanger. (REAR WHEEL)
NOTICE
Painted part of the spring must be placed in the upper side.
SHTS068020200267
(2) Use the special tool to install the return spring. (FRONT WHEEL,
REAR WHEEL - OUTER SPRING).
NOTICE
The folded part of the spring cover must be placed in the upper
side.
SHTS068020200292
7. INSTALL THE WHEEL SENSOR

(If so equipped)
(2) Push the wheel sensor forcefully into the clamping bushing until
NOTICE
SHTS068020200293
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SHTS068020200294
8. ASSEMBLE THE BRAKE DRUM AND WHEEL HUB

(FRONT WHEEL)
(1) See the mark located at 1 or 1' on the brake drum as shown in fig-
ure. Install the drum according to NOTICE.
NOTICE
• The drums, number with R or L.
• The drums, with no R or L.
SHTS068020200295
ble.
NOTICE
Position of marks are located at 2 as shown in the figure. (Broken
9. MOUNTING OF WHEEL HUB WITH BRAKE DRUM

NOTICE
1. Be careful not to push back the wheel sensor too far when
mounting the wheel hub and brake drum. Also, make sure
they are straight so that you do not bump the tip of the wheel
sensor.
2. When inserting the outer hub bearing, avoid tapping on it
with a hammer as this will expose the wheel sensor to
bumps. Insert the outer hub bearing carefully using a lock
nut.
(2) Slowly turn the wheel hub and brake drum and confirm that they
move smoothly.
10. MOUNTING OF TIRE

11. GREASING
(1) After completion of assembly, lubricate the bushings of the brake
spider, cam shaft bracket (REAR WHEEL) and slack adjuster wire
with chassis grease from the lubrication fittings.
12. ADJUSTMENT
(1) Finally, adjust the brake chamber rod stroke as explained in the
section "ADJUSTMENT".
ADJUSTMENT
EN0680202H300026

the time the next inspection is made, replace the lining.
SHTS068020200296

(1) Operate the engine and obtain an air pressure of the 690 kPa {7.0
kgf/cm2, 99.54 lbf/in.2}
NOTICE
SHTS068020200297
3. ADJUST THE BRAKE CHAMBER STROKE

(2) Step on the brake pedal several times while turning the wheel in
the forward direction to make sure that the brake shoes are cor-
rectly positioned.
NOTICE
In the case of spring brake chamber, set the spring brake control
valve to the "OFF" position.
SHTS068020200298
(3) Turn the worm gear shaft of the slack adjuster clockwise fully and
then turn it back at least two notches.
SHTS068020200299
(4) Depress the brake pedal fully and measure the brake chamber
push rod stroke "A".
Assembly standard: 22-30 mm {0.87-1.18 in.}
Repair limit: Brake chamber: 40 mm {1.57 in.}
Spring brake chamber: 45 mm {1.77 in.}
SHTS068020200300
SHTS068020200298
(6) Make sure that there is no dragging, when turning the wheel by
from (2).
NOTICE
In accordance with the same procedure as above, adjust the
stroke for all wheels.
SHTS068020200301

EN0680202H300027
Unit: mm {in.}
Slack adjuster body: — — Replace, Visual check

Wear and damage. if necessary.
Slack adjuster, worm — — Replace, Visual check

gears: if necessary.
Wear and damage.
Slack adjuster, body cover: — — Replace, Visual check

Cam shaft: 39.8 {1.57} 39.5 {1.56) Replace. Measure

Diameter.
Clearance between cam 0.23-0.30 0.6 Replace

shaft and bushing of brake {0.0091-0.0110} {0.024} bushing and/
spider, chamber bracket, or cam shaft.
cam shaft bracket.
Cam shaft collar and — — Replace, Visual check

spacer: if necessary.
Wear and damage.
Brake drum: — — Regrind or Visual check

Cracks and damage. replace.
Brake drum: 406.4 {16.0} Regrind Regrind or Visual check

Inside diameter. 409.4 replace.
{16.12}
Service
410.4
{16.16}
Brake drum: 0-0.1 0.2 Regrind or Measure

Run out. {0-0.0039} {0.0079} replace.
Brake shoe assembly: — — Replace, Visual check

Cracks and damage. if necessary.
Brake lining: 15.5 {0.61} 5.5 Replace. Visual check

Thickness. {0.217}
Clearance between brake 0.02-0.07 0.25 Replace the Visual check

shoe bushing and anchor {0.0008-0.0027} {0.0098} brake shoe
pin. bushing and/
or anchor
pin.
Brake shoe roller and pin: — — Replace, Visual check

Brake shoe return spring — — Replace, Visual check

and spring cover: if necessary.
Damage, Lacking elastic
strength distortion.
EXPANDER (MODELS WITH WEDGE TYPE BRAKE)

DESCRIPTION
EN0680202C100025
SHTS068020200315
1 Retainer 8 E-ring
2 Adjusting bolt 9 Retainer
3 Boot 10 Return spring
4 Cover 11 Retainer ring
5 Adjust lock spring 12 Wedge assembly
6 Adjust ring 13 Body
7 Sleeve assembly
SPECIAL TOOL
EN0680202K100005
Prior to starting an expander overhaul, it is necessary to have these special tools.
S0965-71930 GUIDE
S0968-51020 BOOT SETTING TOOL
S0965-91540 ADAPTER
COMPONENT LOCATOR
EN0680202D100024
16
17
15
13
14
8
9
10
11
12
7
1
2
18
6 20
5
4
A
3
19
: Apply grease (Darina Grease 2: Showa Shell Sekiyu K.K product or equivalent).
SHTS068020200320
1 Retainer 11 Retainer ring

2 Adjusting bolt 12 Wedge assembly
3 Boot 13 Boot
4 Cover 14 Retainer
5 Adjust lock spring 15 Wedge
6 Adjust ring 16 Holder
7 Sleeve assembly 17 Roller
8 E-ring 18 Body
9 Retainer 19 Adjusting bolt assembly
10 Return spring 20 Screw

A 12-18 {120-180, 9-13}
OVERHAUL
EN0680202H200023
1. DISASSEMBLY OF THE EXPANDER

(1) Using the screwdriver, remove the boot from the body.
(2) Turn the adjusting bolt counterclockwise and remove the boot
with adjusting bolt.
SHTS068020200321
(3) Remove the boot and retainer from the adjusting bolt.
NOTICE
When removing the retainer, take care not to damage it.
(4) Using the screwdriver, remove the cover and then remove the
adjust lock spring and adjust ring.
NOTICE
Pay attention to adjusting lock spring jump-out.
SHTS068020200322
(5) Remove the screw and then remove the sleeve assembly.
SHTS068020200323
(6) Install the special tool to the body and tighten the bolt.
(7) Remove the E-ring.
(8) Remove the special tool and then remove the retainer, return
spring and wedge assembly.
NOTICE
Pay attention to return spring jump-out when removing the special
tool.
SHTS068020200324
2. DISASSEMBLY OF THE WEDGE ASSEMBLY

(1) Remove the retainer ring and then remove the boot, retainer and
HOLDER wedge assembly.
(2) Remove the holder and the roller from the wedge.
NOTICE
ROLLER Do not expand open end of holder 26 mm {1.023 in.} or more.
26 mm {1.023 in.}
SHTS068020200325
IMPORTANT POINTS - INSPECTION
1. INSPECTION FOR SLEEVE ASSEMBLY

(1) Fix the sleeve assembly in a vise and install the special tool to the
tappet part.
(2) Install the torque wrench to the special tool to measure the start-
ing torque of the tappet part. Replace the sleeve assembly if the
torque exceeds the standard value.
Standard (N⋅m {kgf⋅cm, lbf⋅ft}

SHTS068020200326
Clockwise (Right turn) 0.6 {6.0, 0.433} or less
Counterclockwise (Left turn) 2.0 {20.0, 1.447} or more
2. INSPECTION FOR RETAINER KEEP TORQUE OF ADJUSTING

BOLT ASSEMBLY
(1) Fix the adjusting bolt fitted retainer in a vise and install the special
tool to clip.
NOTICE
Take care not to damage thread of the adjusting bolt when fixing
adjusting bolt in a vise.
(2) Install the torque wrench to the special tool to measure the start-
ing torque of the retainer. Replace the adjusting bolt if the torque
SHTS068020200327 exceeds the standard value.
Standard: 1.5-5.0 N⋅m {15-50 kgf⋅cm, 1.09-3.61 lbf⋅ft}

HOLDER 1. ASSEMBLY OF THE WEDGE ASSEMBLY
(1) Assemble the roller to the holder and assemble them to the
wedge.
ROLLER NOTICE
Do not expand open end of holder 26 mm {1.023 in.} or more.
(2) Apply grease (Darina Grease 2: Showa Shell Sekiyu K.K. product
or equivalent) to engaged part and contact part of the roller,
holder and wedge.
26 mm {1.023 in.}
(3) Assemble the boot and retainer to the wedge, applying grease to
SHTS068020200325 wedge axle part and boot contact surface.
2. ASSEMBLY OF THE EXPANDER

(1) Fill up grease (Darina Grease 2: Showa Shell Sekiyu K.K. product
or equivalent) to the A part of body.
(2) Apply grease (Darina Grease 2: Showa Shell Sekiyu K.K. product
or equivalent) to the following part.
1. Adjust ring seat surface of body
2. Sleeve sliding part of body and tappet part stabbing part
3. Roller contact surface of tappet part and outer periphery
4. Sleeve assembly outer periphery and gear part
5. Sleeve assembly thread part.
SHTS068020200328
(3) Assemble wedge assembly to body, and install the new retainer
ring using the snap ring pliers.
(4) Install the return spring and then install the special tool.
(5) Install the new E-ring and remove the special tool.
SHTS068020200324
(6) After assembling the sleeve assembly to the body, tighten the
screw applied the LOCTITE 202 or ThreeBond 2415 or equiva-
lent.
NOTICE
Align the screw setting hole of body with the groove of tappet
part.
SHTS068020200323
(7) Install the adjust ring and adjust lock spring.

(8) Using the special tool, Install the cover.
NOTICE
• Be sure to install by hand using such as hammer.
• Before driving cover into sleeve assembly, assemble the
cover to the body groove.
• After assembling the cover, turn the cover while pushing it
and make sure that the cover turns smoothly in order to con-
firm the cover fits securely to the groove of the body.
SST: Guide (S0965-71930)
SHTS068020200329
(9) Assemble the new boot to the adjusting bolt. Apply grease
(Darina Grease 2: Showa Shell Sekiyu K.K. product or equivalent)
to contact part of boot and adjusting bolt, and thread part of
adjusting bolt.
NOTICE
Be sure to assemble the boot to the groove of the adjusting bolt
securely.
SHTS068020200330
(10) Screw adjusting bolt into the sleeve assembly until the dimension
of end surfaces from adjusting bolt to body is about 20 mm {0.787
in.}.
(11) Pull the adjusting bolt lightly to confirm the sleeve slides.
(12) Using the plastic hammer and special tool, press a new boot in.
SST: Boot setting tool (S0968-51020)
(13) Install the retainer to the adjusting bolt.

NOTICE
• Do not cut the boot.
• Pay attention to installing direction of the retainer.
SHTS068020200331

EN0680202H300028
Adjust lock spring: 78.5 N 73.6 N Replace. Measure

Setting load at the specified {8.0 kgf, 17.6 lbf} {7.5 kgf,
setting length at 11.3 {0.45} 16.5 lbf}
Return spring: 147 N 132 N

Setting load at the specified {15 kgf, 33.1 lbf} {13.5 kgf,
setting length at 105.8 {4.17} 29.8 lbf}
Sliding parts of sleeve — — Replace, Visual check

assembly and roller: if necessary.
Wear and damage
Axle dent of sleeve assembly — 0.010 mm Replace, Visual check

and roller: {0.0004 in.} sleeve
Wear and damage or less assembly or
roller.
Sliding parts of wedge and — — Replace, Visual check

roller: if necessary.
Wear and damage
Body inside diameter 38.1-38.2 mm 38.07 mm Replace. Measure

{1.500-1.504 in.} {1.499 in.}
Sleeve assem- Clockwise 0.6 N⋅m — Replace. Measure

bly turning {6.0 kgf⋅cm,
torque 0.433 lbf⋅ft}
or less
Counter- 2.0 N⋅m

clockwise {20.0 kgf⋅cm,
1.447 lbf⋅ft}
or less
Retainer keep torque of 1.5-5.0 N⋅m — Replace. Measure

adjusting bolt assembly {15-50 kgf⋅cm,
1.09-3.61 lbf⋅ft}
TRAILER HAND BRAKE CONTROL VALVE

(MODEL: FM TRACTOR)
EN0680202I200024
DESCRIPTION
EN0680202C100026
SHTS068020200336

COMPONENT LOCATOR
EN0680202D100025
SHTS068020200337


A 9.9-19.6 {100-200, 8-14} B 5.4-7.3 {55-75, 4.0-5.4}
C 2.5-3.9 {25-40, 1.9-2.8}
OVERHAUL
EN0680202H200024

Before disassembling the hand brake valve, mark the aligning mark "A"
on the holder and valve body.
SHTS068020200338
1. LUBRICATION
valve.
a. O-ring
c. Sliding surface
SHTS068020200339

NOTICE
L: 38.3-38.7 mm {1.508-1.523 in.}
SHTS068020200340
2. HAND BRAKE VALVE PERFORMANCE CHARACTERISTIC.

a. Air pressure at outlet port (kPa {kgf/cm2, lbf/in.2})
(a1) (a2)
a 19.6-68.6 460.6-558.6
{0.2-0.7, 2.8-9.9} {4.7-5.7, 66.8-81.0}
(b1) (b2)
b
7-13 37-43
NOTICE
sure of 690 kPa {7.0 kgf/cm2, 99.54 lbf/in.2}

EN0680202H300029
Unit: mm {in.}

Wear and damage

2. 38 {1.496}
dimension. 3. 31 {1.220}



2A$4AA&'051HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧟㧣ಽ
ABS & ASR (DENSO) BR03–1
BR03 ABS & ASR (DENSO) BR03-001
ABS ...........................................................BR03-2
OVERVIEW ..................................................... BR03-2
COMPOSITION AND OPERATION................. BR03-3
OVERVIEW AND FUNCTION ......................... BR03-5
FRONT WHEEL BRAKE...........................BR03-6

COMPONENT LOCATOR ............................... BR03-6
OVERHAUL ..................................................... BR03-7
REAR WHEEL BRAKE...........................BR03-10

OVERHAUL ................................................... BR03-11
BR03–2 ABS & ASR (DENSO)
ABS
OVERVIEW
EN06Z0803C100001
• ABS is a system that makes effective use of the friction between the tires and the road surface to maintain vehicle
stability while the brakes are being applied and for stopping the vehicle.
• Applying the brakes forcefully on a slippery road surface can cause the wheels to be locked, due to excessive braking
force. This causes the vehicle to lose a stability because the locked wheels lose resistance in the lateral direction.
More specifically, if the front wheels are locked, it becomes impossible to steer the vehicle, and if the rear wheels are
locked, the rear of the vehicle may fishtail from side to side.
• Also, when wheel-locking occurs, it is not possible to make effective use of friction between the tires and the road sur-
face. This may cause the braking distance to be increased.
• ABS uses wheel sensors mounted on the axles to constantly monitor the rotation of the wheels. If any of the wheels
is starting to lock up, the ABS ECU sends signals to the ABS control valve and immediately adjusts the brake pres-
sure to prevent wheel-locking.
• In this way, ABS maintains the stability of the vehicle while stopping by making effective use of the friction between
the tires and the road surface.
WHEEL CYLINDER
BRAKE BOOSTER
(FRONT) WHEEL SENSOR
BRAKE BOOSTER
(REAR)
ABS WARNING
LIGHT
WHEEL CYLINDER
WHEEL CYLINDER
SENSOR RING
WHEEL SENSOR
ABS ACTUATER
AIR TANK
ABS ECU
: AIR PIPING
WHEEL CYLINDER : OIL PIPING
BRAKE VALVE : ELECTRICAL WIRING
WHEEL SENSOR SENSOR RING

WHEEL SENSOR
SHTS06Z080300001
COMPOSITION AND OPERATION

EN06Z0803C100002
• The ABS system is comprised of the sensor rings mounted on the wheels, the ABS ECU, which receives signals from
the wheel sensors that monitor the rotational speed of the wheels and outputs control signals to maintain the appro-
priate braking force; ABS control valves, which increase or decrease the braking force, based on the control signals;
the warning light, which gives an alarm if the system malfunctions; the piping, wire harnesses, etc., that link together
the various units that compose the system.
• Pulse signals transmitted by the sensor rings mounted on the wheel hubs, rotated together with the wheels, and the
wheel sensors mounted near sensor ring on the axles are sent to the ABS ECU. The ABS ECU then calculates the
wheels' rotational speed, acceleration, deceleration, and amount of slippage, based on these signals.
• If the limit values for the wheel's deceleration, or slippage ratio are exceeded, the ABS ECU immediately transmits
signals to the ABS control valves to adjust any excess braking force.
• This ABS system controls the four wheels, front, rear, right, and left, independently.
SYSTEM COMPOSITION DIAGRAM
8 1
5 2 10
3 3 8
2 5
2 5
8
6
5 2 4
9
8
AIR PIPING
OIL PIPING
ELECTRICAL WIRING
SHTS06Z080300002
1 Brake valve 6 ABS warning light

2 Wheel cylinder 7 ABS actuator
3 Brake booster 8 Sensor ring
4 ABS + ES start ECU 9 Stop light switch
5 Wheel sensor 10 From air tank
ABS CONTROL FLOWCHART
INPUT SIGNAL ABS ECU OUTPUT SIGNAL
Front left
wheel sensor ABS solenoid valve
for front left wheel
Front right ABS control function
ABS solenoid valve
wheel sensor
for front right wheel
Rear left ABS solenoid valve
ABS actuator
wheel sensor for rear left wheel
control function
Rear right ABS solenoid valve

wheel sensor for rear right wheel
Front left wheel sensor Exhaust brake

Exhaust brake cut relay
control function
ES start
control function
Malfunction Malfunction code

diagnosis function (diagnosis code)
Switches off ABS to allow

Fail-safe function normal brake operation
(safety function)
ABS warning light
SHTS06Z080300003
OVERVIEW AND FUNCTION

EN06Z0803C100003
1. ABS ACTUATOR
• ABS actuator is composed of 2 pcs of ES solenoid valve, 4 pcs of retaining solenoid valve, 4 pcs of reducing valve,
pump and reservoir.
• Control signal from ABS + ES start ECU control the oil pressure of wheel cylinder.
Rr
: AIR PIPE Fr Fr Rr
: OIL PIPE BRAKE VALVE AIR TANK
MT
SFLR
Fr Rr BM M GND SMC1-
BODY EARTH
1.MC AIR MASTER AIR MASTER 2.MC SFRR
ABS SIDE SFLH SRLR
P SFRH (RETAINING SOLENOID)
SMC2-
SFLH (RETAINING SOLENOID)
SRRH (RETAINING SOLENOID) SMC1+ SRRH
SMC1 SMC2 SRLH (RETAINING SOLENOID) SRRR

SFRR (REDUCING SOLENOID) SMC2+
SFLR (REDUCING SOLENOID)
SRRR (REDUCING SOLENOID)
BS SRLR (REDUCING SOLENOID) SFRH
AST AST
SRLH MT
MOTOR BM
SFLH SFRH SRLH SRRH
M
PUMP PUMP
SMC1+ SMC1- (ES SOLENOID) BS GND
SMC2+ SMC2- (ES SOLENOID)
BLAKE FLUID
PURESSURE SENSOR
SFLR SFRR RESERVIOIR SRLR SRRR
VCM
PMC
E2
PMC VCM
FL FR RL RR E2
W/C W/C W/C W/C

FL FR RL RR
HYDRAULIC CIRCUIT DIAGRAM ELECTRIC CIRCUIT DIAGRAM

SHTS06Z080300004
FRONT WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100001
FRONT AXLE
SHTS06Z080300005
1 Knuckle 10 Inner wheel hub bearing

2 Oil seal guide 11 Sensor ring
3 Wheel cylinder 12 Hub bolt
4 Oil seal 13 Brake drum
5 Holder 14 Wheel hub
6 Brake shoe 15 Outer wheel hub bearing
7 Wheel sensor 16 Washer
8 Clamping bushing 17 Wheel hub bearing lock nut
9 Back plate 18 Wheel hub cap

A 34.0-50 {345-510, 25-36}
OVERHAUL
EN06Z0803H200001
1. REMOVE THE WHEEL SENSOR.

(1) Remove the wheels.
Refer to the chapter "WHEEL & TIRE".
(2) Remove the wheel hub, hub bearing and brake drum.
Refer to the chapter "FRONT AXLE".
(3) Loosen the bolt to remove the sensor holder and wheel sensor
together from the back plate.
SHTS06Z080300006
(4) Remove the wheel sensor from the wheel sensor holder.
(5) Remove the clamping bushing from the wheel sensor holder.
NOTICE
Exposing the wheel sensor to strong bumps could cause interior
damage. Never hit the wheel sensor with a hammer or bang it into
other parts.
SHTS06Z080300007
2. REMOVE THE SENSOR RING.

(1) Remove the sensor ring from the hub by using 3-point puller.
NOTICE
• Do not remove the sensor ring unless it is required.
• When removing the sensor ring, be careful not to damage the
wheel hub.
• Do not reuse the removed sensor ring, be sure to replace it
with new one.
SHTS06Z080300008
1. INSPECT THE ONLY WHEEL SENSOR.

(1) With a tester, measure the resistance of wheel sensor.
Standard: 1.0-3.0 kΩ
(2) When the measured value is out of the standard, change the
wheel sensor as it might be considered presumably to be abnor-
mal.
SHTS06Z080300009
2. INSPECT THE SENSOR RING.

(1) Make a visual inspection to check for damage or deformation of
the sensor ring, and also to make sure it is not coming loose from
the wheel hub.
(2) If any damage or malformation is discovered, replace the sensor
ring.
(3) If the sensor ring is coming loose from the wheel hub, use a dolly
block and press in it with a press again.
SHTS06Z080300010
3. INSPECT THE CLAMPING BUSHING.

(1) Make sure that wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed
in with a weak force.
SHTS06Z080300011
4. MOUNT THE SENSOR RING.

(1) Place the sensor ring on the wheel hub and use the dolly block
and a press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to
pressure mount it. Do not use a gas burner or the like to warm the
sensor ring. Doing so could cause malformation of the sensor
ring.
(2) After pressure mounting it, check for flutter of the sensor ring in
the axle direction.
Assembly standard: Less than 0.2 mm {0.0078 in.}
SHTS06Z080300012
5. MOUNT THE WHEEL SENSOR.

(2) Push the wheel sensor fully in the wheel sensor holder with hands
until the wheel sensor makes contact with the clamping bushing.
NOTICE
or attempt to pry it into place with a screwdriver, or the like. Doing
so could damage the wheel sensor.
SHTS06Z080300013
(3) Install the wheel sensor holder and wheel sensor together to the
back plate with bolts.
(4) Mount the wheel hub, hub bearing and brake drum.
Refer to the chapter "FRONT AXLE".
SHTS06Z080300014
6. INSPECT THE WHEEL SENSOR.

SENSOR RING (1) Arrange the wire harness.
(2) With a circuit tester, confirm the output voltage of the wheel sen-
sor (By rotating the tire by one time for 5 seconds)
Standard: 170-1,999 mV
(Range of Alternating Current Voltage)
PUSH (3) In case of out of the standard range at 2), remove the dust cover
located on the back plate unit. Then push the wheel sensor by
using round end bar until the sensor contacts with the sensor ring.
NOTICE
WHEEL SENSOR Do not tap by hammer or turn when pushing the wheel sensor.
SHTS06Z080300015 This may damage the wheel sensor.
REAR WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100002
REAR AXLE
SHTS06Z080300016
1 Wheel sensor 11 Sensor ring

2 Clamping bushing 12 Wheel hub
3 Wheel sensor holder 13 Brake drum
4 Oil seal collar 14 Axle shaft
5 Oil seal 15 Oil seal
6 Axle housing assembly 16 Lock plate
7 Inner wheel hub bearing 17 Lock nut
8 Back plate 18 Washer
9 Brake shoe 19 Outer wheel hub bearing
10 Wheel cylinder

A 35-51 {352-525, 26-37}
2A$4AA&'051HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧟ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧡ᤨ㧠㧣ಽ
OVERHAUL
EN06Z0803H200002

(1) Remove the wheels.
Refer to the chapter "WHEEL & TIRE".
(2) Remove the wheel hub, hub bearing and brake drum.
Refer to the chapter "REAR AXLE".
(3) Remove the wheel sensor.
NOTICE
• Exposing the wheel sensor to strong bumps could cause
interior damage. Never hit the wheel sensor with a hammer
or bang it into other parts.
• Pull out the wheel sensor from the sensor holder by hand.
SHTS06Z080300017
(4) Remove the clamping bushing.

Remove the clamping bushing out of the wheel sensor holder.
SHTS06Z080300018

(1) Use a screwdriver or the like to gradually remove the sensor ring
by tapping evenly on its outer ring.
NOTICE
• When tapping on the sensor ring to remove it, be careful not
to scratch the wheel hub.
with new one.
SHTS06Z080300019
1. INSPECT THE ONLY WHEEL SENSOR.

(2) When the measured value is out of the standard, change the
wheel sensor as it might be considered presumably to be abnor-
mal.
SHTS06Z080300020
2. INSPECT THE SENSOR RING.

the wheel hub.
ring.
block and a press to pressure mount it again.
SHTS06Z080300021
3. INSPECT THE CLAMPING BUSHING.

Change the clamping bushing when it can be pulled off or pushed
SHTS06Z080300022
4. MOUNT THE WHEEL SENSOR

the rear axle wheel sensor holder.
SHTS06Z080300023
NOTICE
SHTS06Z080300017

(1) Place the sensor ring on the wheel hub and use a dolly block and
a press to evenly pressure mount it.
NOTICE
ring.
the axle direction.
SHTS06Z080300024
(3) If the value is still out of the service limit after having performed
the above (2), remove the dust cover on the back plate, and push
the wheel sensor by using a round end bar until the sensor gets in
contact with the sensor ring.
NOTICE
Do not hammer or twist when pushing the wheel sensor. Other-
wise it may damage the wheel sensor.
6. MOUNT THE WHEEL HUB, HUB BEARING AND BRAKE

DRUM.
(1) Refer to the chapter "REAR AXLE".
NOTICE
• Be careful not to push back the wheel sensor too far when
sensor.
• When inserting the outer hub bearing, avoid tapping on it
bumps. Insert the outer hub bearing carefully with a lock nut.
7. INSPECT THE WHEEL SENSOR.

sor (By rotating the tire by one time for 5 seconds)
Basic standard valve: 170-1,999 mV
(3) In case of out of the standard range at 2), remove the dust cover
using round end bar until the sensor contacts with the sensor ring.
NOTICE
Do not tap by hammer or turn when pushing the wheel sensor.
This may damage the wheel sensor.
(4) Mount the axle shaft to the wheel hub and tighten the bolt on the
axle shaft.
2A$4AA9#$%1
#1A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧠㧜ಽ
ABS & ASR (WABCO, FOR AIR OVER HYDRAURIC BRAKE) BR03–1
ABS & ASR BR03
(WABCO, FOR AIR OVER HYDRAURIC BRAKE)

BR03-002
ABS ...........................................................BR03-2
OVERVIEW ..................................................... BR03-2
FUNCTION ...................................................... BR03-6
FRONT WHEEL BRAKE.........................BR03-11

OVERHAUL ................................................... BR03-12

OVERHAUL ................................................... BR03-16
2A$4AA9#$%1
BR03–2 ABS & ASR (WABCO, FOR AIR OVER HYDRAURIC BRAKE)
ABS
OVERVIEW
EN06Z0803C100001
• Applying the brakes forcefully on a slippery road surface can cause the wheels to be locked, due to excessive brak-
ing force. This causes the vehicle to lose a stability because the locked wheels lose resistance in the lateral direction.
• Also, when wheel-locking occurs, it is not possible to make effective use of friction between the tires and the road
surface. This may cause the braking distance to be increased.
(REPRESENTATIVE MODEL)
BRAKE BOOSTER WHEEL CYLINDER
(WITH ABS CONTROL VALVE)
WHEEL SENSOR
BRAKE BOOSTER
ABS CONTROL VALVE
ABS WARNING LIGHT
WHEEL CYLINDER
SENSOR RING
WHEEL CYLINDER
BRAKE BOOSTER
(WITH CONTROL VALVE) WHEEL SENSOR
ABS ECU BOX
WHEEL CYLINDER
BRAKE VALVE SENSOR RING
WHEEL SENSOR
AIR PIPING
WHEEL SENSOR
OIL PIPING
ELECTRICAL WIRING
SHTS06Z080300001
2A$4AA9#$%1

EN06Z0803C100002
9 1
5 2
9
3 7 2 5
8
2 5
9
5 2 4 6
9
AIR PIPING
OIL PIPING
ELECTRICAL WIRING
SHTS06Z080300002
1 Brake valve 6 ABS warning light

2 Wheel cylinder 7 ABS control valve
3 Brake booster 8 Brake booster (with ABS control valve)
4 ABS ECU 9 Sensor ring
5 Wheel sensor
2A$4AA9#$%1
Front left wheel sensor
Front right wheel sensor ABS control valve for

front left wheel
Rear left wheel sensor

ABS control function ABS control valve for
front right wheel
(ABS control valve control

Rear right wheel sensor function)
ABS control valve for
rear left wheel

rear right wheel
Exhaust brake control

function
Malfunction code
(diagnostic code)
Malfunction diagnostic
function

normal brake operation
Fail-safe function
(safety function)
ABS warning light
SHTS06Z080300003
2A$4AA9#$%1
BASIC PRINCIPLE
• Based on its relationship with the slip ratio, which is determined
from the wheels' rotational speed and the vehicle's speed, ABS
controls the brake force so that it will be most effective.
• When the driver applies the brakes, the rotation of the wheels is
controlled and the vehicle speed drops. However, the momentum
of the vehicle attempts to push it forward further even though the
rotation of the wheels is being braked. At this point, slipping will
occur if there is a gap between the wheels' rotational speed and
the vehicle's speed. The slip ratio is a value that indicates the rate
of slippage.
Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio 0 % : No slipping between the wheels and the

road surface
100 % : Wheels locked
• The graph shown at left shows the relationship between the fric-
tion coefficient of the tires and of the road surface and the slip
ratio.
• In an ABS-equipped vehicle, the brake force is controlled to
ensure that it is within the range where the friction coefficient is
high (shaded portion of the graph) without locking the wheels.
This ensures efficient braking performance.
SHTS06Z080300005
OPERATION
1. The ABS control characteristics line graph at left illustrates how
the vehicle's speed, the wheels' rotational speed, the wheel accel-
eration/deceleration, and the air pressure at the ABS control valve
outlet change over time after the brakes are applied.
2. When the brakes are applied, the vehicle's speed and the wheels'
rotational speed drop and at the same time, the wheel accelera-
tion/deceleration speed also drops. At point T1, a gap begins to
open between the wheels' rotational speed and the vehicle's
speed. Passing on point T2, the ABS ECU detects that the wheels
are beginning to lock and is lowering the outlet air pressure of the
ABS control valve to prevent wheel locking from occurring.
3. At point T3, the wheel acceleration/deceleration speed is starting
to return to normal one, and the ABS ECU stops lowering the air
pressure at the ABS control valve outlet and maintains it at a con-
stant level.
4. At point T5, the wheels' rotational speed and the vehicle's speed
are about the same. The ABS ECU detects that the wheels are no
longer likely to be locked and increases the air pressure at the
ABS control valve outlet.
5. The above processes is repeated over and over until the vehicle
comes to a complete stop.
SHTS06Z080300006
2A$4AA9#$%1
FUNCTION
EN06Z0803C100003
FAIL-SAFE FUNCTION
• This ABS system is equipped with a fail-safe function that causes the ABS warning light on the instrument panel to
light and to restore the normal (non-ABS) brake system, should an ABS malfunction occur.
• Note that the ABS system consists of two independent circuits. Should a malfunction occur for whatever reason in
the electrical circuits, that system's ABS is switched off and the normal brake system is restored while ABS control
continued for the other system. This configuration is designed to minimize the effects of any malfunction on ABS
function.
EXHAUST BRAKE CONTROL FUNCTION

• The ABS system of this vehicle is equipped with a function that controls the exhaust brake while ABS is operating.
• If the exhaust brake is applied independently or together with the service brake on a road surface with very low fric-
tion coefficient, the driving wheels may lock. This ABS system prevents the driven wheels from locking in such cases
by automatically releasing the exhaust brake, if necessary, during ABS operation.
CLUTCH ACCELERA- EXHAUST

SWITCH TOR SWITCH BRAKE SWITCH
+ 24V
EXHAUST BRAKE MAGNETIC VALVE
+ 24V
EXHAUST BRAKE CUT RELAY ABS ECU
SHTS06Z080300007

EN06Z0803C100004
1. ABS ECU
• Based on pulse signals from the wheel sensors, the ABS ECU
mounted in the vehicle calculates and evaluates the slip ratio and
the acceleration/deceleration speed of the wheels. Based on the
results, it sends signals to the various control valves as neces-
sary, causing them to operate and apply the brakes to maintain
the slippage of the wheels within the optimal range.
• During braking, the air pressure applied to the brake chambers is
regulated to prevent the wheels from locking. The brakes are
applied so as to maintain the slippage of the wheels within the
optimal range.
• Regardless of whether the vehicle is stopped or being driven, and
whether or not the brakes are being applied, the circuit consisting
of the wheel sensors, control valves, ABS ECU, and wire har-
nesses are constantly being checked by the ABS ECU's fail-safe
circuit. If some sort of malfunction occurs, the fail-safe circuit
warns the driver by lighting the ABS warning light. At the same
time, the ABS system that is experiencing the malfunction is shut
off and braking is restored to normal (non-ABS) operation.
SHTS06Z080300008
2A$4AA9#$%1
2. ABS CONTROL VALVES

1. OVERVIEW
• The ABS control valves are positioned in the brake air circuit
between the relay valves and brake chambers. Based on signals
from the ABS ECU, they adjust the air pressure sent to the brake
chambers in one of three modes: pressure increase, pressure
reduction, or pressure maintenance.
SHTS06Z080300009
BRAKE VALVE
PILOT CHAMBER 14
ABS CONTROL VALVE DIAPHRAGM 5
CHAMBER 7 AIR TANK
INLET VALVE 16
RELAY VALVE
INLET PORT 6 PILOT HOLE 10
SOLENOID VALVE FOR OUTLET PORT 9

DRIVING INLET VALVE 3
CHAMBER 8
SOLENOID COIL 1
SOLENOID COIL 2 BRAKE CHAMBER
DIAPHRAGM 11
SOLENOID VALVE FOR PILOT CHAMBER 12

DRIVING EXHAUST VALVE 4
EXHAUST VALVE 13 EXHAUST PORT 15
SHTS06Z080300010
2A$4AA9#$%1
2. OPERATION
.
PRESSURE INCREASE a. PRESSURE INCREASE MODE

14 5 • When the driver steps on the brake pedal, air from the relay
valve enters through inlet port (6), pushes open diaphragm
6 (5), passes through outlet port (9), and flows into the brake
VALVE OPERATING STATUS
10
chamber. At this point, solenoid coil (1) is not energized, so
9
3 solenoid valve (3) is closed and pilot chamber (14) is open to
the atmosphere. Also, solenoid coil (2) is also not energized,
so solenoid valve (4) is closed. As a result, air passes through
13
pilot hole (10) and enters pilot chamber (12). It then pushes
up diaphragm (11) and closes exhaust valve (13).
1
2
4
11
12
Solenoid valve for driving inlet

OFF
STATUS
valve 3
Solenoid valve for driving

exhaust valve 4 OFF
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300011
b. PRESSURE REDUCTION MODE

PRESSURE REDUCTION • When solenoid coil (1) is energized, solenoid valve (3) opens
14 5 and air also flows into pilot chamber (14). It pushes down on
diaphragm (5), shutting off chambers (7) and (8). At the same
time, solenoid coil (2) is also energized. This causes solenoid
7 valve (4) to open and the operating air from pilot chamber
3 9 (12) passes through exhaust port (15) and is released into the
88 atmosphere. Consequently, the air from the outlet port (9)
side (brake chamber) pushes down on diaphragm (11) and air
is released into the atmosphere. This causes the air pressure
1 of the brake chamber to decrease.
4
15 11 12

ON
STATUS
valve 3

ON
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300012
2A$4AA9#$%1
c. PRESSURE MAINTENANCE MODE

PRESSURE MAINTENANCE • When solenoid coil (1) is energized, solenoid valve (3) opens
14
and air flows through chamber (7) and acts on pilot chamber
5
(14). On the other hand, since solenoid coil (2) is not ener-
gized, solenoid valve (4) is closed and air flows through pilot
7 10 hole (10) and acts on pilot chamber (12). This causes dia-
3 phragms (5) and (11) to shut off their air passages, and the
8
8
chamber (8) pressure, that is to say the air acting on the
brake chamber, is maintained at the pressure that was cur-
rent when the switch from the pressure reduction mode to the
pressure maintenance mode took place.
1
2
11
4
12

ON
STATUS
valve 3

OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300013
3. WHEEL SENSORS
• These sensors are mounted, facing the sensor rings on each
wheel on the front and rear axles.
• The wheel sensors are electromagnet sensors consisting of a
permanent magnet core with a coil of wire wrapped around it.
• The frequency of the pulse signals generated by magnetic induc-
tance between the sensors and the sensor rings they face is pro-
portional to the rotational speed of the wheels. These pulse
signals are sent to the ABS ECU and are used to determine the
wheels, rotational status.
SHTS06Z080300014
PERMANENT
MAGNET
CORE
SENSOR RING
CLAMPING
WHEEL HUB BUSHING
SHTS06Z080300015
2A$4AA9#$%1
4. SENSOR RINGS
• The sensor rings are press-fitted into the insides of the wheel
hubs of each wheel on the front and rear axles, and they face the
wheel sensors described in the preceding section. The sensor
rings are made of a magnetic material, and teeth are cut into the
surface which faces the wheel sensor at regular intervals. Also,
when the sensor ring performs one complete rotation, the sensor
generates pulse signals corresponding to the number of teeth.
SHTS06Z080300016
5. CLAMPING BUSHINGS
• The wheel sensors are held in place through friction by clamping
bushings that are inserted into the mounting brackets. If they are
assembled properly, the clamping bushings serve to eliminate the
need to adjust the clearance between the wheel sensors and sen-
sor rings.
SHTS06Z080300017
6. WHEEL SENSOR HARNESSES

• Each wheel sensor wire harness employs a two-conductor twisted
wire cable. Its function is to protect the wheel sensor signals,
which are vital to the proper operation of the ABS system, from
electromagnetic interference. Under no circumstances should any
part of the wheel sensor wire harnesses be cut or connected to
any other wire.
SHTS06Z080300018
7. ABS WARNING LIGHT

• The status of the ABS system is indicated.
• It lights when the starter switch is turned "ON" and automatically
goes off when the system functions correctly.
• If malfunction occurs in the ABS system while the vehicle is being
driven, the light turns on to alert the driver.
• However, when a defects code is eliminated after repairing it and
the starter switch is turned "ON", the light will remain lit until the
vehicle speed reaches 7-10 km/h {11.2 - 16 mile/h}.
• Then, note that even when the warning light is lit, the ABS sys-
tem, unaffected by the malfunction, continues to operate. Also,
SHTS06Z080300019
the brake whose ABS system experiences the malfunction is
reverted to normal braking operation without ABS.
• When a Diagnosis switch is turned "ON", this light will goes on
and off, which indicates defect code.
8. EXHAUST BRAKE CUT RELAY

• When this relay is energized during ABS operation, the relay con-
tact opens, the current to the solenoid valve for the exhaust brake
is shut down, and the exhaust brake is released.
2A$4AA9#$%1
FRONT WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100001
FRONT AXLE
SHTS06Z080300020

4 Collar 15 Push rod 26 Cover
11 Cylinder cover 22 Anchor pin 33 Wheel sensor
2A$4AA9#$%1
OVERHAUL
EN06Z0803H200001

(2) Pull off the wheel sensor.
NOTICE
other parts.
SHTS06Z080300021
2. REMOVE THE WHEEL HUB, WHEEL HUB BEARINGS AND

BRAKE DRUM.
(1) Refer to the chapter "FRONT AXLE".
SHTS06Z080300022
SHTS06Z080300023

NOTICE
with new one.
SHTS06Z080300024
2A$4AA9#$%1
1. INSPECTION OF ONLY WHEEL SENSOR

(2) When the measured value is out of the basic standard, change
the wheel sensor as it might be considered presumably to be
abnormal.
SHTS06Z080300025
2. INSPECTION OF THE SENSOR RING

the wheel hub.
ring.
SHTS06Z080300026
3. INSPECTION OF THE CLAMPING BUSHING

SHTS06Z080300027

NOTICE
ring.
SHTS06Z080300028 the axle direction.
2. MOUNT THE WHEEL HUB AND BRAKE DRUM.

NOTICE
If the wheel sensors are mounted, hammering on the wheel hubs
and the like on that axle could cause internal damage to the wheel
sensors. Either mount the tire and then tap on the tire or tap on
the wheel hub after removing the right and left wheel sensors.
2A$4AA9#$%1

the knuckle's wheel sensor holder.
(2) Apply a light coating of chassis grease to the hub of the wheel
sensor. Then push it forcefully into the clamping bushing until you
feel that the wheel sensor has made contact with the sensor ring.
NOTICE
SHTS06Z080300029
move smoothly.
(4) Mount the drum dust cover.
4. ADJUST THE WHEEL SENSOR.

SHOULD MAKE (1) Arrange the wire harness.
CONTACT
SENSOR RING sor (By rotating the tire by one time for 5 seconds)
WHEEL HUB
(3) In case of out of the standard range at (2), push the wheel sensor
softly by fingers until the sensor contacts with the sensor ring,
then inspect again from (1).
CLAMPING BUSHING
WHEEL SENSOR
SHTS06Z080300030
5. ABS WIRE HARNESSES

NOTICE
• The front axle chassis harnesses, particularly the ones that pass over the front axle and extend as far as the
wheel sensors, must absorb the movement when the wheels are turned and when the springs move. It is
therefore necessary to always maintain an optimal spacing between the clips.
• In addition, if there is a large amount of variation in the spacing between the clips, the wheel sensor har-
nesses can come into contact with tire chains and sustain damage.
• The wire harness for the front axle wheel sensor extends directly from the clip on top of the king pin cover to
the frame. In particular, make sure that the distance between the clip on top of the king pin cover and the clip
on the frame side is as indicated in the diagram below. There are markings on the wheel sensors in cases
where the wheel sensor harness clips are in locations where the relative movement is particularly great.
These places should be inspected regularly to ensure that the clip positions are still meeting with the same
marking.
SHTS06Z080300031
2A$4AA9#$%1
REAR WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100002
REAR AXLE
SHTS06Z080300032
2A$4AA9#$%1
1 Hole plug 14 Push rod 27 Brake lining

2 Drum cover 15 Piston 28 Rivet
3 Pin 16 Back up ring 29 Cotter pin
4 Collar 17 Piston cup 30 Brake shoe
5 Spring 18 Spring 31 Bushing
6 Boot 19 Air bleeder screw 32 Brake drum
7 Washer 20 Cap 33 Wheel sensor
8 Brake spider 21 Anchor pin 34 Bushing
9 Adjusting cam 22 Retainer 35 Clamping bushing
10 Cylinder cover 23 Lock plate 36 Lock plate (If so equipped)
11 Wheel cylinder assembly 24 Brake shoe assembly 37 Wheel sensor holder
12 Boot 25 Retracting spring
13 Cylinder 26 Spring cover
OVERHAUL
EN06Z0803H200002

BRAKE DRUM.
SHTS06Z080300033
SHTS06Z080300034

NOTICE
with new one.
SHTS06Z080300035
2A$4AA9#$%1

NOTICE
SHTS06Z080300036
4. REMOVE THE CLAMPING BUSHING.

(1) Remove the clamping bushing out of the wheel sensor holder.
SHTS06Z080300037

abnormal.
SHTS06Z080300038

the wheel hub.
ring.
SHTS06Z080300039
2A$4AA9#$%1

(1) Make sure that the wheel sensor is securely fixed.
SHTS06Z080300040

SHTS06Z080300041
NOTICE
SHTS06Z080300042

NOTICE
ring.
the axle direction.
SHTS06Z080300043

NOTICE
sensor.
2A$4AA9#$%1

PUSH sor (By rotating the tire by one time for 5 seconds)
WHEEL SENSOR using round end bar until the sensor contacts with the sensor ring.
NOTICE
SENSOR RING Do not tap by hammer or turn when pushing the wheel sensor.
axle shaft.

NOTICE
• The rear axle chassis harnesses is arranged so that the left and right wheel sensor harnesses are near each
other. Therefore, special care should be taken not to make incorrect connections if the harnesses have been
removed for inspection or repairs.
• If incorrect connections are made, it will interfere with the functioning of the ABS system. For this reason,
caution plates indicating "LEFT" and "RIGHT" are affixed to the harnesses. Be sure to check when connect-
ing the harnesses. (The left harness is on the left side of the vehicle when viewed from the behind and facing
toward the front, and the right harness is on the right side of the vehicle.)
• The wheel sensor harnesses are arranged along the top of the rear axle housing. Therefore, make sure to
allow sufficient harness length between the chassis and the rear axle so that the harnesses can absorb the
up-and-down motion of the rear axle.
2A$4AA9#$%1
2A$4AA9#$%1
(#A0QVTGGHOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧠㧝ಽ
ABS & ASR (WABCO, FOR FULL AIR BRAKE) BR03–1
ABS & ASR BR03
(WABCO, FOR FULL AIR BRAKE) BR03-003
ABS ...........................................................BR03-2
OVERVIEW ..................................................... BR03-2
FUNCTION ...................................................... BR03-6
FRONT WHEEL BRAKE.........................BR03-11

OVERHAUL ................................................... BR03-12

OVERHAUL ................................................... BR03-16
2A$4AA9#$%1
BR03–2 ABS & ASR (WABCO, FOR FULL AIR BRAKE)
ABS
OVERVIEW
EN06Z0803C100001
• Applying the brakes forcefully on a slippery road surface can cause the wheels to be locked, due to excessive braking
force. This causes the vehicle to lose a stability because the locked wheels lose resistance in the lateral direction.
• Also, when wheel-locking occurs, it is not possible to make effective use of friction between the tires and the road sur-
face. This may cause the braking distance to be increased.
(REPRESENTATIVE MODEL)
FRONT RELAY VALVE QUICK RELEASE VALVE
REAR RELAY VALVE
ABS CONTROL VALVE
BRAKE VALVE
ABS WARNING LIGHT
BRAKE CHAMBER
AIR TANK
ABS CONTROL VALVE
BRAKE CHAMBER
SENSOR RING
WHEEL SENSOR
NOTE: : AIR PIPING
ABS ECU BOX
: ELECTRICAL WIRING
SHTS06Z080300001
2A$4AA9#$%1

EN06Z0803C100002
1
2
2 6
6 3
7 3
A 4
5
4 8
8 A
4
A
3
6 3
2 6
2
AIR PIPING BRAKE SECTION

ELECTRICAL WIRING ABS SECTION
SHTS06Z080300002
1 Brake valve 6 Wheel sensor

2 Wheel brake 7 ABS warning light
3 Brake chamber 8 Relay valve
4 ABS control valve A From air tank
5 ABS ECU
2A$4AA9#$%1
Front right wheel sensor ABS control valve for

front left wheel

ABS control function ABS control valve for
front right wheel
(ABS control valve control

Rear right wheel sensor function)
rear left wheel

rear right wheel
Exhaust brake control

function
Malfunction code
(diagnostic code)
Malfunction diagnostic
function

normal brake operation
Fail-safe function
(safety function)
ABS warning light
SHTS06Z080300003
2A$4AA9#$%1
BASIC PRINCIPLE
• Based on its relationship with the slip ratio, which is determined
from the wheels' rotational speed and the vehicle's speed, ABS
controls the brake force so that it will be most effective.
• When the driver applies the brakes, the rotation of the wheels is
controlled and the vehicle speed drops. However, the momentum
of the vehicle attempts to push it forward further even though the
rotation of the wheels is being braked. At this point, slipping will
occur if there is a gap between the wheels' rotational speed and
the vehicle's speed. The slip ratio is a value that indicates the rate
of slippage.
Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio 0 % : No slipping between the wheels and the

road surface
100 % : Wheels locked
• The graph shown at left shows the relationship between the fric-
tion coefficient of the tires and of the road surface and the slip
ratio.
• In an ABS-equipped vehicle, the brake force is controlled to
ensure that it is within the range where the friction coefficient is
high (shaded portion of the graph) without locking the wheels.
This ensures efficient braking performance.
SHTS06Z080300005
OPERATION
1. The ABS control characteristics line graph at left illustrates how
the vehicle's speed, the wheels' rotational speed, the wheel accel-
eration/deceleration, and the air pressure at the ABS control valve
outlet change over time after the brakes are applied.
2. When the brakes are applied, the vehicle's speed and the wheels'
rotational speed drop and at the same time, the wheel accelera-
tion/deceleration speed also drops. At point T1, a gap begins to
open between the wheels' rotational speed and the vehicle's
speed. Passing on point T2, the ABS ECU detects that the wheels
are beginning to lock and is lowering the outlet air pressure of the
ABS control valve to prevent wheel locking from occurring.
3. At point T3, the wheel acceleration/deceleration speed is starting
to return to normal one, and the ABS ECU stops lowering the air
pressure at the ABS control valve outlet and maintains it at a con-
stant level.
4. At point T5, the wheels' rotational speed and the vehicle's speed
are about the same. The ABS ECU detects that the wheels are no
longer likely to be locked and increases the air pressure at the
ABS control valve outlet.
5. The above processes is repeated over and over until the vehicle
comes to a complete stop.
SHTS06Z080300006
2A$4AA9#$%1
FUNCTION
EN06Z0803C100003
FAIL-SAFE FUNCTION
• This ABS system is equipped with a fail-safe function that causes the ABS warning light on the instrument panel to
light and to restore the normal (non-ABS) brake system, should an ABS malfunction occur.
• Note that the ABS system consists of two independent circuits. Should a malfunction occur for whatever reason in the
electrical circuits, that system's ABS is switched off and the normal brake system is restored while ABS control con-
tinued for the other system. This configuration is designed to minimize the effects of any malfunction on ABS function.
EXHAUST BRAKE CONTROL FUNCTION

• The ABS system of this vehicle is equipped with a function that controls the exhaust brake while ABS is operating.
• If the exhaust brake is applied independently or together with the service brake on a road surface with very low fric-
tion coefficient, the driving wheels may lock. This ABS system prevents the driven wheels from locking in such cases
by automatically releasing the exhaust brake, if necessary, during ABS operation.
CLUTCH ACCELERA- EXHAUST

SWITCH TOR SWITCH BRAKE SWITCH
+ 24V
EXHAUST BRAKE MAGNETIC VALVE
+ 24V
EXHAUST BRAKE CUT RELAY ABS ECU
SHTS06Z080300007

EN06Z0803C100004
1. ABS ECU
• Based on pulse signals from the wheel sensors, the ABS ECU
mounted in the vehicle calculates and evaluates the slip ratio and
the acceleration/deceleration speed of the wheels. Based on the
results, it sends signals to the various control valves as neces-
sary, causing them to operate and apply the brakes to maintain
the slippage of the wheels within the optimal range.
• During braking, the air pressure applied to the brake chambers is
regulated to prevent the wheels from locking. The brakes are
applied so as to maintain the slippage of the wheels within the
optimal range.
• Regardless of whether the vehicle is stopped or being driven, and
whether or not the brakes are being applied, the circuit consisting
of the wheel sensors, control valves, ABS ECU, and wire har-
nesses are constantly being checked by the ABS ECU’s fail-safe
circuit. If some sort of malfunction occurs, the fail-safe circuit
warns the driver by lighting the ABS warning light. At the same
time, the ABS system that is experiencing the malfunction is shut
off and braking is restored to normal (non-ABS) operation.
SHTS06Z080300008
2A$4AA9#$%1
2. ABS CONTROL VALVES

1. OVERVIEW
• The ABS control valves are positioned in the brake air circuit
between the relay valves and brake chambers. Based on signals
from the ABS ECU, they adjust the air pressure sent to the brake
chambers in one of three modes: pressure increase, pressure
reduction, or pressure maintenance.
SHTS06Z080300009
BRAKE VALVE
PILOT CHAMBER 14
ABS CONTROL VALVE DIAPHRAGM 5
CHAMBER 7 AIR TANK
INLET VALVE 16
RELAY VALVE
INLET PORT 6 PILOT HOLE 10
SOLENOID VALVE FOR OUTLET PORT 9

DRIVING INLET VALVE 3
CHAMBER 8
SOLENOID COIL 1
SOLENOID COIL 2 BRAKE CHAMBER
DIAPHRAGM 11
SOLENOID VALVE FOR PILOT CHAMBER 12

DRIVING EXHAUST VALVE 4
EXHAUST VALVE 13 EXHAUST PORT 15
SHTS06Z080300010
2A$4AA9#$%1
2. OPERATION
.
PRESSURE INCREASE a. PRESSURE INCREASE MODE

14 5 • When the driver steps on the brake pedal, air from the relay
valve enters through inlet port (6), pushes open diaphragm
6
10 (5), passes through outlet port (9), and flows into the brake
chamber. At this point, solenoid coil (1) is not energized, so
9
3 solenoid valve (3) is closed and pilot chamber (14) is open to
the atmosphere. Also, solenoid coil (2) is also not energized,
13
so solenoid valve (4) is closed. As a result, air passes through
pilot hole (10) and enters pilot chamber (12). It then pushes
up diaphragm (11) and closes exhaust valve (13).
1
2
4
11
12

OFF
STATUS
valve 3

exhaust valve 4 OFF
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300011
b. PRESSURE REDUCTION MODE

PRESSURE REDUCTION • When solenoid coil (1) is energized, solenoid valve (3) opens
14 5 and air also flows into pilot chamber (14). It pushes down on
diaphragm (5), shutting off chambers (7) and (8). At the same
time, solenoid coil (2) is also energized. This causes solenoid
7 valve (4) to open and the operating air from pilot chamber (12)
3 9 passes through exhaust port (15) and is released into the
88 atmosphere. Consequently, the air from the outlet port (9)
side (brake chamber) pushes down on diaphragm (11) and air
is released into the atmosphere. This causes the air pressure
1 of the brake chamber to decrease.
4
15 11 12

ON
STATUS
valve 3

ON
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300012
2A$4AA9#$%1
c. PRESSURE MAINTENANCE MODE

PRESSURE MAINTENANCE • When solenoid coil (1) is energized, solenoid valve (3) opens
14 5
and air flows through chamber (7) and acts on pilot chamber
(14). On the other hand, since solenoid coil (2) is not ener-
gized, solenoid valve (4) is closed and air flows through pilot
7 10 hole (10) and acts on pilot chamber (12). This causes dia-
3 8
phragms (5) and (11) to shut off their air passages, and the
8 chamber (8) pressure, that is to say the air acting on the brake
chamber, is maintained at the pressure that was current when
the switch from the pressure reduction mode to the pressure
maintenance mode took place.
1
2
11
4
12

ON
STATUS
valve 3

OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SHTS06Z080300013
3. WHEEL SENSORS
• These sensors are mounted, facing the sensor rings on each
wheel on the front and rear axles.
• The wheel sensors are electromagnet sensors consisting of a
permanent magnet core with a coil of wire wrapped around it.
• The frequency of the pulse signals generated by magnetic induc-
tance between the sensors and the sensor rings they face is pro-
portional to the rotational speed of the wheels. These pulse
signals are sent to the ABS ECU and are used to determine the
wheels, rotational status.
SHTS06Z080300014
PERMANENT
MAGNET
CORE
SENSOR RING
CLAMPING
WHEEL HUB BUSHING
SHTS06Z080300015
2A$4AA9#$%1
4. SENSOR RINGS
• The sensor rings are press-fitted into the insides of the wheel
hubs of each wheel on the front and rear axles, and they face the
wheel sensors described in the preceding section. The sensor
rings are made of a magnetic material, and teeth are cut into the
surface which faces the wheel sensor at regular intervals. Also,
when the sensor ring performs one complete rotation, the sensor
generates pulse signals corresponding to the number of teeth.
SHTS06Z080300016
5. CLAMPING BUSHINGS
• The wheel sensors are held in place through friction by clamping
bushings that are inserted into the mounting brackets. If they are
assembled properly, the clamping bushings serve to eliminate the
need to adjust the clearance between the wheel sensors and sen-
sor rings.
SHTS06Z080300017
6. WHEEL SENSOR HARNESSES

• Each wheel sensor wire harness employs a two-conductor twisted
wire cable. Its function is to protect the wheel sensor signals,
which are vital to the proper operation of the ABS system, from
electromagnetic interference. Under no circumstances should any
part of the wheel sensor wire harnesses be cut or connected to
any other wire.
SHTS06Z080300018
7. ABS WARNING LIGHT

• The status of the ABS system is indicated.
• It lights when the starter switch is turned "ON" and automatically
goes off when the system functions correctly.
• If malfunction occurs in the ABS system while the vehicle is being
driven, the light turns on to alert the driver.
• However, when a defects code is eliminated after repairing it and
the starter switch is turned "ON", the light will remain lit until the
vehicle speed reaches 7-10 km/h {11.2 - 16 mile/h}.
• Then, note that even when the warning light is lit, the ABS system,
SHTS06Z080300019 unaffected by the malfunction, continues to operate. Also, the
brake whose ABS system experiences the malfunction is reverted
to normal braking operation without ABS.
• When a Diagnosis switch is turned "ON", this light will goes on
and off, which indicates defect code.
8. EXHAUST BRAKE CUT RELAY

• When this relay is energized during ABS operation, the relay con-
tact opens, the current to the solenoid valve for the exhaust brake
is shut down, and the exhaust brake is released.
2A$4AA9#$%1
FRONT WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100001
FRONT AXLE
SHTS06Z080300020
1 Knuckle 12 Cam shaft

2 Oil seal guide 13 Sensor ring
3 O-ring 14 Wheel hub
4 Oil seal 15 Brake drum
5 Brake drum cover 16 Outer wheel hub bearing
6 Brake spider 17 Washer
7 Wheel sensor 18 Wheel hub bearing lock nut
8 Clamping bushing 19 Lock plate
9 Brake shoe 20 Gasket
10 Inner wheel hub bearing 21 Wheel nut
11 Hub bolt 22 Wheel hub cap
2A$4AA9#$%1
OVERHAUL
EN06Z0803H200001

(2) Pull off the wheel sensor.
NOTICE
other parts.
SHTS06Z080300021

BRAKE DRUM.
SHTS06Z080300022
SHTS06Z080300023

NOTICE
with new one.
SHTS06Z080300024
2A$4AA9#$%1

abnormal.
SHTS06Z080300025

the wheel hub.
ring.
SHTS06Z080300026

SHTS06Z080300027

NOTICE
ring.
SHTS06Z080300028 the axle direction.

NOTICE
If the wheel sensors are mounted, hammering on the wheel hubs
and the like on that axle could cause internal damage to the wheel
sensors. Either mount the tire and then tap on the tire or tap on
the wheel hub after removing the right and left wheel sensors.
2A$4AA9#$%1

the knuckle's wheel sensor holder.
(2) Apply a light coating of chassis grease to the hub of the wheel
sensor. Then push it forcefully into the clamping bushing until you
feel that the wheel sensor has made contact with the sensor ring.
NOTICE
SHTS06Z080300029
move smoothly.
(4) Mount the drum dust cover.

SHOULD MAKE
CONTACT
SENSOR RING sor (By rotating the tire by one time for 5 seconds)
WHEEL HUB
(3) In case of out of the standard range at (2), push the wheel sensor
softly by fingers until the sensor contacts with the sensor ring,
then inspect again from (1).
CLAMPING BUSHING
WHEEL SENSOR
SHTS06Z080300030

NOTICE
• The front axle chassis harnesses, particularly the ones that pass over the front axle and extend as far as the
wheel sensors, must absorb the movement when the wheels are turned and when the springs move. It is
therefore necessary to always maintain an optimal spacing between the clips.
• In addition, if there is a large amount of variation in the spacing between the clips, the wheel sensor har-
nesses can come into contact with tire chains and sustain damage.
• The wire harness for the front axle wheel sensor extends directly from the clip on top of the king pin cover to
the frame. In particular, make sure that the distance between the clip on top of the king pin cover and the clip
on the frame side is as indicated in the diagram below. There are markings on the wheel sensors in cases
where the wheel sensor harness clips are in locations where the relative movement is particularly great.
These places should be inspected regularly to ensure that the clip positions are still meeting with the same
marking.
SHTS06Z080300031
2A$4AA9#$%1
REAR WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100002
REAR AXLE
SHTS06Z080300032
1 Wheel sensor 12 Hub bolt

2 Clamping bushing 13 Inner wheel hub bearing
3 Wheel sensor holder 14 Sensor ring
4 Lock plate 15 Wheel hub
5 Oil seal collar 16 Brake drum
6 Axle housing assembly 17 Wheel nut
7 Oil seal 18 Outer wheel hub bearing
8 Brake drum cover 19 Washer
9 Brake spider 20 Lock nut
10 Cam shaft 21 Lock plate
11 Brake shoe 22 Axle shaft
2A$4AA9#$%1
OVERHAUL
EN06Z0803H200002

BRAKE DRUM.
SHTS06Z080300033
SHTS06Z080300034

NOTICE
with new one.
SHTS06Z080300035

NOTICE
SHTS06Z080300036
2A$4AA9#$%1
4. REMOVE THE CLAMPING BUSHING.

(1) Remove the clamping bushing out of the wheel sensor holder.
SHTS06Z080300037

abnormal.
SHTS06Z080300038

the wheel hub.
ring.
SHTS06Z080300039

(1) Make sure that the wheel sensor is securely fixed.
SHTS06Z080300040
2A$4AA9#$%1

SHTS06Z080300041
NOTICE
SHTS06Z080300042

NOTICE
ring.
the axle direction.
SHTS06Z080300043

NOTICE
sensor.
2A$4AA9#$%1

PUSH sor (By rotating the tire by one time for 5 seconds)
WHEEL SENSOR using round end bar until the sensor contacts with the sensor ring.
NOTICE
SENSOR RING Do not tap by hammer or turn when pushing the wheel sensor.
axle shaft.

NOTICE
• The rear axle chassis harnesses is arranged so that the left and right wheel sensor harnesses are near each
other. Therefore, special care should be taken not to make incorrect connections if the harnesses have been
removed for inspection or repairs.
• If incorrect connections are made, it will interfere with the functioning of the ABS system. For this reason,
caution plates indicating "LEFT" and "RIGHT" are affixed to the harnesses. Be sure to check when connect-
ing the harnesses. (The left harness is on the left side of the vehicle when viewed from the behind and facing
toward the front, and the right harness is on the right side of the vehicle.)
• The wheel sensor harnesses are arranged along the top of the rear axle housing. Therefore, make sure to
allow sufficient harness length between the chassis and the rear axle so that the harnesses can absorb the
up-and-down motion of the rear axle.
2A$4AA9#$%1
2A$4AA&'051HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧠㧞ಽ
ES START (EASY & SMOOTH START SYSTEM) (MODELS: WITH DENSO ABS) BR04–1

BR04
(MODELS: WITH DENSO ABS) BR04-001
ES START .................................................BR04-2
DESCRIPTION ................................................ BR04-2
DIAGRAM ........................................................ BR04-3
SPECIAL TOOL ............................................... BR04-4
ADJUSTMENT................................................. BR04-5
BR04–2 ES START (EASY & SMOOTH START SYSTEM) (MODELS: WITH DENSO ABS)
ES START
DESCRIPTION
EN06Z0804C100001
CLUTCH STROKE SENSOR

(INSTALLED ON CLUTCH PEDAL)
STOP LIGHT SWITCH

(INSTALLED ON BRAKE PEDAL)
ABS ACTUATOR
COUTESY SWITCH
(INSTALLED ON LEFT NEUTRAL SWITCH
AND RIGHT SIDE)
VEHICLE SPEED SENSOR
SHTS06Z080400001
DIAGRAM
EN06Z0804J100001
SYSTEM DIAGRAM
ABS+ES start ECU
ABS control function
Exhaust brake
For detecting control function
wheel speed
For detecting
wheel speed
Front right wheel sensor
For detecting
wheel speed
ES solenoid valve
For detecting ES start for front wheel
wheel speed ES start operation
Rear right wheel sensor control function control signal
For controlling ES solenoid valve
actuator
operation release for rear wheel
ES start main switch control function
For adjusting ABS actuator
release timing
Release timing switch
Indicating of ES start
operation, warning,
For operation check
Stop light switch and others ES start indicator
For checking (In combination meter)
operation/ release
Neutral switch
For alarming while ES start buzzer
driver not seated (In combination meter)
Courtesy switch
For checking
operation/ release
Parking brake switch 1
For checking
alarm suspension
Parking brake switch 2
For detecting
Vehicle speed sensor
vehicle speed
(Sensor signal for
combination meter)
For controlling
operation release
Clutch stroke sensor
For requesting
indication of
diagnosis code
Diagnosis monitor
Brake fluid
pressure sensor
Malfunction Malfunction code
diagnosis function (Diagnosis code)
Fail-safe function
(Safety function)
SHTS06Z080400002
PIPING DIAGRAM
8 1
5 2 19
3 3 8
2 5
10
12
13 2 5
11 14 8
5 2 6 15
16
8 9 4
18 17
AIR PIPING
ABS+ES START SECTION
OIL PIPING
ABS SECTION ELECTRICAL WIRING
SHTS06Z080400003
1 Brake valve 11 Stop light switch

2 Wheel cylinder 12 Clutch stroke sensor
3 Brake booster 13 Operation/ release switch
4 ABS + ES start ECU 14 Release timing switch
5 Wheel sensor 15 Neutral switch
6 ABS warning light 16 Courtesy switch
7 ABS actuator 17 Parking switch 1
8 Sensor ring 18 Parking switch 2
9 ES start indicator light 19 From air tank
10 Vehicle speed sensor
SPECIAL TOOL
EN06Z0804K100001
For diagnosing and setup of

S0963-01370 DIAGNOSIS MONITOR
ES start
DEDICATED HARNESS FOR

For connecting diagnosis
S0963-02300 CENTRALIZED DIAGNOSIS
monitor
CONNECTOR
ADJUSTMENT
EN06Z0804H300001
OPERATION CHECK.
1. NORMAL OPERATION CHECK

(1) Turn starter key "ON" position.
(2) Make sure that ES start indicator in the combination meter will go
on.
(3) Then, when only ES start light flashes on/off, it means that 0-point
adjustment of clutch and initial setting of release position are not
made. Accordingly, make them.
NOTICE
At the same time, when ES start indicator light flashes on and off
SHTS06Z080400006 and the buzzer beeps continuously, it means that the switch or the
sensor is not good. Checking those defective parts through diag-
nosis function, repair them.
2. OPERATION CHECK
NOTICE
This check should be performed on "Brake Tester" or at place
where protective device against the vehicle taking off is installed
since taking off operation is needed.
(1) The followings should be fulfilled.
• Starter key: "ON".
• ES start main switch: "ON".
• Parking brake: "RELEASE"
• Vehicle speed: 0 km/h {0 mile/h}.
(2) After stepping on the brake pedal for approx. 1 second, check that
the buzzer beeps once, ES start indicator light goes on and ES
start will operate.
(3) Check that braking force is retained.
(4) By normal operation for taking off (By shifting gear for clutch con-
SHTS06Z080400007 nection), check that ES start will be released.
ADJUSTMENT FOR ERLEASE TIMING

HINT
When any discrepancy (Brake dragging or vehicle moving back is
produced on release timing of ES start, the release timing can be
adjusted at option of driver's taste.
1. HOW TO SET
(1) Turn stater key "ON" and also, put ES start main switch "ON".
ON
SHTS06Z080400008
(2) Push the release timing switch to "FAST" or "SLOW" side for 0.5
sec.
(3) When you want to adjust it to "FAST" side, push the switch to
"FAST" side. And when adjusting it to "SLOW" side, push it to
"SLOW" side.
Accordingly, the release timing will be adjusted by a direction of
the switch to be pushed and its adjusting position will be indicated
by buzzer.
When you want to keep adjusting it, release the switch once and
push it again.
SHTS06Z080400009
(4) Adjustable range is up to 6 to "FAST" and up to 4 to "SLOW" side

and adjusting position will be indicated by buzzer sound.
0
4 3 2 1 1 2 3 4 5 6 NOTICE
However, release timing adjustment can not be made in the follow-
ing cases:
"SLOW" "FAST"
1. When any malfunction is found through diagnosis function.
Buzzar sound 2. When the vehicle running at speed of more than 5 km/h {2.7
‫ޓ‬Neutral position: Long beep mile/h}.
‫ޓ‬All "Fast" side: Short beep
‫ޓ‬All "SLOW" side: 2 Short beeps. 3. When ES start main switch is pushed to "RELEASE" side.
4. When diagnosis monitor connected.
SHTS06Z080400010
INITIAL SETTING OF ES START

HINT
This should be done to memorize Initial value of ES start releasing
position (Contacting point of clutch) and 0-point of clutch control
sensor in the computer.
1. HOW TO SET
(RIGHT-HAND DRIVE)
(1) Disconnect the centralized diagnosis connector (On lower right of
FIXING DUMMY the driver’s side instrument panel) from the dummy connector.
CONNECTOR
NOTICE
Centralized diagnosis connector is normally coupled with fixed
type dummy connector. So, use it by disconnecting from the
dummy one and pulling it to this side. When not using it, make
sure to leave it connected with fixed type dummy one.
BLACK CONNECTOR
WHITE CONNECTOR
SHTS06Z080400011
SHTS06Z080400012
(2) Connect the dedicated harness to the centralized diagnosis con-

nector and diagnosis monitor to the connector tagged by "STD:
ABS/ASR".
SST:
STD:ABS/ASR
OPT:AIRSUS
Dedicated harness (S0963-02300)

Diagnosis monitor (S0963-01370)
(3) Checking installing condition of clutch stroke sensor, step off the
clutch pedal.
STD:ES START
SHTS06Z080400013
(4) By turning starter key "ON", ES start main switch "OFF" and pull-
ing parking brake lever, start engine.
OFF
SHTS06Z080400014
(5) Put Release timing switch on "FAST".

NOTICE
Do not step on clutch pedal deeply.
(6) Check that the buzzer will "beep", "beep", "beep.".
(0-point setting of Clutch stroke sensor will be completed)
NOTICE
When the buzzer beeps, check clutch stroke sensor and its relat-
ing circuit.
SHTS06Z080400015
(7) Turning ES start main switch "ON" and stepping on clutch, shift to
3rd gear.
ON
SHTS06Z080400016
(8) Under this condition, push release timing switch to "FAST" side for
3 sec.
HINT
The above mentioned operation will make the buzzer to be beeped
2 times and lead to initial setting of release position.
In spite of releasing the switch, the condition will be kept.
(9) Connect clutch gradually.
SHTS06Z080400017
(10) When engine revolution falling and then coming back, push
release timing switch to "FAST" side again.
(11) Check that the buzzer will beep, beep and beep.
(Initial setting of release position is completed)
(12) After removing diagnosis monitor, turn stator key to "LOCK" posi-
tion to complete the initial setting.
NOTICE
• When you want to complete the initial setting on the way,
remove off diagnosis monitor.
• In case of the following cases, the initial setting can not be
made.
SHTS06Z080400018 .
1. Malfunction alarm is operating.

2. Parking brake lever is not pulled back.
3. Diagnosis monitor is not connected.
4. Wrong clutch operation was made.
2A$4AA9#$%1HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧣ᤨ㧠㧟ಽ
ES START (EASY & SMOOTH START SYSTEM) (MODELS: WITH WABCO ABS) BR04–1

BR04
(MODELS: WITH WABCO ABS) BR04-002
ES START .................................................BR04-2
DESCRIPTION ................................................ BR04-2
DIAGRAM ........................................................ BR04-3
SPECIAL TOOL ............................................... BR04-4
ADJUSTMENT................................................. BR04-5
ES START CONTROL VALVE ...............BR04-10

OVERHAUL ................................................... BR04-11
BR04–2 ES START (EASY & SMOOTH START SYSTEM) (MODELS: WITH WABCO ABS)
ES START
DESCRIPTION
EN06Z0804C100001
SHTS06Z080400001
DIAGRAM
EN06Z0804J100001
SYSTEM DIAGRAM
ES MAIN SWITCH
RELEASE TIMING
SWITCH
ES START CONTROL
STOP LIGHT SWITCH VALVE
ES START
CONTROLLER
NEUTRAL SWITCH
COURTESY SWITCH
PARKING BRAKE ES START

SWITCH 1 SLOPE INDICATOR LIGHT
SENSOR
PARKING BRAKE
SWITCH 2
BUZZER
BACKUP LIGHT
SWTCH
CLUTCH FLUID
PRESSURE SWITCH
CLUTCH STROKE
SENSOR
SPEED SENSOR
DIAGNOSIS MONITOR
SHTS06Z080400002
PIPING DIAGRAM
STOP LIGHT SWITCH

ES START
CONTROLLER
BRAKE PEDAL
Rr
Fr AIR
FRONT REAR
TANK
4WAY
PROTECTION
VALVE
REAR
BRAKE BOOSTER
ES START VALVE
FRONT
SHTS06Z080400003
SPECIAL TOOL
EN06Z0804K100001
For diagnosing and setup of

S0963-01370 DIAGNOSIS MONITOR
ES start
DEDICATED HARNESS FOR

For connecting diagnosis
S0963-02300 CENTRALIZED DIAGNOSIS
monitor
CONNECTOR
ADJUSTMENT
EN06Z0804H300001
NOTICE
When replacing the clutch disc, clutch stroke sensor or ES start
controller, do the following adjustment.
ADJUSTMENT OF THE CLUTCH STROKE SENSOR.
1. ADJUSTMENT PROCEDURE BY USING FUNCTION FOR

CONFIRMATION OF THE SENSOR CONDITION.
OFF
(1) Set the starter key "ON".
(2) Set the ES main switch "OFF".
SHTS06Z080400006

(RIGHT-HAND DRIVE)
the driver’s side instrument panel) from the dummy connector.
FIXING DUMMY NOTICE
CONNECTOR
BLACK CONNECTOR
WHITE CONNECTOR
SHTS06Z080400007
SHTS06Z080400008

nector and diagnosis monitor to the connector tagged by "ES
start".
SST:
SHTS06Z080400009
(5) Push "FAST" side of the release timing switch three times.
SHTS06Z080400010
HINT
When the sensor status checking function starts by the above-
mentioned operation, ES start indicator lamp on the meter panel
lights up and buzzer beeps once according to the patterns shown
in the figure.
(6) Diagnose if the adjustment is required or not by the condition of

buzzer beeping when the clutch pedal is free.
The buzzer beeps continuously:
Within the range of service limit (adjustment not
required)→Go to 3. How to complete.
The buzzer does not beep or beeps intermittently:
SHTS06Z080400011
Out of the range of service limit (adjustment required) →Go
to 2. Adjustment procedure.
2. ADJUSTMENT PROCEDURE
(1) Loosen the clutch stroke sensor fitting bolt to adjust the sensor as
Buzzer Adjusting procedure
Beeping intermittently Turn the sensor to A direction

A
B Beeping continuously Normal condition
No beeping Turn the sensor to B direction
SHTS06Z080400012 (2) After completing the adjustment, proceed to step 3.
3. HOW TO COMPLETE
(1) Tighten the clutch stroke sensor fitting bolt. (Make sure there is no
misalignment.)
(2) After using the status checking function, turn the release timing
switch to "FAST" side, or ES main switch "ON" before detaching
the diagnosis monitor.
SHTS06Z080400013
INITIALIZATION OF RELEASE POSITION

HINT
This is for memorizing the default value of ES start release posi-
OFF
tion (engaging point of clutch) to ES start controller.
1. HOW TO SETUP
(1) Turn the starter key "ON" and ES main switch "OFF". Then pull
the parking brake lever.
SHTS06Z080400006

(RIGHT-HAND DRIVE)
FIXING DUMMY NOTICE
CONNECTOR
BLACK CONNECTOR
WHITE CONNECTOR
SHTS06Z080400014
SHTS06Z080400015

start".
SST:
SHTS06Z080400009
(4) Make sure that the clutch pedal has returned completely and
press "FAST" side of the release timing switch for 3 seconds.
HINT
When the above operation has been completed, the buzzer beeps
and the indicator lamp also blinks in exact timing with the buzzer
to confirm the startup of the initialization.
(5) Step the clutch pedal and shift the gear to the second and gradu-
ally engage the clutch.
SHTS06Z080400010
(6) When the engine revolution comes into the condition below, press
once more "FAST" side of the release timing switch.
Models equipped with mechanical governor:
Tachometer reading goes down by 50 r/min. below the idling
revolution.
Models equipped with electronic governor or
Tachometer reading goes down and then returns.
(7) The buzzer beeps once and ES start indicator lamp turns off and
then the release position is memorized.
(8) After disconnecting the diagnosis monitor, turn the starter switch
to "LOCK" position to complete the initialization.
NOTICE
• To abort the initialization, disconnect the diagnosis monitor.
• On the following conditions, the initialization is impossible.
.
1. Failure alarm is alerting.

2. ES start is operating.
3. Vehicle speed is 0.5 km/h or above.
4. Parking brake lever has not been pulled.
0 POINT ADJUSTMENT OF SLOPE SENSOR

HINT
This is for memorizing the slope sensor signal when the vehicle is
OFF
on the level to ES start controller. (For equipped with air suspen-
sion models, perform this adjustment at the normal vehicle height
position.)
1. HOW TO SETUP
(1) Make sure the conditions below.
Vehicle load: no load
Road condition: on the level
SHTS06Z080400006
(2) Turn the starter switch "ON" and ES main switch "OFF". Then pull
the parking brake lever.
(RIGHT-HAND DRIVE)
FIXING DUMMY NOTICE
CONNECTOR
BLACK CONNECTOR
WHITE CONNECTOR
SHTS06Z080400016
SHTS06Z080400017

start".
SST:
SHTS06Z080400009
(5) Press "SLOW" side of the release timing switch for 3 seconds.
HINT
When the above operation has been completed, the buzzer beeps
and the indicator lamp also blinks in exact timing with the buzzer
to confirm the setup starts. (This condition continues after the
switch is released.)
(6) Press "SLOW" side of the release timing switch again.
(7) The buzzer beeps once and ES start indicator lamp turns off and
then the slope sensor output value is memorized.
(8) After disconnecting the diagnosis monitor, turn the starter key to
"LOCK" position to complete 0 point adjustment.
SHTS06Z080400018
NOTICE
• 0 point adjustment of slope sensor must be done on the level
road. (If the adjustment is done on slope road, the sensor
does not function properly.)
• If startup of 0 point adjustment is impossible, the road condi-
tion is not on the level. Move the vehicle to a place on the
level.
• On the following conditions, 0 point adjustment is impossi-
ble.
.
1. Failure alarm is alerting.

2. ES start is operating.
3. Vehicle speed is 0.5Km/h {0.14 mile/s} or above.
4. Parking brake lever has not been pulled.
ES START CONTROL VALVE

COMPONENT LOCATOR
EN06Z0804D100001
15
B 14
16
3
17
18
19
20
21 22
23
24
26 25
10 27
7
6
5
4 13
12
3 11 1
9
8
2 A
SHTS06Z080400019
1 Hose 10 Spring 19 Coil cover

2 Bolt 11 O-ring 20 O-ring
3 Bracket 12 Piston 21 O-ring
4 Cover 13 O-ring 22 Valve seat
5 Seal 14 Screw 23 O-ring
6 Spring 15 Solenoid assembly 24 Valve
7 Inlet valve 16 Spring 25 Spring
8 Straight pin 17 Plunger 26 Filter
9 Spring seat 18 Rod 27 Body

A 4.0-6.0 {40-60, 2.9-4.3} B 1.3-1.7 {13-17, 0.49-1.22}
OVERHAUL
EN06Z0804H200001

NOTICE
• When dismounting and storing parts, place a cap on all ports
so not dirt or dust enters.
• Be careful so water, dirt, or dust does not enter inside the
harness connector to prevent solenoid short circuits or
faulty connections.

SCREW NOTICE
Never loosen the screws in the solenoid assembly. Replace the
solenoid assembly if the screws have been loosened.
SOLENOID ASSEMBLY
SHTS06Z080400020

NOTICE
Apply an adequate amount of grease to each O-ring before assem-
bly.
1. Insert the spring in the valve and assemble it in the body.
SHTS06Z080400021
NOTICE
Assemble the valve and the spring as shown in the figure.
SHTS06Z080400022
2. Align and attach the O-ring in the small diameter space in the
VALVE SEAT HOLE valve seat correctly and install it in the body.
NOTICE
Align the valve seat holes and body holes to perform the assem-
bly.
BODY HOLE
SHTS06Z080400023
3. Assemble the O-rings (2 units) in the piston and lubricate the

inside diameter of the piston with grease.
NOTICE
Verify the diameter of the O-ring (small diameter) because there
are multiple settings and then assemble the unit.
D dimension = 22 mm {0.87 in.}
d dimension = 22 mm {0.87 in.}
SHTS06Z080400024
4. Assemble the spring, piston and inlet valve. Press in the inlet
valve and install the straight pin.
NOTICE
Align the inlet valve pin hole and piston pin hole and assemble the
parts. After the assembly is completed, do not rotate the inlet
valve to align the pin holes.
SHTS06Z080400025
5. Position the spring seat collar so it faces the rear side and
install the unit.
6. Apply grease to the outer surface of the O-ring installed in

the piston.
SHTS06Z080400026
7. Apply grease to the inner surface of the body.
8. Insert the piston inlet valve assembly in the body.

NOTICE
Do not turn the piston when inserting it.
SHTS06Z080400027

EN06Z0804H300002
NOTICE
Isopropyl alcohol should only be used to wash the ES start con-
trol valve components.
Valve body inside, piston, — — Replace. Visual check

valve, valve seat, spring
and inlet valve:
Wear and damage
O-ring: — — Replace. Visual check

Crack and damage
%1.12*10HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧜ಽ
Pub. No. S1-YFCE18A 1/2 ’06-9

S1-YFCE18B 1/2 ’06-11
%1.12*10HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧝ᣣ‫ޓ‬᳓ᦐᣣ‫ޓ‬ඦᓟ㧢ᤨ㧝㧜ಽ

S1-YFCE18B - 1 (Chassis Vol 1 Euro 2)

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S1-YFCE18B - 1 (Chassis Vol 1 Euro 2)

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(14'914&HOࡍ࡯ࠫ㧞㧜㧜㧢ᐕ㧝㧝᦬㧢ᣣ‫ᦐ᦬ޓ‬ᣣ‫ޓ‬ඦ೨㧤ᤨ㧞㧟ಽ

Manual Name Pub. No.

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MANUAL NO. S1-YFCE18B 1/2

GENERAL INTRODUCTION GN02-001

CLUTCH MAIN UNIT CL02-001 (CS350) CL02-002 (CS380) CL02-003 (CS430)

CLUTCH CONTROL CL03-001

TR05-001 TR05-002 TR05-003

TRANSMISSION/TRANSFER CONTROL TR06-001

PP02-001 PP02-002 PP02-003 PP02-004 PP02-005

DF02-001 DF02-002 DF02-003 DF02-004 DF02-005

ES START BR04-001 BR04-002

INDEX: CHASSIS GROUP 1/1

CLUTCH MAIN UNIT

WORKSHOP CLUTCH CONTROL

MANUAL TRANSMISSION EQUIPMENT

TRANSMISSION MAIN UNIT

TRANSFER MAIN UNIT

P.T.O. (POWER TAKE-OFF)

TRANSMISSION / TRANSFER CONTROL

PROPELLER SHAFT EQUIPMENT

ABS & ASR

ES START (EASY & SMOOTH START SYSTEM)

GENERAL INTRODUCTION GN02–1

GN02–2 GENERAL INTRODUCTION

GENERAL INTRODUCTION GN02–3

HOW TO USE THIS MANUAL

2. TROUBLESHOOTING IN THIS MANUAL

Thoroughly listen to the conditions and environment for the trou-

Perform diagnostic inspection, checkup of the symptom, function

Classify the inspection results obtained in step 2 to systematically

• Execute the following steps to perform pre-inspection.

GN02–4 GENERAL INTRODUCTION

3. DESCRIPTION IN THIS MANUAL

GENERAL INTRODUCTION GN02–5

(2) Work item

GN02–6 GENERAL INTRODUCTION

5. DEFINITION OF SAFETY TERMS

Provides additional information to help you to perform the repair efficiently.

GENERAL INTRODUCTION GN02–7

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GN02–8 GENERAL INTRODUCTION

PRECAUTIONS FOR WORK

1. CLOTHES AND APPEARANCE

GENERAL INTRODUCTION GN02–9

1. PREPARATIONS FOR DISASSEMBLY

2. INSPECTION DURING DISASSEMBLY

3. ARRANGEMENT OF DISASSEMBLED PARTS

4. CLEANING OF DISASSEMBLED PARTS

5. INSPECTION AND MEASUREMENT

7. ADJUSTMENT WORK CHECK

GN02–10 GENERAL INTRODUCTION

PRECAUTIONS FOR ELECTRICAL SYSTEM

1. REMOVING THE BATTERY CABLE

2. HANDLING OF ELECTRONIC PARTS

3. HANDLING OF WIRE HARNESS

GENERAL INTRODUCTION GN02–11

PRECAUTIONS FOR ELECTRIC WELDING

GN02–12 GENERAL INTRODUCTION

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