S1-MGDE01C 1-2 For GD8J, GH8J & FM8J

S1-MGDE01C-1.
book 1 ページ２０１２年５月２９日火曜日午後３時５６分
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Vehicles.
Applicable for GD8J GH8J, FM8J series, equipped with J08E-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.
Manual Name Pub. No.

Chassis Workshop Manual S1-MGDE01C 2/2
J08E-TI Engine Workshop Manual S5-MJ08E01B
S1-MGDE01C-1.book 2 ページ２０１２年５月２９日火曜日午後３時５６分
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-MGDE01C 1/2

CHAPTER
MODELS GD8J, GH8J, FM8J
GENERAL INTRODUCTION GN02-001
CLUTCH MAIN UNIT CL02-001 (CS380)
CLUTCH CONTROL CL03-001
TR02-003 TR02-004
TRANSMISSION MAIN UNIT TR02-001 (LJ06S) TR02-002 (MF06S)
(EATON FS6109) (ZF 9S1110)
TR05-001 TR05-002 TR05-003

PTO (POWER TAKE-OFF) (TRANSMISSION SERIES: (TRANSMISSION SERIES: (TRANSMISSION SERIES:
LJ06S) MF06S) EATON FS6109)
TRANSMISSION/TRANSFER
TR06-001
CONTROL
PP02-002 PP02-003 PP02-004

PROPELLER SHAFT PP02-001 (LF0932)
(MC1040) (HE1160) (MC0000)
DIFFERENTIAL CARRIER DF02-001 (SH14) DF02-002 (SH18) DF02-003 (THD17)
BRAKE EQUIPMENT BR01-001
SERVICE BRAKE BR02-001
ABS & ASR BR03-001 (ABS & ASR: WABCO MAKE)
EXHAUST BRAKE BR05-001
STEERING EQUIPMENT SR01-001
STEERING UNIT SR02-001
POWER STEERING SR03-001

INDEX: CHASSIS GROUP 1/4
GENERAL INTRODUCTION
CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
WORKSHOP CLUTCH CONTROL
MANUAL TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
PTO (POWER TAKE-OFF)
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.
EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
STEERING EQUIPMENT
STEERING UNIT
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
CAB EQUIPMENT
CAB
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
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 ..........................................................GN02-20
SEALANT ON THE TAPERED
SCREW FOR PIPING....................................GN02-21
NYLON TUBE ................................................GN02-22
ASSEMBLY OF JOINT/GASKET
FOR PIPING ..................................................GN02-25
HANDLING OF LIQUID GASKET..................GN02-27
TROUBLESHOOTING USING
THE TROUBLE LIST .....................................GN02-28
TROUBLESHOOTING USING
A DIAGNOSIS MONITOR..............................GN02-29
DIAGNOSIS USING THE PC
(PERSONAL COMPUTER)
DIAGNOSIS TOOL WITH INTERFACE .........GN02-33
CHASSIS SERIAL NUMBER, VEHICLE
IDENTIFICATION NUMBER AND
ENGINE SERIAL NUMBER...........................GN02-36
RECOMMENDED LUBRICANTS ..................GN02-37
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
SAPH00Z000200001
✩: 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
SAPH00Z000200002
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.
SAPH00Z000200008
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.
INCORRECT
SAPH00Z000200009
3. HANDLING OF WIRE HARNESS

INCORRECT (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
INCORRECT acute angle section of the body and a bolt.
(2) To attach a part, take care not to bite the wire harness.
INCORRECT
INCORRECT
SAPH00Z000200010
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.
INCORRECT INCORRECT
CORRECT
SAPH00Z000200011
PRECAUTIONS FOR ELECTRIC WELDING
1. PRECAUTION FOR ELECTRIC WELDING

Electrical components such as the alternator and tachograph
are directly connected to the battery and one end is earthed
to the chassis frame. Under these conditions, welding cur-
rent will flow back along the earth circuit if electric welding is
carried out and damage may be caused to the alternator,
tachograph, electrical components, etc. Consequently, the
following precautions are always to be taken during welding.
(1) Disconnect the earth terminal of the battery at the frame fitment
and earth the welding equipment securely to the frame itself. (Do
not fit the welding equipment earth to such things as the tire rims,
brake pipes or fuel pipes and leaf spring, etc.)
a. Turn the starter switch off.
b. Disconnect the battery’s negative terminal of the battery.
c. Earth welding equipment securely, near to the area to be
welded.
SAPH00Z000200012
(2) In order to prevent damage to ancillary equipment components
from sparks during welding, take steps such as putting fire-resis-
tant covers over things like the engine, meters, steering wheel,
hoses, leaf spring and tires.
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)

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:
SAPH00Z000200014 (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.
SAPH00Z000200015
(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.
SAPH00Z000200016
(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).
SAPH00Z000200017
TIGHTENING OF BOLTS AND NUTS FOR CHASSIS

EN00Z0002C100005
TYPES AND IDENTIFICATION

There are three types of bolts and nuts.
1. Standard (w/o flange)

(1) Bolts/nuts without flange
SAPH00Z000200018
2. With old flange (w/grooves)

(1) Flange is small and has grooves on its back.
GROOVES
GROOVES
FLANGE OUTER DIAMETER
SAPH00Z000200019
3. With new flange (w/o grooves)

(1) Flange is big and does not have grooves on its back.
FLANGE OUTER DIAMETER
SAPH00Z000200020
4. Comparison of flange outer diameters
Bolt Nut
With old flange With new flange With old flange With new flange
(w/grooves) (w/o grooves) (w/grooves) (w/o grooves)
Thread diameter
Flange Flange Flange Flange
Strength Strength Strength Strength
outer outer outer outer
class class class class
diameter diameter diameter diameter
M8 7T, 9T 15.5 8.8, 10.9 17 7N 15.5 8 17
8.8 20
M10 7T, 9T 18.5 7N 18.5 8 21.5
10.9 21.5
8.8 24
M12 7T, 9T 21.5 7N 21.5 8 26
10.9 26
M14 - - 10.9 30.5 - - 12 30
COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS)

BOLTS/NUTS WITH OLD FLANGE (W/GROOVES)
SEAT SURFACE WITH OLD FLANGE SEAT SURFACE WITH OLD FLANGE
NO COMPATIBILITY
BOLTS/NUTS WITH NEW FLANGE (W/O GROOVES)
SEAT SURFACE WITH NEW FLANGE SEAT SURFACE WITH NEW FLANGE
SAPH00Z000200021
NOTICE
[Bolt/nuts with new flange (w/o grooves)] can not be used on the place where [bolts/nuts with old flange (w/
grooves)] were used. In addition, use care to avoid misassembly because even when nominal sizes and pitches
are same, there is no compatibility in strength if types are different.
STRENGTH CLASSES AND SYMBOLS

Bolt Nut
Symbols
Strength class Strength class Symbols
Carbon steel Boron steel
4T -
7T 7T
9T
2. With new flange (w/grooves)
Bolt Nut
Symbols
Strength class Strength class Symbols
Carbon steel Boron steel
8.8 8
10.9 12
PART NO.
Bolt Nut
Thread
diameter Strength Surface Strength Surface
Part No. Part No.
class treatment class treatment
7T SH111-**** Plating
M8 8N SL113-00807 Plating
M14 9T SH112-**** Plating 8N SL113-01411 Plating
Bolt Nut
Thread
Part No. Part No.
7T SH562-**** Torquer
Bolt Nut
Thread
Part No. Part No.
8.8 91551-808** Plating

M8 8 94151-80800 Plating
10.9 91551-008** Plating
8.8 91552-E10** Neotorquer

M10 8 94151-81001 Neotorquer
10.9 91552-F10** Neotorquer
8.8 91552-E12** Neotorquer

M12 8 94151-81201 Neotorquer
10.9 91552-F12** Neotorquer
M14 10.9 91552-F14** Neotorquer 12 94151-21401 Neotorquer
NOTICE
Some bolts/nuts are applied friction stabilizer on thread surface. Note that their tightening torques are different
from those of plated-only bolts/nuts even if the strength class is same. (Threads with Neotorquer are colored in
light red.)
HINT
The * below the hyphen of a part number shows a thread diameter and length under head, so the numbers vary
depending on type.
LIST OF TIGHTENING TORQUE

Apply a tightening torque specified in the strength class of the bolt/nut used.
NOTICE
Refer to the service manual because tightening torques of some parts do not conform to it due to their tightening
conditions, strength classes, and surface treatments.

Thread diameter Strength classes Tightening Torque
7T 22.04.0 {22445, 16.22.9}

M8
9T 29.05.5 {29656, 23.14.0}
7T 43.08.5 {43886, 31.76.2}

M10
9T 57.011.0 {581112, 42.08.1}
7T 76.015.0 {774152, 56.011.0}

M12
9T 100.020.0 {1,019203, 73.714.7}
M14 9T 160.032.0 {1,630326, 117.923.5}

7T 22.04.0 {22445, 16.22.9}

M8
9T 29.05.5 {29656, 23.14.0}
7T 51.510.0 {525101, 37.97.3}

M10
9T 68.513.5 {698137, 50.59.9}
7T 91.018.0 {927183, 67.013.2}

M12
9T 120.024.0 {1,223224, 88.417.6}

8.8 31.09.3 {31694, 22.86.8}

M8
10.9 39.011.7 {397119, 28.78.6}
8.8 35.010.5 {356107, 25.87.7}

M10
10.9 46.513.8 {474140, 34.210.1}
8.8 63.018.9 {642192, 46.413.9}

M12
10.9 82.024.6 {836250, 60.418.1}
M14 10.9 130.039.0 {1,325397, 95.828.7} 130.026.0 {1,325265, 95.819.1}*
HINT
*: Value is for usage in the fuel tank.
TIGHTENING OF FLARE NUTS AND HOSES

EN00Z0002C100006
1. TIGHTENING TORQUE OF PIPE FLARE NUT

Pipe outer
diameter 4.76 6.35 8 10 12 15
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
13, 20, 22 metal fitting for
10.5 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.
SAPH00Z000200035
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.
SAPH00Z000200036
Tightening torque of tapered joint Unit: Nm {kgfcm, 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.
SAPH00Z000200039
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.
SAPH00Z000200040
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
6 S0942-11510
8 S0942-11520
10 S0942-11530 Release tool
12 S0942-11540
15
SAPH00Z000200041
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.})

6 21.5-22.5 {0.847-0.885}
SAPH00Z000200042 8, 10 22.0-23.0 {0.867-0.905}
12 22.5-23.5 {0.886-0.925}
15 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.
SAPH00Z000200043
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
SAPH00Z000200044
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 (6) 235 {23050, 16.63.6}
SAPH00Z000200045
M14 x 1.5 (8) 374 {38040, 27.52.8}
M16 x 1.5 (10) 405 {41050, 29.63.6}
M18 x 1.5 (12) 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
SAPH00Z000200046 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 6, 10, 12
{-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.})
6 30 {1.181}
8 50 {1.969}
10 65 {2.559}
12 70 {2.756}
15 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
SAPH00Z000200048
• 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
SAPH00Z000200062
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)
SAPH00Z000200063
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)
SAPH00Z000200064
! CAUTION
The central diagnosis connectors are normally connected to the
fixing dummy connectors. Remove the central diagnosis connec-
tors from the dummy connectors before using them. When the
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
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
diagnosis monitor.
SAPH00Z000200065
• The method for outputting diagnosis monitor codes differs
from system to system. Follow the instruction in the chapter
for each system.
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 Not used
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
SAPH00Z000200066
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
SAPH00Z000200067
4. 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.
SAPH00Z000200068
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:
Computer interface
(Hino-Bowie)
The main body and cables for RS232C and USB (09993-E9070)
Cable between vehicle and Hino-Bowie (S0904-21220)
(DENSO DST-i set without LCD)
SAPH00Z000200069
Without Bluetooth (95171-01020)
With Bluetooth (95171-01040)
(DENSO DST-i set with LCD)
Without Bluetooth (95171-01030)
With Bluetooth (95171-01050)
Diagnosis software: HINO Diagnostic eXplorer (HINO-DX)
Reprogramming software: HINO Reprog Manager (HINO-RM)
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.
INTERFACE
DIAGNOSIS
CONNECTOR
SAPH00Z000200070
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) (09843-E9020)
(2) Terminal number
ECU terminal numbers in the text correspond to connectors of
signal check harness as shown below.
SAPH00Z000200071
SAPH00Z000200072
.
(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
SAPH00Z000200073 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-
cation plate stamped the vehicle model and chassis serial number
or vehicle identification number.
IDENTIFICATION
PLATE
SAPH00Z000200074
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
SAPH00Z000200075
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, E-6*1)
*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) LJ06S, MF06S
Gear oil Transmission:

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

Eaton Approved Semi-Syn- —
thetic oil
Gear oil Transmission: SAE 75W-80/75W-85/75W-90/ATF:
(ZF-Ecofluid M ZF 9S1110 Above -40C {-40F}
02B/02E/02L)
(ZF-Ecofluid M SAE 80W/80W-85/80W-90:
02B) Above -20C {-4F}
(ZF-Ecofluid M SAE 40, 85W-90, 90:
02B) Above -0C {33.8F}
(ZF-Ecofluid M SAE 30:
02B) Above -15C {5F}
No. LUBRICANTS POSITION VISCOSITY RECOMENDATIONS (SAE)

3 Hypoid gear oil Differential (Rear):
(API: GL-5) SH14, SH18 THD17
4 Gear oil Steering
(API: GL-4)
No. LUBRICANTS POSITIONS

5 Power steering fluid (ATF DEXRON) Integral power steering gear
6 Cab tilt oil (MIL=H-5606G) or (MIL-H-5606E) Cab tilt cylinder
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
CLUTCH MAIN UNIT (CS380) CL02–1
CLUTCH MAIN UNIT (CS380)

CL02
CL02-001
CLUTCH ASSEMBLY (CS380) ................. 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 ...........................CL02-14
CL02–2 CLUTCH MAIN UNIT (CS380)
CLUTCH ASSEMBLY (CS380)

DATA AND SPECIFICATIONS
EN0220502I200001
CLUTCH FACING Unit: mm {in.}
Material Molded non-asbestos
Type Dry single plate with damper spring
Outside diameter 380 {14.961}
Inside diameter 220 {8.661}
Thickness 5.0 {0.197}
COMPRESSION SPRING Unit: mm {in.}
Clutch cover parts No. 31210-E0240
Free length 92.9 {3.657}
Coil outside diameter 30.5 {1.201}
Diameter of wire 5.5 {0.217}
Quantity 12
Setting load 1,285.5 N {131 kgf, 288.8 lbf}
Setting length 59.6 {2.346}

DESCRIPTION
EN0220502C100001
SAPH022050200001
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
EN0220502F300001
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.
Clutch disc facing gummed with oil or Replace facing or disc assembly.
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.
Flywheel housing misalignment. Replace flywheel housing.
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.
Clutch pedal free-play incorrectly Adjust free-play.
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
EN0220502K100001
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

COMPONENT LOCATOR
EN0220502D100001
SAPH022050200008
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 64-84 {653-856, 48-61} C 9.8-14.7 {100-150, 7.3-10.8}
B 39.2-49.0 {400-500, 29-36}
OVERHAUL
EN0220502H200001
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:
Clutch 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
SAPH022050200009
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.
SAPH022050200010
NOTICE
Before disassembling, make aligning marks on the clutch cover
and pressure plate.
SAPH022050200011
2. DISASSEMBLE THE RELEASE LEVER ASSEMBLY.

(1) Remove the pin and the release lever.
SAPH022050200012
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.
SAPH022050200013
2. REPLACE THE PILOT BEARING.

(1) Remove the pilot bearing.
SST:
Clutch Pilot Bearing Puller (S0965-01970)
Sliding Hammer (S0942-01442)
SAPH022050200014
(2) Using a suitable tapping rod, install the pilot bearing.

NOTICE
After installing the pilot bearing, ensure that it rotates smoothly.
SAPH022050200015
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.
SAPH022050200012
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.
SAPH022050200010
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.
SAPH022050200011
(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.
SAPH022050200016
(3) Install the four pressure plate fixing bolts with the plain washers
through the clutch cover into the tapped holes in the pressure
plate.
SST:
Clutch Pressure Plate Fixing Bolt (SH112-61070)
Plain Washer (SL611-01024)
SAPH022050200017
(4) Install the strap plate bolt with the friction washer and lock washer.
SAPH022050200018
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.}
SAPH022050200019
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.
SAPH022050200020
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)
SAPH022050200021
4. INSTALL THE LOCK PLATE.

NOTICE
Be sure to lock the support nut with the lock plate.
SAPH022050200022
INSPECTION AND REPAIR

EN0220502H300001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
Rivet head depth 2.2-2.8 0.1 Replace disc Measure

{0.0866-0.1102} {0.0039} assembly or
facing.
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 Measure

ment 0.1 {0.0039} {0.0197} friction surface
or replace.
Pressure plate thickness 23 {0.906} 22 {0.866} Replace. Measure
Pressure plate friction — — Regrind the Visual check

surface scoring or rough- friction surface
ness or replace, if
necessary.
Compression spring free 92.9 {3.657} 88.3 Replace. Measure

length {3.476}
Compression spring — 5.0 {0.197} Replace. Measure

squareness
Compression spring set- 1,285 N 1,181.3 N Replace. Measure

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

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

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

rotation if necessary.
CLUTCH CONTROL CL03–1
CLUTCH CONTROL
CL03
CL03-001
CLUTCH CONTROL UNIT........................ CL03-2

DATA AND SPECIFICATIONS ..........................CL03-2
DESCRIPTION .................................................CL03-2
SPECIAL TOOL ................................................CL03-5
INSPECTION AND ADJUSTMENT ..................CL03-6
CLUTCH PEDAL AND

RELEASE UNIT ...................................... CL03-10
COMPONENT LOCATOR...............................CL03-10
OVERHAUL ....................................................CL03-15
CLUTCH MASTER CYLINDER .............. CL03-19

OVERHAUL ....................................................CL03-20
CLUTCH BOOSTER ............................... CL03-21

OVERHAUL ....................................................CL03-22
CL03–2 CLUTCH CONTROL
CLUTCH CONTROL UNIT

EN02Z0203I200001
CLUTCH BOOSTER Unit: mm {in.}
Power cylinder inside diameter 90 {3.543}
Hydraulic cylinder inside diameter 19.8 {0.780}
Relay valve piston outside diameter 16.0 {0.630}
Valve piston outside diameter 23.5 {0.925}
DESCRIPTION
EN02Z0203C100001
CLUTCH RELEASE UNIT
SAPH02Z020300001
1 Release bearing 4 Release fork

2 Lubrication hose 5 Release fork shaft
3 Release bearing hub
MASTER CYLINDER
SAPH02Z020300002
1 Piston 4 Push rod

2 Reservoir tank 5 Return spring
3 Valve
CLUTCH BOOSTER
SAPH02Z020300003
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
S0965-72160 GUIDE
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
SAPH02Z020300009
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.
SAPH02Z020300010
(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.
SAPH02Z020300011
(4) Check the fluid level. If necessary, add or remove clutch fluid in
RESERVE TANK
order to match the "MAX" level.
MAX.
NORMAL
MIN.
SAPH02Z020300012
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

LJ06S, MF06S,
More than 19.5 mm {0.768 in.}
EATON FS8209
ZF 9S1110 More than 17.0 mm {0.669 in.}
SAPH02Z020300013
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
SAPH02Z020300014
b. Loosen the lock nut and turn the master cylinder push rod
LOCK NUT until the push rod play is correct.
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
SAPH02Z020300015
(2) Check the clutch pedal play.

a. Push the pedal until the beginning of clutch resistance is felt.
Assembly Standard: 52-65 mm {2.048-2.559 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.
d. Turn the push rod clockwise about 2.5 turns.
SAPH02Z020300016
Standard:
CLEARANCE
Clearance between release bearing and release lever:
2.0 mm {0.079 in.}
RELEASE e. Tighten the lock nut.
LEVER
RELEASE
BEARING
SAPH02Z020300017
2. CHECK THE CLUTCH PEDAL HEIGHT AND STROKE.
Assembly standard
Pedal height 164-174 mm {6.46-6.85 in.}
Pedal stroke 150-160 mm {5.91-6.29 in.}
SAPH02Z020300018
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

LJ06S 33 mm {1.299 in.}
MF06S, ZF 9S1110 20 mm {0.787 in.}
EATON FS6109 11 mm {0.433 in.}
SAPH02Z020300019
CLUTCH PEDAL AND RELEASE UNIT

COMPONENT LOCATOR
EN02Z0203D100001
SAPH02Z020300020
1 Reservoir tank 10 Switch (For exhaust brake)

2 Master cylinder 11 Switch (For transmission PTO 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: LJ06S
SAPH02Z020300021
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
SAPH02Z020300022
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: EATON FS6109
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
SAPH02Z020300023
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 Anti-rattle spring
7 Tension spring 18 Release bearing hub
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}
TRANSMISSION SERIES: ZF 9S1110
SAPH02Z020300024
1 Cotter pin 11 Cover

2 Clevis 12 Gasket
3 Pin 13 Release fork
4 Push rod 14 Set screw
5 Tension spring 15 Release bearing hub
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} D 14.5-17.5 {148-178, 11-12}
B 37.5-48.5 {383-495, 28-35} E 27.5-32.5 {280-330, 20-23}
C 37.5-48.5 {383-495, 28-35}
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.
SAPH02Z020300025
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.
SAPH02Z020300026
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.
SAPH02Z020300026
3. INSTALL THE SWITCH FOR EXHAUST BRAKE AND TRANS-

MISSION PTO
(1) Install the switch bushing into the switch bracket.
SAPH02Z020300027
(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.
SAPH02Z020300028
SAPH02Z020300029
1. REPLACE THE RELEASE BEARING.

(1) Using a suitable tool and a press, remove the bearing from the
release bearing hub.
SAPH02Z020300030
(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.
SAPH02Z020300031
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.
SAPH02Z020300032
NOTICE
The bearing must be installed with blue colored and engraved fac-
ing of the oil seal outward.
SAPH02Z020300033
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.
SAPH02Z020300034

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
SAPH02Z020300037
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 neces-
sary.
CLUTCH BOOSTER
COMPONENT LOCATOR
EN02Z0203D100003
SAPH02Z020300038
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}
C 14.7-19.6 {150-200,11-14} F 34.3-44.1 {350-449, 26-32}
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.
SAPH02Z020300039
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.
SAPH02Z020300040
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)
SAPH02Z020300041

• 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.
SAPH02Z020300042
(2) After tightening the lock nut, secure the lock nut at three places
with a punch to prevent loosening.
SAPH02Z020300043
(3) Install the piston seal on the piston.
SAPH02Z020300044
(4) Apply the brown colored grease on the piston seal and the inside
of the cylinder shell.
SAPH02Z020300045
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.
SAPH02Z020300046
3. INSTALL THE CYLINDER ASSEMBLY ON THE POWER PIS-

TON.
(1) Insert the control tube bushing and the seal on the control tube.
SAPH02Z020300047
4. ASSEMBLE THE HYDRAULIC CYLINDER.

(1) Using the special tools, install the piston cups on the piston.
SST:
Guide (S0965-72090)
Guide (S0965-72100)
SAPH02Z020300048
SAPH02Z020300049
(2) Apply the red colored grease on the piston cups, the piston and
the inside of the hydraulic cylinder.
SAPH02Z020300050
(3) Install the piston assembly in the hydraulic cylinder.

(4) Install the pin.
SAPH02Z020300051
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 (S0965-72150)
Guide (S0965-72160)
NOTICE
• Take care not to damage the piston cups when installing
them on the piston.
• Coat the O-ring and sliding surfaces with silicone grease as
SAPH02Z020300052
shown in the figure.
6. INSTALL THE PISTON ASSEMBLY TO THE CYLINDER.
SAPH02Z020300053
7. INSTALL THE RETURN SPRING, O-RING, POPPET VALVE

BODY, POPPET VALVE AND CONICAL SPRING.
NOTICE
Coat the O-ring with brown colored grease.
SAPH02Z020300054
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.
SAPH02Z020300055
IMPORTANT POINT - MOUNTING
1. INSTALL THE CLUTCH BOOSTER.

(1) Connect the air and hydraulic lines to the clutch booster.
(2) Install the tension spring.
SAPH02Z020300056

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
TRANSMISSION MAIN UNIT (LJ06S) TR02–1
TRANSMISSION MAIN UNIT (LJ06S)

TR02
TR02-001
TRANSMISSION ASSEMBLY (LJ06S)..... TR02-2

DATA AND SPECIFICATIONS ......................... TR02-2
DESCRIPTION ................................................ TR02-3
TROUBLESHOOTING ..................................... TR02-4
SPECIAL TOOL ............................................... TR02-6
DISMOUNTING AND MOUNTING .................. TR02-7
GEAR SHIFT HOUSING (LJ06S) ............. TR02-9

COMPONENT LOCATOR................................ TR02-9
OVERHAUL ................................................... TR02-11
INSPECTION AND REPAIR .......................... TR02-16
INPUT SHAFT, OUTPUT SHAFT, GEARS AND

RELATED PARTS (LJ06S) ..................... TR02-17
COMPONENT LOCATOR.............................. TR02-17
OVERHAUL ................................................... TR02-19
COUNTER SHAFT, REVERSE IDLER SHAFT

AND GEARS (LJ06S) ............................. TR02-31
OVERHAUL ................................................... TR02-32
TR02–2 TRANSMISSION MAIN UNIT (LJ06S)
TRANSMISSION ASSEMBLY (LJ06S)

EN0332202I200001
Six forward speeds, one reverse

Type 2, 3, 4, 5, 6th, Synchromesh,
1st and Reverse, Constant mesh
1st 6.477
2nd 4.016
3rd 2.450
Gear ratios 4th 1.470
5th 1.000
6th 0.723
Reverse 6.064
Number of teeth input shaft 26
Counter drive gear 43
1st gear 12
2nd gear 21
3rd gear 27
Number of teeth counter shaft
4th gear 36
5th gear —
6th gear 48
Reverse gear 12
1st gear 47
2nd gear 51
3rd gear 40
Number of teeth output shaft 4th gear 32
5th gear —
6th gear 21
Reverse gear 44
Reverse idler gear 23
Power take-off opening On left side of gear case
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)
Viscosity, between -12 and 32C {10 and 90F} SAE90
DESCRIPTION
EN0332202C100001
SAPH033220200001
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 (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 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 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.
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
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
Prior to starting a transmission overhaul, it is necessary to have these special tools.
S0983-95005 SOCKET WRENCH
S0965-01900 PULLER
S0965-02070 INPUT SHAFT PULLER
S0965-31180
HOOK
S0965-31200
S0965-01882 PULLER
S0965-01101 PULLER
DISMOUNTING AND MOUNTING

EN0332202H100001

! 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 TRANSMISSION CONTROL CABLES

WITH THE CABLE BRACKET.
SAPH033220200009
7. REMOVE THE TRANSMISSION.

(1) Remove the lower bolts around the clutch housing.
(2) Support the transmission using a transmission jack or lifting wires
to prevent it from falling.
(3) Remove the remaining bolts around the clutch housing.
(4) Remove the transmission.
SAPH033220200010
1. APPLY HEAT-RESISTANT GREASE TO THE INPUT SHAFT

SPLINE.
SAPH033220200011
2. INSTALL THE TRANSMISSION.

(1) Jack up the transmission until the input shaft spline and the clutch
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.
SAPH033220200010
(4) Install the remaining nuts or bolts around the clutch housing.
Tightening Torque:
37.5-48.5 Nm {383-494 kgfcm, 28-35 lbfft}
4. CONNECT THE TRANSMISSION CONTROL CABLES WITH

THE CABLE BRACKET.
5. CONNECT THE ELECTRIC HARNESS AND OTHER ATTACH-

MENTS.
SAPH033220200012
6. CONNECT THE PROPELLER SHAFT.
7. FILL THE TRANSMISSION WITH GEAR OIL UP TO THE

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

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

Refer to the chapter "TRANSMISSION/TRANSFER CONTROL".
GEAR SHIFT HOUSING (LJ06S)

COMPONENT LOCATOR
EN0332202D100001
SAPH033220200013
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}
SAPH033220200014
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.
SAPH033220200015
(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.
SAPH033220200016
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.
SAPH033220200017
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.
SAPH033220200018
INNER PIN
SLITS
SLITS
OUTER PIN
INSTALL
OUTER PIN INNER PIN

SAPH033220200019
3. INSTALL THE OIL SEAL.

(1) Drive a new oil seal into the shift lever shaft housing with the
installation tool.
SAPH033220200020
(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.
SAPH033220200021
4. INSTALL THE EXPANSION PLUG.

(1) Apply adhesive all around to the expansion plug.
SAPH033220200022
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.
SAPH033220200023
(3) After applying lock agent (LOCTITE#575) to the plug, put the
compression spring and install the plug.
SAPH033220200024
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.
INNER SHIFT LEVER SHAFT
NOTICE
A
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
90˚
INNER SHIFT
LEVER
SAPH033220200025
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.
SAPH033220200026
8. INSTALL THE NEUTRAL SWITCH.

(1) Apply lock agent (LOCTITE#575) to the neutral switch and install
it to the shift lever housing.
SAPH033220200027
9. INSTALL THE TRANSMISSION CASE COVER.

(1) Coat the face of the transmission case with liquid gasket.
NOTICE
• The trace of the liquid gasket must be continuous.
• The liquid gasket must be ThreeBond #1216 or equivalent.
SAPH033220200028
10. INSTALL THE SHIFT LEVER SHAFT HOUSING.

(1) Coat the face of the transmission case cover with liquid gasket.
NOTICE
SAPH033220200029

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

shift fork and sleeve {0.0079-0.0177}
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 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
INPUT SHAFT, OUTPUT SHAFT, GEARS AND RELATED

PARTS (LJ06S)
COMPONENT LOCATOR
EN0332202D100002
SAPH033220200036
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 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 Nut
10 Synchronizer head 33 Front bearing retainer
11 Synchronizer key 34 Gasket
12 Synchronizer sleeve 35 Soft washer
13 6th gear 36 Drain plug
14 Needle roller bearing 37 Filler plug
15 Bushing 38 Transmission case
16 4th gear 39 Straight pin
17 Synchronizer double cone 40 Speedometer driven gear bushing
18 Synchronizer inner cone 41 Speedometer drive gear
19 Pin 42 Speedometer driven gear
20 Synchronizer bushing 43 Rear bearing retainer
21 3rd gear sub-assembly 44 Power take-off cover
22 Output shaft 45 Speed sensor
23 2nd gear sub-assembly

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
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.
SAPH033220200037
(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)
SAPH033220200038
2. REMOVE THE INPUT SHAFT.

(1) Using the special tools, pull out input shaft with the accompanying
bearings.
SST:
Input Shaft Puller (S0965-02070)
SAPH033220200039
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 (S0965-01882)
NOTICE
SAPH033220200040 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.
SAPH033220200041
(3) When removing the output shaft assembly, remove the synchro-
nizer ring and the cone of the input shaft gear.
SAPH033220200042
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.
SAPH033220200043
(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
SAPH033220200044
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
SAPH033220200045
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.
SAPH033220200046
(2) Install the synchronizer key and head.
SAPH033220200047
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
SAPH033220200048
bare hand. This can result in personal injury.
(3) Install the synchronizer bushing, synchronizer inner cone, syn-

chronizer double cone, synchronizer ring and pins.
SAPH033220200049
(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.
SAPH033220200050
(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.
SAPH033220200051
(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
SAPH033220200052
(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.
SAPH033220200053
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
SAPH033220200048
bare hand. This can result in personal injury.

chronizer double cone, synchronizer ring and pin.
SAPH033220200054
(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.
SAPH033220200050
(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
SAPH033220200055
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.
SAPH033220200056
Retainer rings are available in the following sizes: Position "A"
Thickness Color code
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

SAPH033220200057
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.
SAPH033220200058
(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
SAPH033220200059 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
SAPH033220200060
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.
SAPH033220200061
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
SAPH033220200062
(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
SAPH033220200063
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-
SAPH033220200042 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.
SAPH033220200064
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 #1108 or equivalent.
SAPH033220200065
12. INSTALL THE REAR BEARING RETAINER.

NOTICE
(2) Apply liquid gasket or sealing tape to the bolt.
SAPH033220200066
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.
SAPH033220200067
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
5th 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}
SAPH033220200068
1st gear
2nd gear 0.5 {0.0197}

0.15-0.30 {0.0060-0.0118}
3rd gear
4th gear
5th 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}
5th 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
VIEW A
SAPH033220200069
NOTICE
R1 R2 • Caulk the nut securely as shown.
• Make sure that there is no rift in the caulk position.
X
• Completely attach to the shaft ends (R1, R2) as shown in the
figure.
• Stake so that dimension X shown in the figure will be a mini-
mum of 1.5 mm {0.0591 in.}.
• Make sure that there are no breaks in the staked portion of
the lock nut.
VIEW A
SAPH033220200070
• Be sure to stake from the root as shown in the illustration. Do

not stake the tip end only.
LOCK NUT
CORRECT INCORRECT
SAPH033220200071

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 syngear {0.0079} chronizer ring and/
chronizer cone or gear 1.0-1.8 or gear sub assem-
sub assembly {0.0394-0.0708} bly.
5th 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
Needle roller bearing in — — Replace, Visual check

deformed shape if necessary.
COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS

(LJ06S)
COMPONENT LOCATOR
EN0332202D100003
SAPH033220200077
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 5th 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)
SAPH033220200078
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.
SAPH033220200079
(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
SAPH033220200080
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.
SAPH033220200081
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)
SAPH033220200082
5. REMOVE THE COUNTER SHAFT GEARS.

! CAUTION
SAPH033220200083
(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
SAPH033220200084 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.}
SAPH033220200087 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.
SAPH033220200088
(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.
Retainer rings are available in the following sizes
2.4 mm {0.0945 in.} Brown

SAPH033220200089
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
SAPH033220200081
(1) 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.
Retainer rings are available in the following sizes.
2.4 mm {0.0945 in.} Green

SAPH033220200090
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.
Assembly Standard: 1.7-2.2 mm {0.0670-0.0866 in.}
4. PRESS IN THE SEAL COVER AND MAKE IT FLUSH WITH THE

CASE FRONT.
SAPH033220200091
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.
SAPH033220200092
6. MEASURE THE REVERSE IDLER GEAR END PLAY.

Service Limit: 0.7 mm {0.0276 in.}
SAPH033220200093
7. MEASURE THE BACKLASH BETWEEN THE REVERSE IDLER

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

SAPH033220200094

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.
TRANSMISSION MAIN UNIT (MF06S) TR02–1
TRANSMISSION MAIN UNIT (MF06S)

TR 02
TR02-002
TRANSMISSION ASSEMBLY................... TR02-2

DESCRIPTION ................................................ TR02-3
SPECIAL TOOL ............................................... TR02-6
GEAR SHIFT HOUSING ........................... TR02-9

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

RELATED PARTS ................................... TR02-15
OVERHAUL ................................................... TR02-17
COUNTER SHAFT, REVERSE IDLER SHAFT

AND GEARS ........................................... TR02-28
OVERHAUL ................................................... TR02-29
TR02–2 TRANSMISSION MAIN UNIT (MF06S)
TRANSMISSION ASSEMBLY
EN0332302I200001
Type I II
Six forward speeds, one reverse
Type 2, 3, 4, 5, 6th, Synchromesh,
1st and Reverse, Constant mesh
1st 8.189 7.395
2nd 5.340 4.758
3rd 3.076 3.076
Gear ratios: 4th 1.936 1.936
5th 1.341 1.341
6th 1.000 1.000
Reverse 7.142 7.142
Number of teeth input shaft 22
Counter drive gear 47 47
1st gear 12 13
2nd gear 20 22
Number of teeth counter 3rd gear 25 25
shaft 4th gear 32 32
5th gear 43 43
6th gear — —
Reverse gear 21 21
1st gear 46 45
2nd gear 50 49
3rd gear 36 36
Number of teeth output
4th gear 29 29
shaft
5th gear 27 27
6th gear — —
Reverse gear 46 46
Reverse idler gear 29/19
Power take-off opening On left side of gear case
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)
Viscosity, between -12 and 32C {10 and 90F} SAE90
DESCRIPTION
EN0332302C100001
SAPH033230200001
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 (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 Replace 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.
Difficult gear engagement Improper lubrication of control lever Lubricate as required.
(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.
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

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
Prior to starting a transmission overhaul, it is necessary to have these special tools.
S0965-01900 PULLER
S0965-02070 INPUT SHAFT PULLER
S0965-31190
HOOK
S0965-31210
S0965-01882 PULLER
S0965-01101 PULLER
S0965-91250 ADAPTER

EN0332302H100001

! CAUTION

ATTACHMENTS.

SAPH033230200010

SAPH033230200011

SPLINE.
SAPH033230200012

disc spline align.
NOTICE
vehicle.
SAPH033230200011
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.
SAPH033230200013

FILLER PLUG HOLE.


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

COMPONENT LOCATOR
EN0332302D100001
SAPH033230200014
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}
SAPH033230200015
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 5 mm
{0.197 in.} diameter tapping rod.
SAPH033230200016
(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.
SAPH033230200017
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.
SAPH033230200018
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.
SAPH033230200019
INNER PIN
SLITS
SLITS
OUTER PIN
INSTALL
OUTER PIN INNER PIN

SAPH033230200020
3. INSTALL THE OIL SEAL.

(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
SAPH033230200021
4. INSTALL THE EXPANSION PLUG.

(1) Apply adhesive all around to the expansion plug.
SAPH033230200022
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.
SAPH033230200023
6. INSTALL THE TRANSMISSION CASE COVER.

(1) Coat the face of the transmission case with liquid gasket.
NOTICE
SAPH033230200024
7. INSTALL THE SHIFT LEVER SHAFT HOUSING.

(1) Coat the face of the transmission case cover with liquid gasket.
NOTICE
SAPH033230200025

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

fork and sleeve {0.0079-0.0177}
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 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
INPUT SHAFT, OUTPUT SHAFT, GEARS AND RELATED

PARTS
COMPONENT LOCATOR
EN0332302D100002
SAPH033230200031
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.
SAPH033230200032
(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.
SAPH033230200033
2. REMOVE THE INPUT SHAFT.

(1) Using the special tools, pull out input shaft with the accompanying
bearings.
SST:
Input Shaft Puller (S0965-02070)
SAPH033230200034
3. REMOVE THE OUTPUT SHAFT REAR BEARING.

! CAUTION
(2) Using the special tools, remove the output shaft rear bearing.
SST:
Hook (S0965-31210)
Puller (S0965-01882)
NOTICE
SAPH033230200035 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.
SAPH033230200036
(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.
SAPH033230200037
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.
SAPH033230200038
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
SAPH033230200039
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.
SAPH033230200040
(2) Install the synchronizer key and head.
SAPH033230200041
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.
SAPH033230200042
(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
SAPH033230200043
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.
SAPH033230200044
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.
SAPH033230200045
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
SAPH033230200046 • 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

SAPH033230200047
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
SAPH033230200048
(2) Select a retainer ring.

NOTICE
2.8 mm {0.1102 in.} None
SAPH033230200049 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
SAPH033230200050 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.
SAPH033230200051
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 No. engraved 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.
SAPH033230200052
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
SAPH033230200053
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.
SAPH033230200054
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.
SAPH033230200055
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 #1216 or equivalent.
SAPH033230200056
13. INSTALL THE REAR BEARING RETAINER.

NOTICE
(2) Apply liquid gasket or sealing tape to the bolt.
SAPH033230200057
14. INSTALL THE POWER TAKE-OFF COVER.

NOTICE
SAPH033230200058
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.
SAPH033230200059
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 0.25-0.40 {0.0098-0.0157}

SAPH033230200060
1st gear
2nd gear 0.5 {0.0197}

0.15-0.30 {0.0060-0.0118}
3rd gear
4th gear
5th gear 0.15-0.50 {0.0049-0.0162} 0.6 {0.0236}
<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
into the groove on the output shaft.
A
NOTICE
• Caulk the nut securely as shown.
VIEW A
SAPH033230200061

R2 figure.
R1
X
mum of 1.5 mm {0.0591 in.}.
the lock nut.
VIEW A
SAPH033230200062

LOCK NUT
CORRECT INCORRECT
SAPH033230200063

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
0.75-1.8
{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
Needle roller bearing in — — Replace, Visual check

deformed shape if necessary.
COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS

COMPONENT LOCATOR
EN0332302D100003
SAPH033230200070
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.
SAPH033230200071
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)
SAPH033230200072
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.
SAPH033230200073
(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
SAPH033230200074
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.
SAPH033230200075
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.
SST: Puller (S0965-01101)
SAPH033230200076
6. REMOVE THE COUNTER SHAFT GEARS.

! CAUTION
SAPH033230200077
(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
SAPH033230200078 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.}
SAPH033230200079
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.
SAPH033230200082
(3) Select a retainer ring.

NOTICE
2.45 mm {0.0965 in.} White
SAPH033230200083 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
SAPH033230200075
3. DISTANCE BETWEEN THE GEAR CASE OUTER SURFACE

AND THE FRONT BEARING OUTER RACE.
4. PRESS IN THE SEAL COVER NOT TO HAVE MISMATCH WITH

THE CASE FRONT.
SAPH033230200084
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.
SAPH033230200085
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.
SAPH033230200071
7. MEASURE THE REVERSE IDLER GEAR END PLAY.

SAPH033230200086
8. INSTALL THE SEAL COVER.

(1) Coat seal cover with liquid gasket.
NOTICE
SAPH033230200087
9. MEASURE THE BACKLASH BETWEEN THE REVERSE IDLER

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

SAPH033230200088

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.
TRANSMISSION MAIN UNIT (EATON FS6109) TR02–1
TR02 TRANSMISSION MAIN UNIT

(EATON FS6109) TR02-003
TRANSMISSION ASSEMBLY .................. TR02-2

TR02–2 TRANSMISSION MAIN UNIT (EATON FS6109)
EN0332502I200001
Manufacture EATON
Transmission model FS6109
Crawler 12.637
1st 8.806
2nd 6.550
3rd 4.768
4th 3.548
Gear ratios
5th 2.481
6th 1.845
7th 1.343
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.
TRANSMISSION MAIN UNIT (EATON FS6109) TR02–3

EN0332502H100001

! CAUTION

ATTACHMENTS.

SHTS033250200001

SHTS033250200002
TR02–4 TRANSMISSION MAIN UNIT (EATON FS6109)

SPLINE.
SHTS033250200003

disc spline align.
NOTICE
vehicle.
SHTS033250200002
Tightening Torque:
37.5-48.5 Nm {382-494 kgfcm, 28-35 lbfft}

THE CABLE BRACKET.

MENTS.
SHTS033250200004

FILLER PLUG HOLE.


DISASSEMBLY AND ASSEMBLY

NOTICE
When disassembling and assembling the transmission, refer to
the MANUFACTURE ORIGINAL MANUAL.
TRANSMISSION MAIN UNIT (ZF 9S1110) TR02–1
TRANSMISSION MAIN UNIT (ZF 9S1110)

TR 02
TR02-004
TRANSMISSION ASSEMBLY .................. TR02-2

TRANSMISSION FLUID FOR ZF .................... TR02-3
DISMOUNTING AND MOUNTING ................ TR02-10
TR02–2 TRANSMISSION MAIN UNIT (ZF 9S1110)
EN0334002I200001
Manufacture ZF
Transmission model 9S1110
Crawler 12.728
1st 8.829
2nd 6.281
3rd 4.644
4th 3.478
Gear ratios
5th 2.538
6th 1.806
7th 1.335
8th 1.000
Reverse 12.040
Without power take-off Approx. 8.8 litters {1.94 lmp.gal., 2.32 US.gal.}
Oil capacity, gear box
With power take-off Approx. 9.3 litters {2.05 lmp.gal., 2.46 US.gal.}
For a complete information on ZF transmission,

Lubricant type
see “List of lubricant” in this manual.
NOTICE
For other details, refer to ZF manuals.
TRANSMISSION FLUID FOR ZF

EN0334002I200002
List of lubricants: ZF 9S1110 without Intarder (02.04.2012)
1. Approved lubricant classes
Product groups Lubricant classes

Note: Instead of the "0" as the last figure,
there may also be a: 2;3;4;5. First fill (4) Service fill (5)
(Example: 12AS1935, 16S2223)
Ecomid without Intarder ZF-Ecofluid M ZF-Ecofluid M

9S1110 02B / 02E 02B / 02E / 02L
2. Oil and filter change intervals

! CAUTION
Please refer to the previous pages, Section 1 , tables, for information on the lubricant classes released for the
individual product groups.
ZF-Ecofluid M was specially designed for applications with manual transmissions and automatic transmissions in commercial vehicles. The
combination of a hydrocrack base oil with a specially balanced additive package ensures excellent oxidation stability and is thus excellently
suited for very long oil change intervals. It warrants high-quality transmission component protection, in particular of the synchronizers and the
gearings. As a result of the flat viscosity characteristic curve, the oil is suited for applications in all climate zones, particularly in hot and cold
regions. Moreover, in comparison with mineral transmission fluids, ZF-Ecofluid M helps to reduce fuel consumption by 0.5 up to 1.0%.
ZF-Ecofluid M
Lubricant class 02B 02L
02E
Application Oil and filter change intervals (2)
1,000 h 5,000 h 10,000 h

Off-road operation e.g. minefield application
20,000 km 100,000 km 200,000 km
Average speed up to 20 km/h
1 year 1 year 2 year
Outside temperatures > 40C

Long-distance transport > 44 t
120,000 km 240,000 km 360,000 km
Short-distance transport
1 year 2 years 3 years (3)
Tough operating conditions
Average speed from 20 to 60 km/h
Long-distance transport 160,000 km 300,000 km 540,000 km

Average speed as of 60 km/h 1 year 2 years 3 years (3)
3. Low temperature limits
Lubricant classes Oil type / SAE viscosity grade Initial vehicle start-up at oil sump temperatures
ZF-Ecofluid M
75W / 75W-80 / 75W-85 / 75W-90 / ATF - 40˚C
02B / 02E / 02L
02B 80W / 80W-85 / 80W-90 - 20˚C
40, 85W-90, 90 0˚C

02B
30 - 15˚C
4. Explanation of footnotes and comments
Footnotes
1. In moderate climate zones, shift quality of non-automated transmissions is impaired when using the lubrication
classes 02B.
2. Oil and filter change required, depending on what occurs first. Only use genuine ZF filter inserts.
- Intarder 2: 6085 298 026
- Intarder 3: 0501 215 163
- WSK: 0501 202 378
3. These intervals only apply to a hose breather in a dry area. If there is no hose breather in the dry area, the oil change
intervals specified for lubricant class 02L apply. This restriction does not apply to bus applications.
In the case of transmissions filled ex-works with lubricant class 02E, no oil change must be effected during the first
two years as of initial registration. In case of retrofitting or repair in this period, oil refills with lubricant class 02E or
02L are permitted.
Exception: The limits of application in accordance with the TE-ML 02 (operating hours, mileage [km]) are already met
prior to the expiration of the first two years.
4. First filling: The lubricant classes listed are compulsory for initial fillings of transmissions as well as fillings during
transmission break-in (under 7,500 km). ZF factory oil fills must fulfill additional requirements according to ZF Oil
Specification 02.
5. Service filling: The lubricant classes listed are compulsory for service oil changes according to the oil-change inter-
vals mentioned under Section 2. These lubricant classes may generally only be used in broken-in transmissions
(7,500 km and more). In the case of transmissions filled ex-works with lubricant class 02E, due attention must always
be paid to footer 4.
6. All lubricants of TE-ML 14 may be used. Oil change intervals and temperature limits of TE-ML 02 do apply.
Comments
1. Instructions for transmission ventilation in accordance with Installation Guidelines 1203 765 110 and 1328 765 101
must be followed.
2. A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing
points (grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).
3. Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not
permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.
4. ZF will not assume liability for damage caused by non-observance of our maintenance instructions.
5. Lubricant classes and approved trade products
Lubricant class 02B

NOTICE
In moderate climate zones, shift quality is impaired if viscosity grades higher than SAE 80W are used.
Manufacturer (02B) Trade name (02B)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GS 80W
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GS 80W-90
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GX 80 W 90 ML
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP ROTRA TRUCK GEAR S, SAE 75W-90
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AUTOL GETRIEBEÖL 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP 80W
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP 80W
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP 85W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL EP PLUS 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL SNA-E 75W-90
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA GEAR OIL MZ 80
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA GEAR OIL MZ 90
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SYNTOGEAR FE 75W-90 EP
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SYNTOGEAR FE 80W-90
BAYWA AG, MÜNCHEN/D TECTROL MULTIGEAR PLUS 8090
BAYWA AG, MÜNCHEN/D TECTROL UNIGEAR 80
BEHRAN OIL CO., TEHRAN/IR BEHRAN SAMAND OEM 1 80W-90
BELGIN MADENI YAGLAR, GEBZE KOCAELI/TR BELGEAR EP MB 80
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR EP 80W
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR EP 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HT 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR SHX-M SAE 75W-90
BUCHER AG LANGENTHAL, LANGENTHAL/CH GEAR ZX TP SAE80W/90 GL4/5
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL EP 80W
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL EP 80W/90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UNISYNT TX
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE 80W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE PLUS 75W90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EP 80W
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL MANUAL EP 80W
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL MANUAL EP 80W
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL MANUAL EP 80W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SYNTRAX UNIVERSAL 80W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL SYNTRAX UNIVERSAL PLUS 75W-90
CENTRO HANDELS GMBH & CO. KG, KARLSRUHE/D CENTRO MEHRZWECKGETRIEBEÖL SAE 80W
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES 80W-90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP FE+LD 75W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL TRANSMISIONES 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL TRANSMISIONES F SAE 80
CEPSA LUBRICANTS S.A., MADRID/E MAN SUPER AXLE 3343
CHEVRON BRASIL LUBRIFICANTES LTDA., RIO DE J./BR UNIVERSAL EP SAE 80W
CHEVRONTEXACO, GHENT/B CALTEX TRANSLUBE LD SAE 80W
CHEVRONTEXACO, GHENT/B CALTEX TRANSLUBE LD SAE 90
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 80W
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 80W-90
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 85W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR 80W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR S 75W-90
CLAAS KGAA MBH, HARSEWINKEL/D CLAAS AGRISHIFT 4SC 80W90
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR A (80W)
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR TDM 80W
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR TDMX 80W90
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR TXS 75W90
DAF TRUCKS N.V., EINDHOVEN/NL DAF SUPER 80W90

DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR MULTIPURPOSE GEAR OIL SAE 80W90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR UNIGEAR 75W90 LD
DAF TRUCKS N.V., EINDHOVEN/NL DAF SUPER 80W90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR MULTIPURPOSE GEAR OIL SAE 80W90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR UNIGEAR 75W90 LD
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA HY 80W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA HY DB 80W
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA LSX 75W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA TRUCK GEAR 80W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL GP-D 80W
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE 1 SHC 75W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE GX-A 80W
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE S 80W-90
FABRIKA MAZIVA FAM A.D, KRUEVAC/SRB MULTIHIPO 75W-90 SINT
FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON SUPER EP GEAR OIL 80W/90 GL-4
FINKE MINERALÖLWERK GMBH, VISSELHÖVEDE/D AVIATICON FINKOGEAR SUPER 80W-90
FUCHS PETROLUB AG, MANNHEIM/D FUCHS TITAN GEAR MP 80
FUCHS PETROLUB AG, MANNHEIM/D TITAN EG MP 80
FUCHS PETROLUB AG, MANNHEIM/D TITAN SUPERGEAR MC 80W-90
GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS G-BOX GL-4/GL-5 75W-90
GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS G-TRUCK GL-4 80W-90
GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS G-TRUCK GL-4/GL-5 80W-90
GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS TRANS KP-2 (SAE 80W85)
GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS TRANS KP-4 (SAE 80W-90)
GENOL GMBH & CO., WIEN/A GENOL GEAR-SYN 80W-90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 793 80W90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 896
GRUPA LOTOS SA, GDANSK/PL TITANIS SUPER GL-5 75W90
GRUPA LOTOS SA, GDANSK/PL TITANIS SUPER GL-5 80W/90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 80W
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 80W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 85W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR TDL 80W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR XP 80W
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR XP 80W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR XP 90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR XP DURA MAX 80W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR XP MAX 90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF SYNGEAR 75W-90
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL TOTAL DRIVE LINE ED 75W90
HARMS MINERALÖLE, PRISDORF/D OILFINO VARIUS G 300 SAE 80W-90
HIGH INDUSTRIAL LUBRICANTS & LIQUIDS (HILL) CO./KZ FASTROIL TRANSMISSION GB 1 SAE 80W-90
HINDUSTAN PETROLEUM CORP LTD., MUMBAI/IND HP GEAR OIL EP 80W90 (MN)
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 80W
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA P ECO 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA TCX ECO 75W-90
IGOL FRANCE SA, AMIENS/F GEAR M 80W90
IGOL FRANCE SA, AMIENS/F SYNTHEGEAR SAE75W90
IGOL FRANCE SA, AMIENS/F TRANS EPA SAE80W-85W
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR ALT 80W-90 (LL)
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR ALT 90
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR HP 80W(T)
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR HP 80W-90 (T)
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR HP 90(T)
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO UNIDRIVE 80W-90
IPIRANGA PRODUTOS DE PETROLEO S, RIO DE JANEIRO/BR IPIRGEROL EP 80W
KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KOMPRESSOL-MEHRZWECK-GETRIEBEOEL SAE 80W-90
KRAFFT S.L., ANDOAIN/E HIDROIL SAE 80W90

KROON-OIL B.V., ALMELO/NL GEARLUBE GL-4 80W-90
KROON-OIL B.V., ALMELO/NL TRANSMISSION OIL SP 1011
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 GEAR OIL XG SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 35 SAE 80 W
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 35 SAE 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 35 SAE 90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 TRANS XGS SAE 75W-90
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEÖL TDL SAE 80W-90
LIQUI MOLY GMBH, ULM/D LIQUI MOLY GETRIEBEÖL GL 4 SAE 80W
LIQUI MOLY GMBH, ULM/D LIQUI MOLY GETRIEBEÖL GL 4 SAE 85W-90
LLK FINLAND OY, HAMINA/FIN TEBOIL EP SAE 80W
LLK FINLAND OY, HAMINA/FIN TEBOIL EP SAE 80W-90
LUBRICANT OIL COMPANY, SINOPEC, BEIJING/CN SINOPEC GREATWALL 80W/90 GL-4
LUBRICANT OIL COMPANY, SINOPEC, BEIJING/CN SINOPEC GREATWALL MTF 80W/90
LUBRICANT OIL COMPANY, SINOPEC, BEIJING/CN SINOPEC GREATWALL MTF 85W/90
LUBRICANT OIL COMPANY, SINOPEC, BEIJING/CN SINOPEC GREATWALL MTF C-I 80W
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL SHD 75W-90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL TDL 80W-90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL DB 80W
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL HD 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL MEHRZWECKGETRIEBEOEL GL 4 SAE 80W
MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGOL MEHRZWECKGETRIEBEOEL GL 4 SAE 85W-90
MILLERS OILS LIMITED, BRIGHOUSE/GB SYNTRAN FE
MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL MEHRZWECK-GETRIEBEOEL GL 4 SAE 80W
MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL MEHRZWECK-GETRIEBEOEL GL 4 SAE 85W90
MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL MEHRZWECK-GETRIEBEOEL GL 4 SAE 90
MOL-LUB KFT., ALMÁSFÜZITÖ/H MOL HYKOMOL 80W
MORRIS LUBRICANTS, SHREWSBURY/GB LODEXOL 80W/90
MORRIS LUBRICANTS, SHREWSBURY/GB LODEXOL HPS 75W-90
MORRIS LUBRICANTS, SHREWSBURY/GB LODEXOL SS 80W
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR MB 80W
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR SYNT TDL 75W-90
NESTE MARKKINOINTI OY, ESPOO/FIN NESTE GEAR EP 80W-90
NESTE MARKKINOINTI OY, ESPOO/FIN NESTE HYPOIDI TDL S 75W-90
NEW PROCESS AG, TÜBACH/CH EP GEAROIL SAE 80W
NEW PROCESS AG, TÜBACH/CH GEAROIL SYNTH
OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND SUPER M4 80W
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEÖL SAE 80W
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST MEHRZWECK-GETRIEBEÖL SAE 80W-90
OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST SYNTH GETRIEBEÖL SAE 75W-90
OK NEDERLAND, STAPHORST/NL OK UNI-CARDAN OIL LD-SAE 75W/90
OK NEDERLAND, STAPHORST/NL QUINTOL TRANSMISSION OIL VS-45 SAE 75W/90
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL MP SAE 80W-85
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL MP SAE 85W-90
OMV REFINING & MARKETING GMBH, WIEN/A OMV UNIGEAR S SAE 75W-90
OMV REFINING & MARKETING GMBH, WIEN/A OMV UNIGEAR SAE 80W-90
OOO "LLK-INTERNATIONAL", MOSCOW/RUS LUKOIL TRANSMISSION TM-4 SAE 80W
OOO "LLK-INTERNATIONAL", MOSCOW/RUS LUKOIL TRANSMISSION TM-4 SAE 80W-85
OOO "LLK-INTERNATIONAL", MOSCOW/RUS LUKOIL TRANSMISSION TM-4/5 SAE 75W-90
OPET PETROLCULUK A.S., IZMIR/TR FULLGEAR EP MT 80W
OPET PETROLCULUK A.S., IZMIR/TR ORSA EP MT 80W
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR GL-4 80W
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR GL-4 80W/90
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR LL 80W-90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GEAR OIL EP/FZ SAE 80W
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GEAR OIL EP/FZ SAE 80W/90

PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR CBS SAE 75W/85
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W/85
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN EP GEAR 80W
PANOLIN AG, MADETSWIL/CH PANOLIN EP GEAR 80W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY SYNTH 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN TOPGEAR 80W/90
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX TRM-4 (SAE 80W)
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX TRM-4 SAE 90
PETROGAL S.A., LISBOA/P GALP TRANSOIL 80W90
PETROGAL S.A., LISBOA/P GALP TRANSOIL 80W
PETROGAL S.A., LISBOA/P GALP TRANSVEX TDL 75W90
PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL TUTELA TRANSMISSION STARGEAR
PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL TUTELA TRANSMISSION STARGEAR AX-ED
PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL TUTELA TRANSMISSION STARGEAR HD
PHI OIL GMBH, ST. GEORGEN BEI SALZBURG/A UNIGEAR GOLD 75W90
PRISTA OIL EAD, ROUSSE/BG PRISTA EP 80W
PTT PUBLIC COMPANY LIMITED, BANGKOK/TH PTT EUROTRAN 341 SAE 80W-90
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL GETRIEBEÖL MZG SAE 80W-90 GL 4
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E CARTAGO FE LD 75W90
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E CS EP M SAE 80W
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E REPSOL CARTAGO EPM SAE 80W
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E REPSOL CARTAGO EPM SAE 90
S-OIL CORPORATION, SEOUL/KOREA DRAGON GEAR TM 80W
SASOL OIL, RANDBURG/ZA SYN GEAR DIFFERENTIAL OIL 75W-90 (SAE 75W-90)
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARLU EP GEAR LUBE 80W/90 (GL-4)
SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL SPIRAX G 80W (IN BRASIL ONLY)
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX GX 80W
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX GX 80W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MA 80W
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX MX 80W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX S3 AM 80W-90
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX S3 G 80W
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX S3 G 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS GETRIEBEFLUID SML 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS WIOLIN MEHRZWECK-GETRIEBEÖL 80
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS WIOLIN MEHRZWECK-GETRIEBEÖL 80W-90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS WIOLIN MEHRZWECK-GETRIEBEÖL 90
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS WIOLIN RSG 80
STATOIL LUBRICANTS, STOCKHOLM/S GEARWAY G4 80W
STATOIL LUBRICANTS, STOCKHOLM/S STATOIL GEARWAY G4 80W-90
STRUB + CO AG, REIDEN/CH STRUB MULTIGEAR SGO 80W-90
STRUB + CO AG, REIDEN/CH VULCOGEAR SYNT SGX 75W-90
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEDEX GEAR OIL SAE 80W
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEDEX SUPER GEAR OIL (3343M) SAE 80W90
TNK LUBRICANTS, MOSCOW/RUS TNK TRANS 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC FDL 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F GULF GEAR LUBRICANT 80W-85
TOTAL LUBRIFIANTS S.A., PARIS/F GULF SYTHETIC GEAR LUBRICANT 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP 80W-85
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION RS FE 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION SYN FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF EP 80W
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF EP 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF SYNTHESE FE 75W-90

TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF UNIVERSAL FE 80W-90
UNIL OPAL, SAUMUR CEDEX/F UNIL OPAL GEAR EP SAE 80W85W
VALVOLINE CUMMINS LTD. INDIA, HARYANA/IND GEAR GARD PLUS SAE 80W90
VALVOLINE EUROPE, DORDRECHT/NL SYNPOWER GEAR OIL TDL 75W-90
VIAL OIL LTD., MOSCOW/RUS CONSOL TRANS LUX SAE 75W-90
YACCO, ST PIERRE LES ELBEUF/F BVX 1000
YPF S.A., ENSAENADA/RA HELICOIDAL M (80W)
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL GEAR OIL STO SAE 80W-90
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID X SAE 80W-90
Lubricant class 02E

Manufacturer (02E) Trade name (02E)
CASTROL INTERNATIONAL, PANGBOURNE READING/
CASTROL SYNTRANS Z LONG LIFE 75W-80
GB
CEPSA LUBRICANTS S.A., MADRID/E MAN SUPER GEAR 341-Z5
DAF TRUCKS N.V., EINDHOVEN/NL DAF XTREME 75W-80
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA BZV ECO 75W-80
PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL TUTELA TRANSMISSION XT-D 540 (SAE 75W-80)
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSON XS FE 75W-80
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID M SAE 75W80
Lubricant class 02L

Manufacturer (02L) Trade name (02L)
BAYWA AG, MÜNCHEN/D TECTROL SYNTOGEAR MA 7580
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL PRISMA TF SAE 75W80
CHEVRONTEXACO, GHENT/B MULTIGEAR MTF 75W-80
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR TDS 75W80
DAF TRUCKS N.V., EINDHOVEN/NL DAF PREMIUM 75W80
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR MT/LD GEAR OIL 75W80
DEUTSCHE PENTOSIN WERKE GMBH, WEDEL/D PENTOSIN TLD 75W-80
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL DELVAC XHP TRANSMISSION OIL 75W-80
FUCHS PETROLUB AG, MANNHEIM/D FUCHS TITAN CYTRAC MAN SYNTH 75W-80
GINOUVES GEORGES SA, LA FARLEDE/F YORK 994 75W80
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF SYNGEAR FE 75W-80
IGOL FRANCE SA, AMIENS/F TRANS GEAR ZF PLUS 75W80
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 60 NTECH SAE 75W-80
MEGUIN GMBH & CO. KG MINERALOELWERKE, MEGOL PREMIUM GETRIEBEOEL HC GL 4 SAE 75W-80
SAARLOUIS/D
MOL-LUB KFT., ALMÁSFÜZITÖ/H MOL HYKOMOL SYNTRANS 75W80
OMV REFINNG & MARKETING GMBH, WIEN/A OMV GEAR OIL LDI SAE 75W-80
PETROGAL S.A., LISBOA/P GALP TRANSVEX TDL ULTRA 75W80
PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL TUTELA TRANSMISSION FE-GEAR (SAE 75W-80)
RALOY LUBRICANTES S.A. DE C.V., TIANGUISTENCO/MEX KRÖNEN TRANSMISSION SYNTHETIC OIL 341 SAE 75W-80
RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SSG SPEC SYNT LKW GETRIEBEÖL 75W-80
SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GBSHELL TRANSMISSION ZFLD-PLUS 75W-80
UNIL OPAL, SAUMUR CEDEX/F GERION LD 75W80
YACCO, ST PIERRE LES ELBEUF/F BVX Z 1000 SAE 75W80

EN0334002H100001

! CAUTION

ATTACHMENTS.

SAPH033400200005

SAPH033400200006

SPLINE.
SAPH033400200007

disc spline align.
NOTICE
vehicle.
SAPH033400200006
Tightening Torque:
37.5-48.5 Nm {382-494 kgfcm, 28-35 lbfft}

THE CABLE BRACKET.

MENTS.
SAPH033400200008

FILLER PLUG HOLE.


DISASSEMBLY AND ASSEMBLY

NOTICE
When disassembling and assembling the transmission, refer to
the MANUFACTURER'S ORIGINAL MANUAL.
PTO (POWER TAKE-OFF) (TRANSMISSION SERIES: LJ06S) TR05–1

TR05
(TRANSMISSION SERIES: LJ06S) TR05-001
POWER TAKE-OFF ASSEMBLY .............. TR05-2

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

OVERHAUL ..................................................... TR05-5
TR05–2 PTO (POWER TAKE-OFF) (TRANSMISSION SERIES: LJ06S)
POWER TAKE-OFF ASSEMBLY

EN0332205I200001
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
23/26
(PTO output gear/ PTO 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-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.
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

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} D 19-25 {200-250, 15-18}
B 39.5-58.5 {400-600, 29-43} E 39.2-47.0 {400-480, 29-34}
C 48.5-67.5 {500-700, 37-50} F 54-68 {551-693, 40-50}
OVERHAUL
EN0332205H200001

! CAUTION
Do not work on the transmission while it is still hot.
This can result in personal injury.

EXHAUST ALL AIR FROM THE AIR TANKS.
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.
SHTS033220500003
2. REMOVE THE OUTPUT SHAFT FLANGE.

(1) Remove the lock nut.
(2) Use a suitable puller to 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
4. REMOVE THE OUTPUT SHAFT.

(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
(2) Set the shift fork in its original position.

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.
(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.
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
6. 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.
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
1. MEASURE THE BACKLASH BETWEEN THE GEAR "A" AND

"B".
SHTS033220500017
(1) Put the fuse (1 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.
(4) If it is not within specification, adjust the backlash with adapter.
Adapters are available in following size.
Adapters are available in following size.
SHTS033220500018
Groove line Adapter Thickness
None 6.12 mm {0.2409 in.}
One 5.99 mm {0.2358 in.}
Two 5.86 mm {0.2307 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 #1108 or equivalent.
(2) Install the reamer bolts to the position "A".
3. FILL THE TRANSMISSION WITH TRANSMISSION OIL.
SHTS033220500019

EN0332205H300001
Output shaft and output — — Replace, Visual check

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

Wear if necessary.
Oil seal lip: — — Replace, Visual check

Shift shaft and case cover — — Replace, Visual check

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

Improper rotation if necessary.
PTO (POWER TAKE-OFF) (TRANSMISSION SERIES: MF06S) TR05–1

TR05
(TRANSMISSION SERIES: MF06S)

TR05
TR05-002

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

OVERHAUL ..................................................... TR05-5
TR05–2 PTO (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
Direction of rotation Opposite engine's
Gear ratio
12/29
(PTO 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
Can not be operated Faulty switches Replace switch.
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

1. SET THE POWER TAKE-OFF ON A VISE.

REMOVE THE OUTPUT SHAFT FLANGE.
(1) Remove the lock nut.
(2) Use a suitable puller to 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
3. REMOVE THE OUTPUT SHAFT.

(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
power take-off 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.
(2) Set the shift fork in its original position.
(3) Set the taper roller bearing in its original position.
SHTS033230500005
(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.
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
7. CHECK THE OUTPUT SHAFT AXIAL PLAY.

(1) Use a dial gauge to check the output shaft axial play.
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
1. MEASURE THE BACKLASH BETWEEN THE GEAR "A" AND

"B".
SHTS033230500016
(1) Put the fuse (1 x 10 mm {0.394 in.}) on the surface of gear "A"
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:
0.080-0.16 mm {0.0032-0.0062 in.}
NOTICE
Power take-off case gasket thickness: 0.5 mm {0.0197 in.}
SHTS033230500017
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 #1108 or equivalent.
(2) Install the reamer bolts to the position "A".
3. FILL THE TRANSMISSION WITH TRANSMISSION OIL.
SHTS033230500018

EN0332305H300001
Output shaft and output — — Replace, Visual check

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

Wear if necessary.
Oil seal lip: — — Replace, Visual check

Shift shaft and case cover — — Replace, Visual check

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

Improper rotation if necessary.
PTO (POWER TAKE-OFF) (EATON) TR05–1
PTO (POWER TAKE-OFF) (EATON)

TR05
TR05-003

DESCRIPTION ................................................ TR05-2
POWER TAKE-OFF UNIT (TYPE 1) ......... TR05-4

COMPOMENT LOCATOR ............................... TR05-4
OVERHAUL ..................................................... TR05-4
POWER TAKE-OFF UNIT (TYPE 2) ......... TR05-5

COMPOMENT LOCATOR ............................... TR05-5
OVERHAUL ..................................................... TR05-6
TR05–2 PTO (POWER TAKE-OFF) (EATON)

EN0332505I200001
POWER TAKE-OFF
Type 1 Counterclockwise viewed from output shaft flange

Direction of rotation
Type 2 Clockwise viewed from output shaft flange
Type 1 35 x 60 mm {1.38 x 2.36 in.} (A x B: Refer to DESCRIPTION below)

Size of output shaft flange
Type 2 Pitch circle diameter 79.3 mm {3.12 in.}
Type Electric-pneumatic control
DESCRIPTION
EN0332505C100001
TYPE 1
2 3
1
B
SHTS033250500001
POWER TAKE-OFF UNIT

1 Output shaft flange 3 Gasket
2 Power take-off unit
TYPE 2
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.
POWER TAKE-OFF UNIT (TYPE 1)

COMPOMENT LOCATOR
EN0332505D100001
1 2
SHTS033250500003
1 Power take-off unit 3 Gasket

2 Output shaft flange 4 Stud bolt

A 33-45 {337-458, 25-33}
OVERHAUL
EN0332505H200001

! CAUTION

2. REMOVE THE POWER TAKE-OFF AND GASKET.

(1) Remove the power take-off and gasket then clean the aperture
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) Check the transmission gear and the gear backlash.
POWER TAKE-OFF UNIT (TYPE 2)

COMPOMENT LOCATOR
EN0332505D100002
SHTS033250500004
1 PTO 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 AND GASKET.

(1) Remove the power take-off and gasket then clean the aperture
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 PTO drive gear in the transmission and
the driven gear in the PTO 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-
SHTS033250500005 ing the PTO
SHTS033250500006
2. CHECK THE BACKLASH BETWEEN THE PTO 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.
SHTS033250500007
(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 PTO 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 back-
lash 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 PTO
(1) Bench mount the adapter to the PTO with gasket.
(2) Mount the dial gauge, then hold the input gear in PTO 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.
SHTS033250500008
4. MOUNT THE ADAPTER AND THE PTO

(1) Remount the adapter assembly, all gaskets and the PTO to the
transmission in their respective sequence.
(2) Secure all nuts and hexagon bolts to proper torque.
(3) Run the PTO momentarily and check for noise.
NOTICE
The transmission and PTO have no lubrication at this time so run-
ning time should be as short as possible.
a. If the PTO whines it may be mounted too tight, too little back-
lash. This indicates that gaskets should be added.
b. If the PTO clatters it may be mounted too loose, too much
SHTS033250500009
backlash. This indicates that gaskets should be removed.
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
(TRANSMISSIONSERIES: LJ06S)........... TR06-7
DESCRIPTION ................................................ TR06-7
PROPOSAL TOOL .......................................... TR06-8
OVERHAUL ................................................... TR06-10
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

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)
Excessive play in shift lever. Worn bushing in joint or shift lever Replace.
Loose mounting bolts and nuts Inspect and tighten.
Power shift slips out of gear on Faulty adjustment of control cable Adjust.
rough road. assembly
TRANSMISSION CONTROL LINKAGE

COMPONENT LOCATOR
EN03Z0306D100001
CAB SIDE
SAPH03Z030600001
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
SAPH03Z030600002
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
SAPH03Z030600003
ADJUSTMENT
EN03Z0306H300001
ADJUSTMENT PROCEDURE
STEERING WHEEL 1. ADJUST THE NEUTRAL POSITION OF THE GEAR SHIFT
CENTER LEVER.
P
SHIFT KNOB
CENTER (1) Check that the distance between the knob center and the steering
wheel center conforms to the following:
Assembly standard: 370-400 mm {14.567-15.748 in.}
SAPH03Z030600004
(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)
To lengthen it Distance gets longer. (Lever leans right
side.)
CHANGE THE
LENGTH OF
To shorten it Distance gets shorter. (Lever leans left
CABLE
side.)
GUIDE PIPE
NOTICE
• Do not adjust cables with holding guide pipe.
SAPH03Z030600005
• 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;
SAPH03Z030600006
(4) If not, adjust the length of the shift lever control cable.
BALL JOINT Length of cable Position of shifting direction
To lengthen it Distance gets longer. (Lever leans back-

ward.)
CHANGE THE CONTROL CABLE
LENGTH OF (FOR SHIFT To shorten it Distance gets shorter. (Lever leans front-
CABLE DIRECTION)
ward.)
GUIDE PIPE
NOTICE
• Do not adjust cables with holding guide pipe.
SAPH03Z030600007
• When changing the length of cable, do not bend the cable.
2. CHECK THE SHIFT AND SELECT STROKE.

LJ06S, MF06S
Select stroke: Unit: mm {in.}
1 3 5 Transmission series S1 S3
S2 45-55
LJ06S, MF06S —
N {1.772-2.165}
S2 50-70 60-80
EATON FS6109
{1.968-2.755} {2.362-3.149}
R 2 4 6
30-50
ZF 9S1110 —
S1 S1 S1 {1.181-1.968}
SAPH03Z030600009
EATON FS6109 Shift stroke: Unit: mm {in.}

5 7 Transmission series S2
R 1 3 Without power shift 100-120 {3.937-4.724}
S2 LJ06S
With power shift 90-110 {3.544-4.330}
N
Without power shift 110-130 {4.330-5.118}
S2 MF06S
With power shift 75-95 {2.952-3.740}
Lo 6 8
2 4 EATON FS6109/8209 110-130 {4.331-5.118}
ZF 9S1110 100-120 {3.937-4.724}
S3 S1
SAPH03Z030600010
ZF 9S1110
R 1 3 5 7
S2
N
S2
C 2 4 6 8
S1 S1 S1 S1
SAPH03Z030600011
POWER SHIFT (TRANSMISSIONSERIES: LJ06S)

DESCRIPTION
EN03Z0306C100001
2 3 4 5
A B
C
C
1 6 7 D 6 E 8 E 6 D 7 6
SAPH03Z030600012
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
SAPH03Z030600013
COMPONENT LOCATOR
EN03Z0306D100002
SAPH03Z030600014
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.
SAPH03Z030600015
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}
SAPH03Z030600016
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.
SAPH03Z030600017
(4) Remove the boot "A" and "B".
SAPH03Z030600018
(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.
SAPH03Z030600019
(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.
SAPH03Z030600020
3. PULL OUT THE POWER SHIFT VALVE AND PISTON.

(1) Remove the power shift valve sub-assembly from the booster cyl-
inder slowly.
SAPH03Z030600021
(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
SAPH03Z030600022
(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.
SAPH03Z030600023
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
SAPH03Z030600024
(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.
SAPH03Z030600025
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
SAPH03Z030600026
(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.
SAPH03Z030600027
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.
SAPH03Z030600028
(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.
SAPH03Z030600029
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.
SAPH03Z030600030
(2) Apply silicone grease to the inner surface of the rod seals.
SAPH03Z030600031
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.
SAPH03Z030600032
(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
SAPH03Z030600033
(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".
SAPH03Z030600034
(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.
SAPH03Z030600035
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.
SAPH03Z030600036
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.
(2) Move the valve sub-assembly to make 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
SAPH03Z030600037
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
SAPH03Z030600038
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.
SAPH03Z030600039
(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
SAPH03Z030600040
BOOT "B" CASE

JOINT ASSEMBLY INSTALL SECURELY
SAPH03Z030600041
(4) Align the concave mark with the convex mark of boot "B".
SAPH03Z030600042
(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.
SAPH03Z030600043
(6) Apply silicone grease to the inner surface of the boot "C" and
install it to the joint assembly.
SAPH03Z030600044
(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"
SAPH03Z030600045
(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.
SAPH03Z030600017
IMPORTANT POINT - INSPECTION
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, if neces-
mation sary.
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 neces-
sary.
Other parts: — — Replace the Visual check and measure

Wear, play and damage parts, if neces-
NOTICE sary.
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
SAPH03Z030600048
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
SAPH03Z030600053
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.
SAPH03Z030600054
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.
SAPH03Z030600055
(2) Remove the connector.

(3) Remove the O-ring and filter from the connector.
SAPH03Z030600056
(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.
SAPH03Z030600057
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.
SAPH03Z030600058
B C
A
SAPH03Z030600059
(3) Remove the clamp. Then pull out the straight pin and disassemble
the pipe and actuating rod.
SAPH03Z030600060
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.

SAPH03Z030600061
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.
SAPH03Z030600062
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.
SAPH03Z030600063
(2) Using a slotted screwdriver or similar tool, remove the seal ring
inside the cylinder.
NOTICE
Be careful not to damage the cylinder.
SAPH03Z030600064
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.
SAPH03Z030600060
(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
SAPH03Z030600065
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.}
SAPH03Z030600062
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.
SAPH03Z030600066
(3) Apply grease (Airmaster Paste) to the new seal ring.

(4) Install the seal ring in the cylinder.
SEAL RING
SAPH03Z030600067
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.
SAPH03Z030600068
(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.
SAPH03Z030600069
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.
SAPH03Z030600070
(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.
SAPH03Z030600056
(5) Install the nut.
SAPH03Z030600055
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.}
SAPH03Z030600071
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.
SAPH03Z030600072

EN03Z0306H300003
Spring length A: Replace if the Measure

41.3 (38.8-43.7) mm standard range
{1.63 (1.53-1.72) in.} is exceeded.
B:
31.9 (30.0-33.8) mm
A {1.26 (1.18-1.33) in.}
C:
25.0 (23.5-26.5) mm
B {0.98 (0.92-1.04) in.}
Boots wear and damage — — Replace, Visual check

if necessary.
Filter dirtiness — — Replace, Visual check

if necessary.
PROPELLER SHAFT (LF0932) PP02–1
PROPELLER SHAFT (LF0932)

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 (LF0932)
PROPELLER SHAFT ASSEMBLY

EN0440902I200001
Type Tubular shaft type
Universal joint All metal, round bearing type with needle roller bearing
DESCRIPTION
EN0440902C100001
SAPH044090200001
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
5 Lubrication fitting
TROUBLESHOOTING
EN0440902F300001

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
EN0440902K100001
Prior to starting a propeller shaft overhaul, it is necessary to have this special tool.

COMPONENT LOCATOR
EN0440902D100001
FRONT
SAPH044090200003
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
SAPH044090200004
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
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.
SAPH044090200005
1. DISASSEMBLE THE UNIVERSAL JOINT ASSEMBLY.

(1) Remove the retainer ring from the yoke.
SAPH044090200006
(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.
SAPH044090200007
(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.
SAPH044090200008
2. SEPARATE THE YOKE SHAFT AND SLIDING YOKE. (REAR)

(1) Separate the yoke shaft and sliding yoke.
(2) Remove the dust cover seal from the yoke shaft.
SAPH044090200009
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.
SAPH044090200010
(6) Using a hammer, tap the bearing plate to make a clearance.
SAPH044090200011
(7) Using a commercial puller, remove the center bearing.

NOTICE
Be careful not to catch your fingers between bearing plate and
dust deflector.
SAPH044090200012
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.
SAPH044090200013
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
SAPH044090200014
(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.
SAPH044090200015
(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.
SAPH044090200016
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.}
SAPH044090200017
(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
SAPH044090200018
2.22 {0.0874} White
2.30 {0.0906} Red
2.38 {0.0937} Green
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.
SAPH044090200009
5. ASSEMBLE THE YOKE SHAFT AND SLIDING YOKE.

(1) Align the phasing arrows as shown in the figure.
SAPH044090200019
6. INSTALL THE CENTER BEARING PLATE AND CENTER

BEARING.
SAPH044090200020
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.
SAPH044090200021
(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
SAPH044090200022 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
SAPH044090200023
d. Using the special tool, tighten the lock nut.

SAPH044090200010
(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.
SAPH044090200024
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:
SAPH044090200005

EN0440902H300001
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
PROPELLER SHAFT (MC1040) PP02–1
PROPELLER SHAFT (MC1040)

P 02
PP02-002

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

Worn or damaged center bearing Replace the bearing.
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
2. SEPARATE THE YOKE SHAFT AND SLIDING YOKE.

(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
3. REMOVE THE CENTER BEARING.

SHTS044120200013
SHTS044120200014
(7) Using a commercial puller, remove the center bearing.

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 80 mm
{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
PROPELLER SHAFT (HE1160) PP02–1
PROPELLER SHAFT (HE1160)

P 02
PP02-003

DESCRIPTION ................................................ PP02-2
SPECIAL TOOL ............................................... PP02-3
OVERHAUL ..................................................... PP02-6
PP02–2 PROPELLER SHAFT (HE1160)

EN0441102I200001
DESCRIPTION
EN0441102C100001
SHTS044110200001

3 Yoke shaft 8 Lock plate
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)

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 12: 65-87 {663-887, 48-64}
16: 166.8-225.3 {1,700-2,300, 123-166}
TRANSMISSION TO REAR AXLE
SHTS044110200004
1 Universal joint yoke 8 Yoke shaft

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

A 49-61.8 {500-630, 36-45} B 12: 65-87 {663-887, 48-64}
16: 166.8-225.3 {1,700-2,300, 123-166}
OVERHAUL
EN0441102H200001

NOTICE
SHTS044110200005

NOTICE
NOTICE
SHTS044110200006
ing.
the universal joint yoke.
SHTS044110200007

roller bearing.
c. Press the opposite bearing out of the yoke lug.
SHTS044110200008
the yoke.
SHTS044110200009

roller bearing.
SHTS044110200010
NOTICE
in mind.
piece.
SHTS044110200011

(3) Remove the felt seal, split retainers and felt ring retainer, or dust
seal from the yoke shaft.
! CAUTION
SHTS044110200012
3. REMOVE THE CENTER BEARING. (IF SO EQUIPPED)

SHTS044110200013
SHTS044110200014
(7) Using a commercial puller, remove the center bearing subassem-

bly.
NOTICE
dust deflector.
SHTS044110200015

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.
SHTS044110200016

INTO THE YOKES.
cap so that measurements "B" is equivalent to measurement "A".
both ends.
SHTS044110200017

Unit: mm {in.}
Color code
0.00 Silver
0.04 {0.0016} Yellow
0.08 {0.0031} Black
0.12 {0.0047} Green
SHTS044110200018
NOTICE
SHTS044110200019
(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
SHTS044110200020
(3) Press the universal joint bearings into the yoke over the spider
journal.
NOTICE
SHTS044110200021
(4) Install the universal joint yoke to the universal joint spider.
NOTICE
needle roller bearing, fit in the lock washer, and tighten the univer-
sal joint cap.
NOTICE
SHTS044110200022 sure that the raised portion fits within the bearing bore the yoke
shaft and sliding yoke.
ancer.
Assembly standard:
0.98-4.90 Nm {10-50 kgfcm, 8.7-43.3 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.

and sliding area of the felt ring.
SHTS044110200024
SHTS044110200025
yoke.
! CAUTION
SHTS044110200026
4. INSTALL THE DUST COVER SEAL.

(2) Install the new dust cover seal on the shaft by pushing it in the
dust cover seal groove.
and sliding area of the dust cover seal.
SHTS044110200027

BEARING ASSEMBLY. (IF SO EQUIPPED)
SHTS044110200028
NOTICE
center bearing.
Grease:
SHTS044110200029

water or oil that has been heated to between 80-100C {176-
212F}.
NOTICE
{248F}.
installation.
! CAUTION
SHTS044110200030 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
SHTS044110200031

SHTS044110200032

SHTS044110200033

so equipped.
Grease:
SHTS044110200034

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 (C) between uni- 0.025-0.075 0.1 Replace needle Measure

versal joint spider and nee- {0.0010-0.0029} {0.0039} roller bearing
dle roller bearing sub-assembly
(C = A - B) or universal
joint spider. A B
PROPELLER SHAFT (MC0000)

P 02
PP02-004

DESCRIPTION ................................................ PP02-2
SPECIAL TOOL ............................................... PP02-3
OVERHAUL ..................................................... PP02-5

EN0441702I200001
Type Tubeless shaft type [Rear axle (Front) to Rear axle (Rear)]
DESCRIPTION
EN0441702C100001
SHTS044170200001
1 Universal joint yoke 4 Sliding yoke

3 Yoke shaft 6 Phasing arrow
TROUBLESHOOTING
EN0441702F300001

SPECIAL TOOL
EN0441702K100001

COMPONENT LOCATOR
EN0441702D100001
REAR AXLE (FRONT) TO REAR AXLE (REAR)
SHTS044170200003
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
EN0441702H200001

NOTICE
SHTS044170200004

NOTICE
NOTICE
SHTS044170200005
ing.
(4) Remove the universal joint bearings and universal joint spider
from the universal joint yoke.
SHTS044170200006

Tap the yoke in area shown to achieve removal of universal
joint bearing.
c. Press the opposite bearing out of he yoke lug.
SHTS044170200007
the yoke.
SHTS044170200008

roller bearing.
SHTS044170200009
NOTICE
in mind.
piece.
SHTS044170200010

(3) Remove the felt seal, split retainers and felt ring retainer from the
yoke shaft.
! CAUTION
SHTS044170200011

NOTICE
SHTS044170200012

INTO THE YOKES.
cap so that measurements "B" is equivalent to measurements "A".
both ends.
SHTS044170200013

Unit: mm {in.}
Color code
0.00 Silver
0.04 {0.0016} Yellow
0.08 {0.0031} Black
0.12 {0.0047} Green
SHTS044170200014
NOTICE
SHTS044170200015
(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
SHTS044170200016
journal.
NOTICE
(4) Install the universal joint yokes to the universal joint spider.
SHTS044170200017
NOTICE
needle roller bearing, fit in the lock plate, and tighten the universal
joint cap.
NOTICE
sure that the raised portion fits within the bearing bore the yoke
SHTS044170200018 shaft and sliding yoke.
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.}

and sliding area of the felt seal.
SHTS044170200020
SHTS044170200021
yoke.
! CAUTION
SHTS044170200022

so equipped.
Grease:
SHTS044170200023

EN0441702H300001
Unit: mm {in.}
Propeller shaft dam- 0-0.5 1.0 Replace. Measure

age and bend {0-0.0197} {0.0393}

beads if necessary.

if necessary.
Sliding spline back- At spline 0.25 Replace. Measure

lash (Inspect the 0.062-0.174 {0.0098}
spline backlash at slid- {0.0025-0.0068}
ing yoke lug 80 mm
{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
DIFFERENTIAL CARRIER (SH14) DF02–1
DIFFERENTIAL CARRIER (SH14)

DF02
DF02-001
DIFFERENTIAL CARRIER (SH14) ........... DF02-2

DATA AND SPECIFICATIONS ......................... DF02-2
DESCRIPTION ................................................ DF02-2
TROUBLESHOOTING ..................................... DF02-3
SPECIAL TOOL ............................................... DF02-4
COMPONENT LOCATOR................................ DF02-5
OVERHAUL ..................................................... DF02-7
INSPECTION AND REPAIR .......................... DF02-20
DF02–2 DIFFERENTIAL CARRIER (SH14)

EN0551402I200001
Type Single-reduction, single-speed, by hypoid gearing
Gear ratio 3.900, 4.100, 4.333
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
SAPH055140200001
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

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
EN0551402K100001
Prior to starting a differential carrier overhaul, it is necessary to have these special tools.
S0966-51040 ADJUSTER TOOL
S0964-01151 GAUGE ASSEMBLY

COMPONENT LOCATOR
EN0551402D100001
SAPH055140200006
1 Air breather 4 Gasket

2 Axle housing assembly 5 Oil drain plug
3 Oil filler plug 6 Differential carrier assembly

A 113-147 {1,152-1,499, 83-108} C 9.8-19.6 {100-200, 7-14}
B 78.4-117.6 {800-1,200, 58-86}
SAPH055140200007
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 113-147 {1,100-1,500, 80-108} E 19-25 {190-260, 14-18}
B 277-353 {2,800-3,600, 203-260} F 369-421 {3,700-4,300, 268-311}
C 19-25 {190-260, 14-18} G 167-213 {1,700-2,200, 123-159}
D 589-781 {6,000-8,000, 434-578}
OVERHAUL
EN0551402H200001

NOTICE
Make aligning marks before disassembling.
SAPH055140200008
2. DISMOUNT THE DIFFERENTIAL CARRIER ASSEMBLY.

(1) Drain the gear oil and remove the axle shaft.
(2) Using a jack, dismount the differential carrier assembly.
SAPH055140200009
1. MOUNT THE DIFFERENTIAL CARRIER ASSEMBLY ON A

WORK STAND.
SAPH055140200010
2. DIFFERENTIAL CASE
(1) Remove the bearing cap.
NOTICE
(2) Using a puller, remove the taper roller bearing.
ALIGNING MARK
SAPH055140200011
(3) Disassemble the ring gear.

a. Make aligning mark both the differential case and the ring
gear.
ALIGNING MARK b. Using press, fix the differential gear assembly.
c. Remove the bolts and then ring gear.
NOTICE
Be careful not to drop the ring gear.
SAPH055140200012
(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.
SAPH055140200013
3. HYPOID PINION
(EXAMPLE) ALIGNING (1) Remove the bolts and then disassemble the hypoid pinion and the
MARK shims.
NOTICE
Make aligning mark the differential cage and differential carrier.
SAPH055140200014
(2) Remove the bolts, nuts, and washers.

(3) Using brass bar and hammer, knock through the cylindrical roller
bearing outer race.
SAPH055140200015
4. BEARING CAGE
(1) Uncaulk the lock nut and remove the nut.
SAPH055140200016
SAPH055140200017
(2) Using a puller, remove the taper roller bearing outer race.
SAPH055140200018
(3) Using a press, remove the hypoid pinion.
SAPH055140200019
(4) Using a puller, remove the taper roller bearing inner race.
SAPH055140200020
(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
SAPH055140200021
(2) If the backlash is more than service limit, replace the thrust
washer for side gear and/or pinion.
SAPH055140200022
(3) Assemble the differential case.

NOTICE
• Align the aligning marks when assembling.
• Apply lock agent (ThreeBond 1360K or equivalent) on the
bolt threads.
SAPH055140200023
(4) Install the ring gear to the differential case and tighten it with bolts.
NOTICE
Apply lock agent (ThreeBond 1360K or equivalent) on the bolt
threads.
SAPH055140200024
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.
SAPH055140200025
(2) Installing the pilot 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
SAPH055140200026
(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 drive pin-
ion the inner taper roller bearing inner race.
SAPH055140200027
c. Install the spacer.
SAPH055140200028
(4) Installing the differential cage and outer taper roller bearing inner
race
a. Apply gear oil to the outer taper roller bearing inner race.
b. Using wear plates and press, press into the shaft of hypoid
pinion the differential cage and outer taper roller bearing inner
race.
SAPH055140200029
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.
SAPH055140200030
(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, 1.4-2.2} 1.48-2.45 {15-25, 1.1-1.8}
NOTICE
• Adjust the preload without attaching the oil seal to the pinion
SAPH055140200031 bearing cage.
• When only one bearing is replaced, apply the preload for
"New bearing".
• Note the measured torque because it will be used in adjust-
ment of the preload of the differential side bearing.
HINT
Alternatively, the preload can be measured by setting the drive
pinion assembly on the pipe base.
(3) When the measured value exceeds the standard value, adjust the
spacer thickness.
Types of spacer:
13.975-14.375 mm {0.550-0.566 in.}
(17 types in 0.025 mm {0.0010 in.} increments)
(4) After adjusting the preload, remove the flange coupling tempo-
rarily.
(5) 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.
SAPH055140200032
NOTICE
Apply wheel bearing grease on the oil seal lip part.
SAPH055140200033
(6) Install the flange yoke coupling and tighten the lock nut.
SAPH055140200030
(7) Stake the lock nut using the chisel and hammer.
SAPH055140200034
NOTICE
R1 R2 • Completely attach to the shaft ends (R1, R2) as shown in the
figure.
X
mum of 1.5 mm {0.0591 in.}.
the lock nut.
VIEW A
SAPH055140200035

LOCK NUT
CORRECT INCORRECT
SAPH055140200036
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.
NOTICE
Apply lock agent (ThreeBond 1360K or equivalent) on the bolt
threads.
SAPH055140200037
5. ADJUSTMENT OF PINION FITTING HEIGHT (CONICAL DIS-

TANCE)
(1) Install the pinion cage assembly and adjust the height with shims.
SST: Gauge Assembly (S0964-01151)
SAPH055140200038
A: 27 mm {1.063 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.}
SAPH055140200039
(2) How to use the pinion depth gauge: Set the pinion depth gauge.
A: 27 mm {1.063 in.}
SAPH055140200040
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
SAPH055140200041
assembly and apply liquid gasket (ThreeBond #1215 or equiva-
lent) on the mounting surfaces of differential carrier case and
bearing cage.
6. 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".
SAPH055140200042
(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 (S0966-51040)
SAPH055140200043
b. Hit the bearing cap with a copper hammer.
SAPH055140200044
(3) Measure the gear backlash at three or four points on the circum-
ference of the gear.
SAPH055140200045
(4) Adjust the backlash by turning the adjusting nuts. Turn the both
nuts by the same angle.
BACKLASH: "A"-Decrease "B"-Increase
SAPH055140200046
7. 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.
SAPH055140200047
(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
SAPH055140200048
b. Heel and face contact
A: Heel contact - Unadjust, replace the pinion and ring

gear as a set.
B: Face contact - Adjust
SAPH055140200049
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
Side bearing preload = ASSY preload (preload measured here) -
Pinion bearing preload (preload measured in item 3)
• Check if the side bearing preload calculated by the above for-
mula is within the standard value in the table below.
Assembly standard:
SAPH055140200050 Side bearing preload turning torque Unit: Nm {kgfcm, lbfft}
Gear ratio 3.900 4.100 4.333
0.51-0.75 0.48-0.71 0.46-0.67
New
{5.2-7.6, {4.9-7.2 {4.7-6.8,
bearing
0.38-0.55} 0.36-0.52} 0.34-0.49}
0.38-0.62 0.36-0.59 0.34-0.56
Re-used
{3.9-6.4, {3.7-6.0, {3.5-5.7,
bearing
0.28-0.46} 0.27-0.43} 0.25-0.41}
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
SAPH055140200046
(3) Tighten the bearing cap and install the lock plate.
SAPH055140200051
1. MOUNTING
(1) Using scraper, remove the rust on the joint surface between the
axle housing and the differential carrier assembly.
SAPH055140200052
(2) 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.
SAPH055140200053
(3) 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.
SAPH055140200009
(4) After applying the liquid gasket (ThreeBond #1215 or #1216 or

equivalent) round 14 bolts (10 pieces), install the bolts and
tighten them regularly.
SAPH055140200054
(5) Connect the propeller shaft.

NOTICE
Tightening Torque:
61-91 Nm {623-927 kgfcm, 45-67 lbfft}
(6) Fill the axle housing with specified gear oil up to the filler plug
hole.
Gear oil:
SAPH055140200055

EN0551402H300001
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: B-A: 0.140-0.261 0.4 Replace. Measure

Clearance {0.0055-0.0103} {0.016}
Thrust washers thick- Side gear: 1.3 Replace. Measure

ness (Side gear and 1.5-1.7 {0.051}
pinion gear) {0.059-0.067}
Pinion gear: 1.3

1.45-1.75 {0.051}
{0.057-0.069}
Differential side gear 0.054-0.148 0.5 Replace. Measure

and axle shaft: {0.0021-0.0058} {0.0196}
Spline backlash
Flange coupling: — — Replace, Visual check


DF02
DF02-002
DIFFERENTIAL CARRIER (SH18) ........... DF02-2

DESCRIPTION ................................................ DF02-2
SPECIAL TOOL ............................................... DF02-4
OVERHAUL ..................................................... DF02-7

EN0551602I200001
Type Single-reduction, single-speed, by hypoid gearing
Gear ratios 4.333, 4.555, 4.875, 5.285
Oil capacity 11 L {2.42 lmp gal. / 2.91 U.S gal.}
DESCRIPTION
EN0551602C100001
SAPH055160200001
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
EN0551602F300001

bearings
pinion gear
gears and pinions
and pinion gear
Abnormal noise (Oil system, etc.) Insufficient oil Add oil; check for leakage.
SHAFT".
SPECIAL TOOL
EN0551602K100001

COMPONENT LOCATOR
EN0551602D100001
SAPH055160200006
1 Air breather 5 Oil drain plug

2 Axle housing assembly 6 O-ring
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}
SAPH055160200007
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 167-223 {1,700-2,300, 123-166} E 19-25 {190-260, 14-18}
B 344-456 {3,500-4,700, 254-336} F 456-554 {4,650-5,650, 336-408}
C 19-25 {190-260, 14-18} G 314-406 {3,200-4,140, 232-299}
D 589-781 {6,000-8,000, 434-578}
OVERHAUL
EN0551602H200001

NOTICE
SAPH055160200008

SAPH055160200009
1. MOUNT THE DIFFERENTIAL CARRIER ASSEMBLY ON THE

WORK STAND.
SAPH055160200010
SAPH055160200011
(2) Remove the bearing cap then remove the differential case assem-
bly with a wire and a chain block.
NOTICE
(3) Using a puller, remove the taper roller bearing.
SAPH055160200012
(4) Disassemble the ring gear.

gear.
b. Using press, fix the differential gear assembly.
ALIGNING MARK c. Remove the ring gear.
NOTICE
SAPH055160200013
(5) Disassemble the differential case.

NOTICE
Be sure to check the aligning marks on the differential case before
disassembling. Remove the bolts and nuts so that the case sepa-
rates.
SAPH055160200014
3. DISASSEMBLE THE HYPOID PINION.

(1) Remove the bolts and then remove the hypoid pinion and the
shims.
SAPH055160200015
(2) Remove the bolts, nuts, and washers.

(3) Using brass bar and hammer, knock through the cylindrical roller
bearing outer race.
SAPH055160200016
4. BEARING CAGE
SAPH055160200017
SAPH055160200018
SAPH055160200019
(3) Using a puller, remove the cylindrical roller bearing inner race.
SAPH055160200020
(4) Using a press, remove the hypoid pinion.
SAPH055160200021
(5) Using a puller, remove the taper roller bearing inner race.
SAPH055160200022
(6) Using a brass bar and a hammer, knock through the taper roller
bearing outer race.
SAPH055160200023
OUTER RACE
SAPH055160200024
NOTICE
gear face to the gear side.
• A: Pinion
• B: Side gear
• C: Thrust washer
SAPH055160200025
washer for side gear and/or pinion.
Assembly standard: 0.20-0.60 mm {0.0079-0.0236 in.}
Service limit: 0.9 mm {0.0354 in.}
SAPH055160200026

NOTICE
• Apply adhesive (ThreeBond 1360K or equivalent) on the bolt
threads.
SAPH055160200027
(4) Install the ring gear to the differential case and tighten it with bolts.
NOTICE
• Apply adhesive (ThreeBond 1360K or equivalent) on the bolt
threads.
• When adhesive is not applied, caulk the nut in the same man-
ner as step (3).
SAPH055160200028
2. ASSEMBLY OF THE 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.
SAPH055160200029
(2) Installing the pilot 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
SAPH055160200030
(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 drive pin-
ion the inner taper roller bearing inner race.
SAPH055160200031
c. Install the spacer.
SAPH055160200032
(4) Installing the differential cage and outer taper roller bearing inner
race
a. Apply gear oil to the outer taper roller bearing inner race.
b. Using wear plates and press, press into the shaft of hypoid
pinion the differential cage and outer taper roller bearing inner
race.
SAPH055160200033
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.
SAPH055160200034
(2) Use a torque wrench, measure the preload at the lock nut.
Assembly standard: Turning torque Unit: Nm {kgfcm, lbfft}
2.46-3.43 {25-35, 1.9-2.0} 1.97-2.94 {20-30, 1.5-1.6}
NOTICE
• Adjust the preload without attaching the oil seal to the pinion
bearing cage.
"New bearing".
SAPH055160200035
HINT
(3) When the measured value exceeds the standard value, adjust
the spacer thickness.
Types of spacer:
18.175-18.725 mm {0.715-0.737 in.}
rarily.
(5) 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.
SAPH055160200036
NOTICE
Apply wheel bearing grease on the oil seal lip part.
SAPH055160200037
SAPH055160200034

NOTICE
• Caulk the nut securely as shown.
VIEW A
SAPH055160200038

R2 figure.
R1
X
mum of 1.5 mm {0.0591 in.}.
the lock nut.
VIEW A
SAPH055160200039

LOCK NUT
CORRECT INCORRECT
SAPH055160200040

OUTER RACE
washers.
NOTICE
Apply adhesive (ThreeBond 1360K or equivalent) on the bolt
threads.
SAPH055160200041
5. ADJUSTMENT OF THE PINION FITTING HEIGHT (CONICAL

DISTANCE).
(1) Install the pinion cage assembly and adjust the height with shims.
SAPH055160200042
A: 46 mm {1.811 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.}
SAPH055160200043
(2) How to use the pinion depth gauge: Set the pinion depth gauge.
A: 46 mm {1.811 in.}
SAPH055160200044
EXAMPLE:
Standard pin-
46.0 mm – 0.2 mm = 45.8 mm
The engraved
value "a"
NOTICE
Upon completing the adjustment, remove the bearing cage
SAPH055160200045
assembly and apply liquid gasket (ThreeBond #1215, #1216 or
equivalent) on the mounting surfaces of differential carrier case
and bearing cage.
6. 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
SAPH055160200046

1/4TURN a. Tighten the adjusting nut fully, then loosen the adjusting nut
by 1/4 turn + 1 notch.
SAPH055160200047
SAPH055160200048
Assembly standard:
0.30-0.41 mm {0.0119-0.0161 in.}
SAPH055160200049
BACKLASH: A-Decrease B-Increase
SAPH055160200050

NOTICE
the factory's mark.
SAPH055160200051
(2) Example of the unsatisfactory engagement


gear as a set.
SAPH055160200052
b. Heel and face contact

gear as a set.
SAPH055160200053

bearings, using a torque wrench.
NOTICE
pinion bearing preload (preload measured in item 3).
SAPH055160200054
Assembly standard: Side bearing preload turning torque

Gear ratio 4.333 4.555 4.875 5.285
0.57-0.63 0.54-0.60 0.51-0.56 0.47-0.51
New bearing
{5.8-6.4, 0.42-0.46} {5.5-6.1, 0.40-0.44} {5.2-5.7, 0.38-0.41} {4.8-5.2, 0.35-0.37}
Re-used 0.46-0.52 0.44-0.49 0.41-0.46 0.37-0.42
bearing {4.7-5.3, 0.34-0.38} {4.4-5.0, 0.32-0.36} {4.2-4.7, 0.31-0.33} {3.8-4.3, 0.28-0.31}
NOTICE
nut.
SAPH055160200050
SAPH055160200055
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.
SAPH055160200056

NOTICE
• The liquid gasket must be ThreeBond #1215, #1216 or equiv-
alent.
SAPH055160200057
housing.
NOTICE
Place the carrier assembly so that the ring gear teeth faces toward
the right-hand side of vehicle.
SAPH055160200009
(5) After applying the liquid gasket (ThreeBond #1215 or #1216 or

equivalent) round 16 bolts (12 pieces), install the bolts and
tighten them regularly.
SAPH055160200058
(6) Connect the propeller shaft.

NOTICE
Tightening Torque:
14 bolt: 128-156 Nm {1,300-1,600 kgfcm, 94-115 lbfft}
16 bolt: 167-225 Nm {1,700-2,300 kgfcm, 123-166 lbfft}
(7) Fill the axle housing with specified gear oil up to the filler plug
hole.
Gear oil:
Refer to the Owner's manual.
SAPH055160200059

EN0551602H300001
Unit: mm {in.}



Wear and damage


Wear and damage
Spider and pinion: B-A: 0.4 Replace. Measure

Clearance 0.145-0.270 {0.016}
{0.006-0.011}

ness (Side gear and 1.9-2.1 {0.067}
pinion gear) {0.075-0.082}
Pinion gear: 1.7

1.9-2.1 {0.067}
{0.075-0.082}

and axle shaft: {0.0021-0.0058} {0.0196}
Spline backlash
Flange coupling: — — Replace, Visual check

DIFFERENTIAL CARRIER (THD17) DF02–1
DIFFERENTIAL CARRIER (THD17)

DF02
DF02-003
DIFFERENTIAL CARRIER (THD17)......... DF02-2

DESCRIPTION ................................................ DF02-2
SPECIAL TOOL ............................................... DF02-6
OVERHAUL ................................................... DF02-10
DF02–2 DIFFERENTIAL CARRIER (THD17)
DIFFERENTIAL CARRIER (THD17)

EN0551802I200001
Single-reduction, single-speed, by hypoid gearing with Inter-axle differen-

Type
tial and transfer gear, used for the forward axle of tandem drive axles.
Gear ratios 5.428, 5.857
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
SAPH055180200001
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
SAPH055180200002
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
SAPH055180200003
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
Abnormal noise (Oil system, etc.) Insufficient oil Add oil, check for leakage.
SHAFT".
SPECIAL TOOL
EN0551802K100001
S0983-95501
SOCKET WRENCH
S0983-96502

COMPONENT LOCATOR
EN0551802D100001
SAPH055180200009
1 Air breather 5 Oil drain plug

2 Axle housing assembly 6 O-ring
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
SAPH055180200010
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 456-554 {4,650-5,650, 336-408}
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 12.0-15.0 {120-153, 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
SAPH055180200011

(2) Disconnect the air hose.
SAPH055180200012
(3) Remove the through shaft.
SAPH055180200013
SAPH055180200014
1. THROUGH SHAFT
SAPH055180200015
2. MOUNT THE DIFFERENTIAL CARRIER ASSEMBLY ON THE

WORK STAND.
SAPH055180200016
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.
SAPH055180200017
(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.
SAPH055180200018
(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.
SAPH055180200019
4. OIL PUMP
(1) Remove the oil strainer from the carrier cover.
SAPH055180200020
(2) Loosen the bolts and remove the oil pump assembly and the oil
pipe from the carrier cover.
SAPH055180200021
5. INTER-AXLE DIFFERENTIAL GEAR

(1) Check for the aligning marks for the differential gear case then
loosen the bolts and separate it.
SAPH055180200022
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
SAPH055180200023
(3) Dismounting the ring gear

gear.
b. Using press, fix the differential gear assembly.
ALIGNING MARK c. Remove the bolts then ring gear.
NOTICE
SAPH055180200024
(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.
SAPH055180200025
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.
SAPH055180200026
(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.
SAPH055180200027
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
SAPH055180200028
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
SAPH055180200029
Thickness of retainer ring Color code

COLOR CODE
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
SAPH055180200030 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}
SAPH055180200031
(5) After assembly, tighten it to the specified torque.

SAPH055180200032

OUTER RACE
washers.
NOTICE
Apply lock agent (Lock tight) which is equivalent to ThreeBond
1360K on the bolt threads.
SAPH055180200033
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.
SAPH055180200034
(2) Using the torque wrench, measure the preload at the lock nut.
Assembly Standard: Turning torque Unit: Nm {kgfcm, lbfft}
1.97-2.94 {20-30, 1.4-2.1} 1.48-2.45 {15-25, 1.1-1.8}
NOTICE
"New bearing".
SAPH055180200035
HINT
(3) When the measured value exceeds the standard value, adjust
the spacer thickness.
Types of spacer:
16.250-16.800 mm {0.640-0.661 in.}
rarily.
(5) After completing the adjustment, loosen the lock nut.
(6) Remove the lock nut and the pinion drive gear.
SAPH055180200036
(7) Install the pinion assembly and tighten the bolts.

(8) Install the pinion drive gear and tighten the lock nut with specified
torque.
SAPH055180200037
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.}
SAPH055180200038
(2) How to use the pinion depth gauge:

Set the pinion depth gauge.
A: 34 mm {1.339 in.}
SAPH055180200039
(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
SAPH055180200040
EXAMPLE:
Standard pin-
34.0 mm – 0.2 mm = 33.8 mm
The engraved
value "a"
SAPH055180200041
(4) Caulk the pinion drive gear lock nut.

NOTICE
A • Caulk the nut securely as shown in the figure.
VIEW A
SAPH055180200044

R2 figure.
R1
X
mum of 1.5 mm {0.0591 in.}.
the lock nut.
VIEW A
SAPH055180200042

LOCK NUT
CORRECT INCORRECT
SAPH055180200043
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
SAPH055180200045
washer for the side gear and/or for the pinion.
SAPH055180200046

NOTICE
• Apply lock agent (Lock tight) which is equivalent to ThreeB-
ond 1360K on the bolt threads.
SAPH055180200047
(4) Install the ring gear to the differential case and tighten the bolts.
NOTICE
• Apply lock agent (Lock tight) which is equivalent to ThreeB-
ond 1360K on the bolt threads.
• When lock agent is not applied, stake the nut in the same
manner as step (3).
SAPH055180200048
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
SAPH055180200049

1/4 TURN a. Tightening the adjusting nut fully then loosen the adjusting nut
by 1/4 turn +1 notch.
SAPH055180200050
SAPH055180200051
SAPH055180200052
BACKLASH: "A" - Decrease "B" - Increase
SAPH055180200053

NOTICE
the factory's mark.
SAPH055180200054
(2) Example of the unsatisfactory engagement.


gear as a set.
SAPH055180200055
b. Heel and face contact.

gear as a set.
SAPH055180200056

bearings using a torque wrench.
NOTICE
pinion bearing preload (preload measured in item 3).
SAPH055180200057
Assembly standard: Side bearing preload turning torque

Gear ratio 5.428 5.857
New bearing 0.37-0.45 {3.8-4.5, 0.28-0.32} 0.34-0.41 {3.5-4.2, 0.25-0.30}
Re-used bearing 0.28-0.36 {2.9-3.7, 0.20-0.26} 0.26-0.33 {2.6-3.4, 0.19-0.24}
NOTICE
nut.
SAPH055180200058
SAPH055180200059
9. DRIVE GEAR AND PINION DRIVE GEAR

(1) Measure the drive gear and pinion drive gear backlash.
SAPH055180200060
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
SAPH055180200061
washer for the side gear and/or for the pinion.
SAPH055180200062

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.
SAPH055180200063
(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.
SAPH055180200064
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".
SAPH055180200065
(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.
SAPH055180200066
(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.
SAPH055180200067
(5) Install the oil strainer to the differential carrier cover.
SAPH055180200068
(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
SAPH055180200069
(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.
SAPH055180200070
(10) Place the thrust washer on the drive gear.

NOTICE
Apply molybdenum grease to the both sides of the thrust washer.
SAPH055180200071
(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".
SAPH055180200072
(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.
SAPH055180200073

NOTICE
• Caulk the nut securely as shown in the figure.
SAPH055180200074

R2 figure.
R1
X
mum of 1.5 mm {0.0591 in.}.
the lock nut.
VIEW A
SAPH055180200042

LOCK NUT
CORRECT INCORRECT
SAPH055180200043
1. DIFFERENTIAL CARRIER ASSEMBLY

NOTICE
SAPH055180200075
housing.
NOTICE
Fit the O-ring to the stud bolt.
SAPH055180200076
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
SAPH055180200077

NOTICE
• Caulk the nut securely as shown in the figure.
SAPH055180200078

R2 figure.
R1
X
mum of 1.5 mm {0.0591 in.}.
the lock nut.
VIEW A
SAPH055180200042

LOCK NUT
CORRECT INCORRECT
SAPH055180200043
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"
SAPH055180200079
4. PROPELLER SHAFT
(1) Install the propeller shafts.
NOTICE
Tightening Torque:
14 bolt: 127.5-156.9 Nm {1,300-1,600 kgfcm, 94-115 lbfft}
16 bolt: 166.8-225.4 Nm {1,700-2,300 kgfcm, 123-166 lbfft}
SAPH055180200080

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 B-A: 0.4 Replace. Measure

spider and pinion: 0.140-0.261 {0.016}
Clearance {0.006-0.010}
Inter axle differential 1.7-1.9 1.5 Replace. Measure

thrust washers thick- {0.068-0.076} {0.060}
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

Spider and pinion: B-A: 0.4 Replace. Measure

Clearance 0.145-0.270 {0.016}
{0.0058-0.0108}

Wear and damage

ness 1.9-2.1 {0.067}
{0.075-0.082}
Pinion gear: 1.5

1.7-1.9 {0.060}
{0.067-0.074}

and axle shaft: {0.0021-0.0058} {0.020}
Spline backlash
Flange coupling spline: — — Replace, Visual check

BRAKE EQUIPMENT BR01–1
BRAKE EQUIPMENT
BR01
BR01-001
SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DIAGRAM ........................................................ BR01-3
TROUBLESHOOTING ................................... BR01-11
BR01–2 BRAKE EQUIPMENT
SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN06Z0801C100001
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).
Spring brake control system Single line for all spring brake chambers.
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 light.
Wheel brake Drum brake with internally expanding, leading-trailing shoes operation
by expander in all wheels.
NOTICE
See "DIAGRAM" of the following page the component parts
(Valves, Switches, etc.) used in easy system.
DIAGRAM
EN06Z0801J100001
MODELS: EXCEPT FOR GD8JGTA-QHR, GD8JJTG-QHR, GD8JMTG-QHR

A5
E5
CAB SIDE CHASSIS SIDE
17 22
10
21
A4 C3
A2
22
8 9
21
4 A3
19
G2
7
G1
3 5 Q1
H1
M7
P3
C4
24
2 S1
21 14
1 E1 E10
RR
C1
FR
23 26
C2 P4
15
E2 P5
E4 18
P1 E11
6 P2 E3
M1 A1 16
25
11 25 E21
12 E20
25 H2 25 E23
M7 C5
E22
M5
3 H3
20
: AIR HOSE 15
: AIR PIPE
: NYLON TUBE 13
H5
J1
27 28
J3
J2
EQUIPPED WITH TRANSMISSION PTO
SAPH06Z080100001
1 Brake valve 15 Brake chamber - Rear

2 Stop light switch 16 Relay valve - Rear
3 Brake chamber - Front 17 Air dryer
4 Exhaust brake 18 Double check valve
5 Exhaust brake magnetic valve 19 Safety valve
6 Parking brake valve 20 Transmission power shift
7 4-way protection valve 21 Lower pressure switch
8 Air tank - Water separator 22 Pressure sensor
9 Air tank - Front 23 Multi joint
10 Air tank - Rear 24 Air suspension seat
11 Relay valve - Front 25 ABS control valve
12 Air compressor 26 ASR control valve
13 Clutch booster 27 Transmission PTO
14 Relay valve - Wheel parking 28 PTO magnetic valve
MODELS: GD8JGTA-QHR, GD8JJTG-QHR, GD8JMTG-QHR
A5
E5
17 22
10 29
21
A4 C3
A2
22
8 9 29
21
4 A3
19
G2
7
G1
3 5 Q1
H1
M7
P3
C4
25
24
2 S1
21 14
1 E1 E10
RR
C1
FR
23 26
C2 P4
15
E2 P5
E4 18
P1 E11
6 P2 E3
M1 A1 16
C6
25 E21
12 C5
25 E20
11 25
H2 E23
M8 E22
C7
M5
3 H3
20
: AIR HOSE 15
: AIR PIPE
: NYLON TUBE 13
H2
J1
H2 30
E30 E10
R1
27 28
J3
23 R3
J2
R2
31 R4
32 EQUIPPED WITH TRANSMISSION PTO
30
EQUIPPED WITH AIR SUSPENSION
SAPH06Z080100002
1 Brake valve 17 Air dryer

2 Stop light switch 18 Double check valve
3 Brake chamber - Front 19 Safety valve
4 Exhaust brake 20 Transmission power shift
5 Exhaust brake magnetic valve 21 Lower pressure switch
6 Parking brake valve 22 Pressure sensor
7 4-way protection valve 23 Multi joint
8 Air tank - Water separator 24 Air suspension seat
9 Air tank - Front 25 ABS control valve
10 Air tank - Rear 26 ASR control valve
11 Relay valve - Front 27 Transmission PTO
12 Air compressor 28 PTO magnetic valve
13 Clutch booster 29 Test connection
14 Relay valve - Wheel parking 30 Air spring (If so equipped)
15 Brake chamber - Rear 31 Air suspension protection valve (If so equipped)
16 Relay valve - Rear 32 Leveling valve (If so equipped)
MODEL: GH
31
18
2 CAB SIDE CHASSIS SIDE G11
A2
4 A8 8 30
M4
P11
R A4
A5
C3
29
1 F G1 E5
5 7
G2 9 10 29
3 8 E8
A3
M7 15
17 C5 30
E1
C1
C2 E4
E2 11 E3
P1 16
P2 P3 P4
6
M8
19
E21 E7
Q1
M9
14 E22 E6
M8
19
13 M5 H1 P5
30
: AIR HOSE
17 12 M1 A1
C6
: AIR PIPE
30 M7
15 : NYLON TUBE
3
M5 H1
J3
13 H4
22
M3 21 M6 J1
23 M5 H1 J2
M6
EQUIPPED WITH EQUIPPED WITH

TRANSMISSION POWER SHIFT TRANSMISSION PTO
(MF06 TRANSMISSION) (MF06 TRANSMISSION)
7 28
24 R4
M10

13 H1
27
M5 H3
H2 R2
7
S1 26
20
R5
EQUIPPED WITH EQUIPPED WITH 28

AIR SUSPENSION SEAT AIR SUSPENSION
(EATON FS6109 TRANSMISSION)
22 R1
H1
R2 27
M10
H3 H2 J2 26
EQUIPPED WITH AIR SUSPENSION

AND TRANSMISSION PTO
(EATON FS6109 TRANSMISSION)
SAPH06Z080100003
H1 24
M10
M10
H3 H2
22
21 13 M5 H3 H1
M6 J2
EQUIPPED WITH
TRANSMISSION PTO EQUIPPED WITH
(EATON FS6109 TRANSMISSION) EATON FS6109 TRANSMISSION
28
R4
M5 H1 27
R2 R1
J3
R3
27 R2
J1
22 J2 26 26
R5
EQUIPPED WITH 28
AIR SUSPENSION EQUIPPED WITH
AND PTO AIR SUSPENSION
(MF06 TRANSMISSION) (MF06 TRANSMISSION)
SAPH06Z080100004
1 Brake valve 17 ABS control valve - Front

2 Stop light switch 18 Air dryer
3 Brake chamber - Front 19 ABS control valve - Rear
4 Exhaust brake 20 Air suspension seat
5 Exhaust brake magnetic valve 21 Power take-off
6 Parking brake valve 22 Power take-off magnetic valve
7 4-way protection valve 23 Transmission power shift
8 Air tank - Water separator 24 Range preselection lever
9 Air tank - Front 25 Height control valve
10 Air tank - Rear 26 Air suspension protection valve
11 Relay valve - Front 27 Leveling valve
12 Air compressor 28 Air spring
13 Clutch booster 29 Double check valve
14 Relay valve - Wheel parking 30 Test connection (If so equipped)
15 Brake chamber - Rear 31 ASR
16 Relay valve - Rear
MODEL: FM (EQUIPPED WITH ABS)

A5
A4
7 8 P1
Q1
E1
A8 A3
10
C1 G1
CAB CHASSIS A2
SIDE SIDE
9 8
B1
C0
2
E0
4 E9
R
F
M11 13
M13 22
1 C5 27
P5 E5
E1
C1
C2 E4 17
E2
P1 E6
23
E14
3 P2
21 E21 E11
S1
A0 M1 A1 A1-1 A1-2 A2 18 M15

25 B1 P15
M10 H10 M17 19 M21
24
5 6 H6
M5 H2 P16 19 M22
C8 M16
22 P4 18
C6
M12 P6 14
P7 14 E13 E22 E12
P8
17
M14 16
P5
15 E8
23
E15
4 Q3
: AIR HOSE
: AIR PIPE
: NYLON TUBE
SAPH06Z080100005
G1
10
G2
11 12
EQUIPPED WITH EXHAUST BRAKE
G1
W1
G1
G2
G2
11 11
J1
J2 M6
20
W1 W2 M9
26
EQUIPPED WITH EQUIPPED WITH DIFFERENTIAL LOCK AND PTO

INTER-AXLE DIFFERENTIAL LOCK (ZF 9S1110 TRANSMISSION)
SAPH06Z080100006
1 Brake valve 15 Spring brake valve - Front

2 Stop light switch 16 Spring brake valve - Rear
3 Parking brake valve 17 Relay valve - Rear
4 Spring brake chamber - Front 18 Spring brake chamber - Rear
5 Air compressor 19 Brake chamber - Rear
6 Clutch booster 20 Inter-axle differential lock magnetic valve
7 Air tank - Rear 21 Air dryer
8 Air tank - Water separator 22 ABS control valve - Front
9 Air tank - Front 23 ABS control valve - Rear
10 4-way protection valve 24 Range preselection lever
11 Exhaust brake magnetic valve 25 Air suspension seat
12 Exhaust brake 26 PTO magnetic valve
13 Relay valve - Front 27 Multi joint
14 Double check valve
TROUBLESHOOTING
EN06Z0801F300001

Not enough braking (Wheel brake Lining is wet with grease or fluid Replace the lining.
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 (Control sys- Leakage of compressed air from brake Tighten further or replace gasket.
tem) system
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 relay valve and Repair or replace.
quick release valve
Clogging of brake system Replace pipe, hose, etc.
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
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 brake valve 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
Loose hub bearing Adjust or replace bearing.
SERVICE BRAKE (MODELS: WITH FULL AIR BRAKE) BR02–1
SERVICE BRAKE BR02
(MODELS: WITH FULL AIR BRAKE) BR02-001
AIR DRYER (MODEL: GD) .......................BR02-3 PROTECTION VALVE

DATA AND SPECIFICATIONS ......................... BR02-3 (FOR AIR SUSPENSION) .......................BR02-34
DESCRIPTION ................................................ BR02-3 DATA AND SPECIFICATIONS ....................... BR02-34
COMPONENT LOCATOR................................ BR02-4 DESCRIPTION .............................................. BR02-34
OVERHAUL ..................................................... BR02-5 COMPONENT LOCATOR.............................. BR02-35
INSPECTION AND REPAIR ............................ BR02-7 OVERHAUL ................................................... BR02-36
INSPECTION AND REPAIR .......................... BR02-36
AIR DRYER (MODEL: GH) .......................BR02-8
DATA AND SPECIFICATIONS ......................... BR02-8 PROTECTION VALVE
DESCRIPTION ................................................ BR02-8 (WITH 4-WAY PROTECTION VALVE).....BR02-37
COMPONENT LOCATOR................................ BR02-9
DATA AND SPECIFICATIONS ....................... BR02-37
OVERHAUL ................................................... BR02-10
DESCRIPTION .............................................. BR02-37
COMPONENT LOCATOR.............................. BR02-38
OVERHAUL ................................................... BR02-39
AIR DRYER (MODEL: FM) .....................BR02-13 ADJUSTMENT............................................... BR02-39
DATA AND SPECIFICATIONS ....................... BR02-13 INSPECTION AND REPAIR .......................... BR02-41
DESCRIPTION .............................................. BR02-14
COMPONENT LOCATOR.............................. BR02-15 SPRING BRAKE CONTROL VALVE ......BR02-42
OVERHAUL ................................................... BR02-16
DESCRIPTION .............................................. BR02-42
CHECK VALVE........................................BR02-18 OVERHAUL ................................................... BR02-44
DATA AND SPECIFICATIONS ....................... BR02-18 INSPECTION AND REPAIR .......................... BR02-46
DESCRIPTION .............................................. BR02-18
COMPONENT LOCATOR.............................. BR02-18 RELAY VALVE (FOR SERVICE BRAKE)
[MODELS: GD, GH, FM]
(FOR SPRING BRAKE)
DOUBLE CHECK VALVE .......................BR02-20
[MODELS: GH, FM] ................................BR02-47
DATA AND SPECIFICATION.......................... BR02-20
DESCRIPTION .............................................. BR02-20 DATA AND SPECIFICATIONS ....................... BR02-47
COMPONENT LOCATOR.............................. BR02-21 DESCRIPTION .............................................. BR02-47
OVERHAUL ................................................... BR02-22 DATA AND SPECIFICATIONS ....................... BR02-48
INSPECTION AND REPAIR .......................... BR02-22 DESCRIPTION .............................................. BR02-48
OVERHAUL ................................................... BR02-50
SAFETY VALVE ......................................BR02-23 INSPECTION AND REPAIR .......................... BR02-51
DESCRIPTION .............................................. BR02-23
RELAY VALVE (FOR SERVICE BRAKE REAR)
[MODEL: GD] ..........................................BR02-52
BRAKE VALVE........................................BR02-24
DESCRIPTION .............................................. BR02-52
DATA AND SPECIFICATION.......................... BR02-24
DESCRIPTION .............................................. BR02-24
OVERHAUL ................................................... BR02-54
OVERHAUL ................................................... BR02-27
BR02–2 SERVICE BRAKE (MODELS: WITH FULL AIR BRAKE)
RELAY VALVE (FOR SPRING BRAKE) BRAKE CHAMBER (MODEL: FM)

[MODEL: GD] ......................................... BR02-56 [FOR REAR (REARWARD)
BR 02
DATA AND SPECIFICATIONS........................BR02-56 BRAKE (S-CAM TYPE)] .........................BR02-89

DESCRIPTION...............................................BR02-56 DATA AND SPECIFICATION ..........................BR02-89
COMPONENT LOCATOR ..............................BR02-57 DESCRIPTION...............................................BR02-89
OVERHAUL ....................................................BR02-58 COMPONENT LOCATOR ..............................BR02-90
INSPECTION AND REPAIR ...........................BR02-59 OVERHAUL ....................................................BR02-90
INSPECTION AND REPAIR ...........................BR02-91
SPRING BRAKE CHAMBER (MODEL: GD) [FOR
REAR BRAKE (WEDGE TYPE)] ............ BR02-60 WHEEL BRAKE (WEDGE TYPE) .......... BR02-92
DATA AND SPECIFICATION ..........................BR02-60 DATA AND SPECIFICATIONS........................BR02-92
DESCRIPTION...............................................BR02-60 DESCRIPTION...............................................BR02-92
COMPONENT LOCATOR ..............................BR02-61 SPECIAL TOOL..............................................BR02-94
OVERHAUL ....................................................BR02-62 COMPONENT LOCATOR ..............................BR02-95
INSPECTION AND REPAIR ...........................BR02-63 OVERHAUL ....................................................BR02-97
ADJUSTMENT .............................................BR02-102
SPRING BRAKE CHAMBER (MODEL: FM) [FOR INSPECTION AND REPAIR .........................BR02-104
FRONT BRAKE (S-CAM TYPE)]............ BR02-64

DATA AND SPECIFICATION ..........................BR02-64
WHEEL BRAKE (S-CAM TYPE) .......... BR02-105
DESCRIPTION...............................................BR02-64 DATA AND SPECIFICATIONS......................BR02-105
SPECIAL TOOL..............................................BR02-65 DESCRIPTION.............................................BR02-106
COMPONENT LOCATOR ..............................BR02-65 SPECIAL TOOL............................................BR02-111
OVERHAUL ....................................................BR02-66 COMPONENT LOCATOR ............................BR02-112
INSPECTION AND REPAIR ...........................BR02-70 OVERHAUL ..................................................BR02-119
ADJUSTMENT .............................................BR02-126
INSPECTION AND REPAIR .........................BR02-128
SPRING BRAKE CHAMBER (MODELS: GH, FM)
[FOR REAR BRAKE (S-CAM TYPE)] .... BR02-71
EXPANDER (MODELS WITH WEDGE TYPE
DESCRIPTION...............................................BR02-71
BRAKE).................................................BR02-130
BRAKE CHAMBER (MODEL: GD) [FOR FRONT

WHEEL BRAKE SLACK ADJUSTER (AUTO
BRAKE (WEDGE TYPE)] ....................... BR02-79
ADJUSTER) (MODELS WITH S-CAM TYPE
DESCRIPTION...............................................BR02-79 BRAKE).................................................BR02-138
BRAKE CHAMBER (MODEL: GH) [FOR FRONT
BRAKE (S-CAM TYPE)] ......................... BR02-86
DESCRIPTION...............................................BR02-86
COMPONENT LOCATOR ..............................BR02-87
OVERHAUL ....................................................BR02-87
INSPECTION AND REPAIR ...........................BR02-88
AIR DRYER (MODEL: GD)

EN0680202I200002
Type Purge tank, desiccant, auto-purge valve.

Air and Water discharging time (Reclamation cycle) Approx. 50 sec.
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
20
SECTION X-X
D
SAPH068020200001
1 Chamber (Purge tank) 11 Valve spring A Outlet (Dried air to air tank)
2 Case cover 12 Piston B Orifice
3 Check valve 13 Purge valve C Inlet (From air compressor)
4 Spring 14 Plug D Purged air
5 Body 15 Pressure regulator E Dehumidification
6 Desiccant case 16 Adjusting screw F Reclamation
7 Filter 17 Piston G To purge valve
8 Desiccant 18 Piston spring
9 Oil separator filter 19 Heater
10 Valve body 20 Silencer
COMPONENT LOCATOR
EN0680202D100002
SAPH068020200002
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
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

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} F 19.6-29.4 {200-300, 15-22}
OVERHAUL
EN0680202H200002
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
A
SAPH068020200003
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.
2. 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.
SAPH068020200004
(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: 880 kPa {9.0 kgf/cm2, 128
lbf/in.2}
(3) Tighten the adjusting screw lock nut.
SAPH068020200005
(4) Watch the air pressure gauge needle and see that it stops at the
valve closing pressure shown below.
Governor valve closing pressure: 780 kPa {8.0 kgf/cm2, 114
lbf/in.2}
SAPH068020200006

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
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: GH)

Type Purge tank, desiccant, auto-purge valve.

DESCRIPTION
SAPH068020200012
1 Chamber (Purge tank) 13 Purge valve A Inlet (From air compressor)

2 Case cover 14 Plug B Orifice
3 Check valve 15 Pressure regulator C Outlet (Dried air to air tank)
4 Spring 16 Adjusting screw D Purged air
5 Body 17 Piston E Dehumidification
6 Desiccant case 18 Piston spring F Reclamation
7 Filter 19 Heater
8 Desiccant 20 Silencer case
9 Oil separator filter 21 Silencer body
10 Valve body 22 Filter plate
11 Valve spring 23 Filter
12 Piston 24 Retainer ring
COMPONENT LOCATOR
SAPH068020200013
1 O-ring 13 Check valve 25 Exhaust stem spring

2 Plate 14 Case cover 26 Exhaust stem
3 Piston 15 Set spring 27 Pressure regulator assembly
4 Valve spring 16 Filter plate 28 Valve seat
5 Valve body 17 Filter 29 Plate
6 Purge valve 18 Desiccant 30 Heater
7 Silencer case 19 Desiccant case 31 Thermostat
8 Silencer plate 20 Oil separator filter 32 Silencer body
9 Silencer 21 Body 33 Filter plate
10 Retainer ring 22 Valve stopper 34 Filter
11 Exhaust cover 23 Governor valve 35 Retainer ring
12 Chamber 24 Piston assembly

A 3.9-6.9 {40-70, 2.9-50} 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} F 19.6-29.4 {200-300, 15-22}
OVERHAUL

NOTICE
When disassembling the air dryer, never to disassemble the its
silencer body because its threaded portion is coated with lock
agent (Lock tight).
SILENCER
CASE
SILENCER
BODY
SAPH068020200014
1. LUBRICATION
(1) When assembling the air dryer, use new O-ring, gasket and seal.
• A: O-ring
2. BEFORE TIGHTEN THE BOLT WITH SPECIFIED TIGHTENING

TORQUE, TAP ALL OVER THE OUTER SURFACE OF THE
DESICCANT CASE WITH A PLASTIC HAMMER.
• C: Bolt
SAPH068020200015
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.
2. 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.
SAPH068020200016
(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: 880 kPa {9.0 kgf/cm2, 128
lbf/in.2}
(3) Tighten the adjusting screw lock nut.
SAPH068020200017
(4) Watch the air pressure gauge needle and see that it stops at the
valve closing pressure shown below.
Governor valve closing pressure: 780 kPa {8.0 kgf/cm2, 114
lbf/in.2}
SAPH068020200018
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


AIR DRYER (MODEL: FM)

EN0680202I200003
Type Purge tank, desiccant, auto-drain valve.

DESCRIPTION
EN0680202C100003
SAPH068020200019
1 Check valve 16 Adjuster screw

2 Spring 17 Heater (If so equipped)
3 Filter 18 Silencer case
4 Chamber (Purge tank) 19 Silencer body (If so equipped)
5 Desiccant case 20 Filter plate (If so equipped)
6 Desiccant 21 Filter (If so equipped)
7 Oil filter 22 Retainer ring (If so equipped)
8 Body A Inlet (from air compressor)
9 Valve body B Orifice
10 Valve spring C Outlet (dried air to air tank)
11 Piston D Inlet (from air tank)
12 Purge valve E Purged air
13 Pressure regulator F Dehumidification
14 Piston G Reclamation
15 Piston ring
COMPONENT LOCATOR
EN0680202D100003
SAPH068020200020
1 Bracket 10 Valve body

2 Chamber (purge tank) 11 Purge valve
3 Check valve 12 Silencer case
4 Desiccant case 13 Retainer ring
5 O-ring 14 Filter plate
6 Plate 15 Filter
7 Body 16 Silencer body (If so equipped)
8 Piston 17 Filter plate (If so equipped)
9 Valve spring 18 Filter (If so equipped)

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
EN0680202H200003

NOTICE
When disassembling the air dryer, never to disassemble the its
silencer body because its threaded portion is coated with lock
agent (Lock tight).
SILENCER
CASE
SILENCER
BODY
SAPH068020200014
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.
SAPH068020200021
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

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
SAPH068020200026
1 Connector 4 Valve spring

2 O-ring 5 Valve holder
3 Valve
COMPONENT LOCATOR
EN0680202D100004
SAPH068020200027
1 Connector 4 Valve spring

2 O-ring 5 Valve holder
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
DOUBLE CHECK VALVE

DATA AND SPECIFICATION
Type Piston type
DESCRIPTION
SAPH068020200031
1 Valve body 5 Plug

2 Valve A Outlet
3 Guide B Inlet
4 Gasket
COMPONENT LOCATOR
SAPH068020200032
1 Valve body 4 Gasket

2 Valve 5 Plug
3 Guide

A 34.3-44.1 {350-450, 25.3-32.5}
OVERHAUL
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".
SAPH068020200033
Valve and guide: — — Clean or replace, Visual check

Rust, wear and damage if necessary.
Valve body and plug: — — Clean or replace, Visual check

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
SAPH068020200036
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
SAPH068020200037
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
SAPH068020200038
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}
SAPH068020200039
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.
SAPH068020200040
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.
SAPH068020200041
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.
SAPH068020200042
5. REMOVE THE BRAKE VALVE ASSEMBLY.

ALIGNING MARK (1) Apply aligning marks on the brake valve assembly and pedal
bracket assembly.
SAPH068020200043

ALIGNING NOTICE
MARK
Before disassembling the brake valve, apply aligning marks on
the brake valve cover, primary valve body and secondary valve
body.
SAPH068020200044
ALIGNING MARK
SAPH068020200045
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.

SAPH068020200046
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
SAPH068020200047
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
must be removed.
DIMENSION
"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}
SAPH068020200048
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.
SAPH068020200044
ALIGNING MARK
SAPH068020200049
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
SAPH068020200050
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
SAPH068020200051
e. Drive in slowly the plunger. Measure the plunger stroke and

supply pressure at the point where the primary and second-
PLUNGER
ary 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. S4716-03311
PRESSURE
AIR TANK Measurement item Standard value
Plunger stroke 0.8-1.6 mm {0.0315-0.0629 in.}
19-41 kPa
Supply pressure
SECONDARY {0.2-0.4 kgf/cm2, 2.76-5.94 lbf/in.2}
SAPH068020200052
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
SUPPLY Parts No. S4716-03311
PLUNGER
AIR TANK Measurement item Standard value
Plunger stroke 3.6-4.7 mm {0.1418-0.1850 in.}
Supply pressure 196 kPa {2.0 kgf/cm2, 28.4 lbf/in.2}
SECONDARY
SAPH068020200053
g. Drive in further the plunger. Measure the plunger stroke and

supply pressure at the point where the primary and second-
PLUNGER
ary pressures increase rapidly. If the measurements do not
match with the standard values, replace each spring.
PRIMARY Parts No. S4716-03311
SUPPLY
PLUNGER
Measurement item Standard value
AIR TANK Plunger stroke 5.94-7.26 mm {0.2339-0.2858 in.}
SECONDARY
SAPH068020200054
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.
PRIMARY Parts No. S4716-03311
SUPPLY
PLUNGER
Measurement item Standard value
AIR TANK Plunger stroke 8.34-9.76 mm {0.3284-0.3842 in.}
SECONDARY
SAPH068020200055
(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": 147.7-157.7 mm {5.815-6.208 in.}
C
B
SAPH068020200056
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.
Tightening Torque:
LOCK NUT (Lock nut): 14-26 Nm {143-265 kgfcm, 11-19 lbfft}
PUSH ROD
BOOT
PLUNGER
SAPH068020200057
(3) Check the clearance between stop light switch and buffer.
STOP LIGHT SWITCH
"D": 0.5-1.5 mm {0.0197-0.0590 in.}
BUSHING
BUFFER
SAPH068020200058

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 length/ 176.5 N (Free
setting load {18 kgf, 39.68 lbf} length)
Sub spring: 21.6 mm {0.85 in.}/ 20.5 mm PRIMARY

Free length/ 21.6 mm {0.85in.}/ {0.81 in.}
setting length/ 9.8 N (Free
setting load {1.0 kgf, 2.20 lbf} length)
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.
Free length/ 16.5 mm {0.65 in.}/ (Free
setting length/ 95.1 N length)
setting load {9.7 kgf, 21.38 lbf}
Secondary: 43.2 mm PRIMARY
45.8 mm {1.80 in.}/ {1.70 in.}

16.0 mm {0.63 in.}/ (Free
4.9 N length)
{5.0 kgf, 11.02 lbf}
SECONDARY
Primary and secondary — — Replace, Visual check

piston: if necessary.
Wear and damage
SECONDARY PISTON PRIMARY PISTON
Primary and secondary — — Replace, Visual check

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.} if necessary.
Free length/ 12.5 mm {0.49 in.}/ (Free
setting length/ 52.0 N length)
setting load {5.3 kgf, 11.68 lbf}
PRIMARY
Secondary: 21.8 mm
22.8 mm {0.90 in.}/ {1.13 in.}
13.0 mm {0.51 in.}/ (Free
49.0 N length)
{5.0 kgf, 11.02 lbf} SECONDARY
Secondary valve body: — — Replace, Visual check

Primary valve body: — — Replace, Visual check

PROTECTION VALVE (FOR AIR SUSPENSION)

EN0680202I200006
Type Spring type

Open 637 kPa {6.5 kgf/cm2, 92.4 lbf/in.2}
Operating pressure
Close 510 kPa {5.2 kgf/cm2, 74.0 lbf/in.2}
DESCRIPTION
EN0680202C100007
SAPH068020200066
1 Valve body 5 Dust seal plate

2 O-ring 6 Retainer ring
3 Valve A Inlet
4 Compression spring B Outlet
COMPONENT LOCATOR
EN0680202D100006
SAPH068020200067
1 Body 4 Spacer 7 Dust seal plate

2 O-ring 5 Shim 8 Retainer ring
3 Piston 6 Spring 9 Dust seal
OVERHAUL
EN0680202H200005
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.
SAPH068020200068

EN0680202H300007
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 if necessary.
PROTECTION VALVE (WITH 4-WAY PROTECTION VALVE)

EN0680202I200008
Type Spring type (4-way protection)

Port 21, 22, 23 620-660 kPa {6.4-6.7 kgf/cm2, 89.93-95.72 lbf/in.2}
Open
Port 24 570-610 kPa {5.9-6.2 kgf/cm2, 82.67-88.47 lbf/in.2}
Opening pressure
Port 21, 22, 24 440-480 kPa {4.5-4.8 kgf/cm2, 63.82-69.61 lbf/in.2}
Close
Port 23 490-530 kPa {5.0-5.4 kgf/cm2, 71.07-76.87 lbf/in.2}
DESCRIPTION
EN0680202C100009
SAPH068020200071
1 Main 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
EN0680202D100008
8 3
4
9
5
10
11 6
7
12
13
11
10
SAPH068020200072
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 Main spring 10 Valve spring
NOTICE
The parts in 3, 9 and 11 are not the ones to be reusable.
OVERHAUL
EN0680202H200007
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
SAPH068020200073
ADJUSTMENT
EN0680202H300010
AIR LEAKAGE
1. CHECK VALVE
(1) By-pass check valve at No.1 side.
a. Confirm no leakage of air at inlet port, when applying air pres-
sure 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2} and 392 kPa {4 kgf/
cm2, 56.89 lbf/in.2} from outlet port No.21 and No.22.
SAPH068020200074
(2) Center check valve

a. Confirm no leakage of air at the outlet port No.21 and No.22,
when applying air pressure 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2}
and 980 kPa {10 kgf/cm2, 142 lbf/in.2} from the inspection
port.
SAPH068020200075
(3) Check valve at No.2 side

a. Confirm no leakage of air at the inspection port, when apply-
ing air pressure 49 kPa {0.5 kgf/cm2, 7.11 lbf/in.2} and 980
kPa {10 kgf/cm2, 142 lbf/in.2} from the outlet port No.23 and
No.24.
2. OTHER AIR TIGHTNESS

(1) When applying air pressure 0-980 kPa {0-10 kgf/cm2, 0-142 lbf/
in.2}, confirm that any leakage of air should be 0 cm3/min.
SAPH068020200076
PERFORMANCE CHARACTERISTIC
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 pressure,
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 pres-
sure, which should be pressure in the following table.
Opening valve pressure

620-660 kPa
Port No.23
{6.3-6.7 kgf/cm2, 89.61-95.29 lbf/in.2}
570-610 kPa
Port No.24
{5.8-6.2 kgf/cm2, 82.67-88.47 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 980 kPa {10 kgf/cm2, 142 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 closing
valve pressure, which should be 440-480 kPa {4.5-4.8 kgf/cm2,
64.01-68.27 lbf/in.2} (Port No.21, 22 and 24), and 490-530 kPa
{5.0-5.4 kgf/cm2, 71.07-76.87 lbf/in.2} (Port No.23).
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 3 seconds.
NOTICE
• Perform test again by increasing aims, when the respective
pressures is low and by decreasing it when high in the above
inspection.
• After inspecting, make sure to tighten the inspection port
securely.

EN0680202H300011
Unit: mm {in.}
Sliding surface and contact — — Replace, Visual check

surface of body: if necessary.
Wear and damage
Sliding surface and contact — — Replace, Visual check

surface of valve seat and if necessary.
piston:
Wear and damage
Main spring and valve spring: Main spring 137.3 N Replace, Measure and Visual check
Free length/ (Port 21, 22, 24): {14.0 kgf, if necessary.
Setting length/ 42.4 {1.67}/ 30.87 lbf}
Setting load 27.5 {1.08}/ (Setting load)
Crack, rust and damage 158.9 N
{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}
SPRING BRAKE CONTROL VALVE

EN0680202I200010
Type Variable pressure control type

Outlet pressure difference between parking and releas-
Within 147 kPa {1.5 kgf/cm2, 21.32 lbf/in.2}
ing stroke at a specified lever angle
DESCRIPTION
EN0680202C100011
SAPH068020200080
1 Body cover 11 Handle return spring

2 Feed valve spring 12 Pull rod
3 Piston 13 Knob
4 Feed valve 14 Compression spring
5 Valve seat 15 Release knob
6 Valve body 16 Handle body
7 Piston spring A Inlet
8 Valve spring B Outlet
9 Cam C Exhaust (PARK)
10 Cam holder
COMPONENT LOCATOR
EN0680202D100010
SAPH068020200081
1 Body cover 8 Valve spring

2 Shim 9 Valve seat
3 Piston spring 10 Handle body
4 Valve body 11 Stopper
5 Cam holder 12 Compression spring
6 O-ring 13 Knob sub assembly
7 Piston sub assembly 14 Pull rod

A 5.4-7.4 {55-75, 4.0-5.4} B 3.4-4.9 {35-50, 2.6-3.6}
OVERHAUL
EN0680202H200009

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
SAPH068020200082
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.
SAPH068020200083
(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
SAPH068020200084
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 980 kPa {10.0 kgf/cm2, 142 lbf/in.2} to the inlet line.
GAUGE
TANK
SAPH068020200085
(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:
Handle angle: Outlet pressure: kPa {kgf/cm2, lbf/in.2}
15 275 {2.8, 39.9}
35 441.6-500.4 {4.5-5.1, 64.0-72.6}
Over 42 980 {10.0, 142}
NOTICE
The characteristic shown is under the inlet pressure of 980 kPa
{10.0 kgf/cm2, 142 lbf/in.2}
SAPH068020200086
(3) Confirm the following functions.

a. The control handle is locked at PARK position.
b. The control handle automatically turn to OFF position when the
lever is released at PARK position.
980
DISCHARGE PRESSURE (kPa)
883
785
275 kPa
686
588 471 29.4 kPa
490
392
294
196
42
98
0
0 10 20 30 40 45 50 55
PARK 15 35
RELEASE
POSITION HANDLE ROTATION POSITION
ANGLE ( )
(AIR TANK PRESSURE: 980 kPa)
SAPH068020200087

EN0680202H300013
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, valve Piston spring 500.1 N Replace, Measure and visual check
spring and handle 27.9 {1.10}/ {51.0 kgf, 112.43 lbf} if necessary.
return spring: 25.0 {0.98}/ (Setting load)
Free length/ 553.1 N
Setting length/ {56.4 kgf, 124.34 lbf}
Setting load
Crack, rust and damage Valve spring 17.6 N
19.6 {0.77}/ {1.8 kgf, 3.96 lbf}
10.5 {0.41}/ (Setting load)
19.6 N
{2.0 kgf, 4.41 lbf}
VALVE SPRING
Handle return 6.9 N
spring {0.7 kgf, 1.55 lbf}
19.3 {0.76}/ (Setting load)
13.5 {0.53}/
7.8 N
{0.8 kgf, 1.76 lbf} PISTON SPRING
HANDLE RETURN
SPRING
Feed valve spring: — — Replace, Visual check

Rust and damage if necessary.
P_BR02_001_No tree.fm 47 ページ２０１２年５月３０日水曜日午後３時５５分
RELAY VALVE
(FOR SERVICE BRAKE) [MODELS: GD, GH, FM]
(FOR SPRING BRAKE) [MODELS: GH, FM]
EN0680202I200011
Type Diaphragm type

Pressure difference between signal and outlet pressure Max 20 kPa {0.20 kgf/cm2, 2.90 lbf/in2}
DESCRIPTION
EN0680202C100012
FOR SERVICE BRAKE FRONT (MODELS: GD, GH, FM)

FOR SPRING BRAKE (MODELS: GH, FM)
C C B
SAPH068020200092
1 Cover A Signal
2 Valve body B Inlet
3 Silencer C Outlet
4 Protection hose D Exhaust
5 Clamp band
P_BR02_001_No tree.fm 48 ページ２０１２年５月３０日水曜日午後３時５５分
Type Diaphragm type

Pressure difference between signal and outlet pressure 40-60 kPa {0.41-0.61 kgf/cm2, 5.80-8.70 lbf/in2}
DESCRIPTION
FOR SERVICE BRAKE REAR (MODELS: GH, FM)
C C B
4
3
SAPH068020200093
1 Cover A Signal
2 Valve body B Inlet
3 Silencer C Outlet
4 Protection hose D Exhaust
5 Clamp band
COMPONENT LOCATOR
EN0680202D100011
SAPH068020200094
1 Valve body with silencer 7 Cover

2 O-ring 8 Piston
3 Valve spring 9 Retainer ring
4 Valve 10 Piston spring (Rear relay valve)
5 Valve guide 11 Filter (Rear relay valve)
6 Valve seat

A 12-19 {123-193, 8.9-14}
OVERHAUL
EN0680202H200010

NOTICE
Before disassembling the relay valve, mark the aligning marks "A"
on the cover and valve body.
SAPH068020200095
1. LUBRICATION
(1) Apply WABCO grease to the sliding surfaces on each component
part and to the O-ring groove.
A: O-ring
B: Sliding surface
2. ALIGN THE COVER AND VALVE BODY.

(1) When assemble the cover and valve body, align the aligning
marks "A" which were applied at disassembly.
SAPH068020200096

EN0680202H300014
Valve: — — Clean or replace, Visual check

P_BR02_001_No tree.fm 52 ページ２０１２年５月３０日水曜日午後５時１８分
RELAY VALVE (FOR SERVICE BRAKE REAR) [MODEL: GD]

EN0680202I200012
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, 3.55-7.82 lbf/in.2}
DESCRIPTION
EN0680202C100013
SAPH068020200098
1 Cover 10 Plug
2 Diaphragm 11 Silencer
3 Valve body 12 Protection hose
4 Valve sub assembly 13 Clamp band
5 Valve cap
6 Spring A Signal
7 Valve B Outlet
8 Filter C Exhaust
9 Valve D Inlet
COMPONENT LOCATOR
EN0680202D100012
SAPH068020200099
1 Valve sub assembly 9 Valve

2 Cover 10 O-ring
3 Guide 11 Spring
4 Valve 12 Valve cap
5 Gasket 13 Clip
6 Plug 14 OSilencer
7 Filter 15 Pipe
8 Valve body 16 Dust cover

A 11.8-14.7 {120-150, 9-10} C 58.8-78.4 {600-800, 44-57}
B 49-58.8 {500-600, 36-43}
OVERHAUL
EN0680202H200011

NOTICE
Before disassembling the relay valve, mark the aligning marks "A"
on the cover and valve body.
SAPH068020200100
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
(3) When installing the cover to the body, align the aligning marks
which were applied at disassembly.
SAPH068020200101

EN0680202H300015
Check valve: — — Replace, Visual check

Cover, guide and plug: — — Clean or replace, Visual check

Damage, wear and rust if necessary.
Spring: 46 {1.81}/ 52.0 N Replace, Visual check

Free length/ 30 {1.18}/ {5.30 kgf, 11.69 if necessary.
Setting length/ 59.3 N lbf}
Setting load {6.05 kgf, 13.33 (Setting load)
Crack, rust and damage lbf}
Relay valve body and cap — — Clean or replace, Visual check

sliding surface: if necessary.
Damage, wear and rust
P_BR02_001_No tree.fm 56 ページ２０１２年５月３０日水曜日午後５時１８分
RELAY VALVE (FOR SPRING BRAKE) [MODEL: GD]

EN0680202I200013
Type Diaphragm type (with double check valve combined)

Pressure difference between signal and outlet pressure Less than 29.4 kPa {0.30 kgf/cm2, 4.26 lbf/in.2}
DESCRIPTION
EN0680202C100014
SAPH068020200106
1 Cover 10 Plug
2 Diaphragm 11 Silencer
3 Valve body 12 Protection hose
4 Valve sub assembly 13 Clamp band
5 Valve cap
6 Spring A Signal
7 Valve B Outlet
8 Filter C Exhaust
9 Valve D Inlet
COMPONENT LOCATOR
EN0680202D100013
SAPH068020200107
1 Valve sub assembly 9 Valve

2 Cover 10 O-ring
3 Guide 11 Spring
4 Valve 12 Valve cap
5 Gasket 13 Clip
6 Plug 14 OSilencer
7 Filter 15 Pipe
8 Valve body 16 Dust cover

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
EN0680202H200012

NOTICE
Before disassembling the relay valve, apply the aligning mark A to
the cover and body.
SAPH068020200108
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
(3) When installing the cover to the body, align the aligning marks
which were applied at disassembly.
SAPH068020200109

EN0680202H300016
Check valve: — — Replace, Visual check

Cover, guide and plug: — — Clean or replace, Visual check

Damage, wear and rust if necessary.
Spring: 46 {1.81}/ 52.0 N Replace, Visual check

Free length/ 30 {1.18}/ {5.30 kgf, 11.69 if necessary.
Setting length/ 59.3 N lbf}
Setting load {6.05 kgf, 13.33 (Setting load)
Crack, rust and damage lbf}
Relay valve body and cap — — Clean or replace, Visual check

sliding surface: if necessary.
Damage, wear and rust
SPRING BRAKE CHAMBER (MODEL: GD)

[FOR REAR BRAKE (WEDGE TYPE)]
EN0680202I200019
Type Spring and piston type brake chamber combined with diaphragm type chamber
DESCRIPTION
EN0680202C100020
SAPH068020200113
1 Elbow 4 Diaphragm
2 Clamp 5 Push rod assembly
3 Piggyback 6 Bracket
COMPONENT LOCATOR
EN0680202D100019
11
10
6
7
9
8
3
1
A
2
12
: Apply grease (Dynamax No.2: COSMO OIL CO., LTD product or equivalent).
SAPH068020200114
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
EN0680202H200018
1. DISASSEMBLY OF SPRING BRAKE CHAMBER

NOTICE
Piggyback is very dangerous because there is very strong spring
inside it. Never disassemble the piggyback.
SAPH068020200115
(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.
SAPH068020200116
(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.
SAPH068020200117
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.
SAPH068020200118
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.
SAPH068020200119
(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
SAPH068020200120
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.
SAPH068020200121
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.}

EN0680202H300022
Bracket, push rod, dia- — — Replace, Visual check

phragm and piggyback: if necessary.
Wear and damage
SPRING BRAKE CHAMBER (MODEL: FM)

[FOR FRONT BRAKE (S-CAM TYPE)]
EN0680202I200020
Spring and piston type brake chamber combined with diaphragm type chamber
Type
with breather tube
DESCRIPTION
EN0680202C100021
SAPH068020200123
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
(Service) - 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
EN0680202D100020
SAPH068020200125
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
EN0680202H200019
1. DISMOUNTING THE CHAMBER ASSEMBLY

(1) Before dismounting the chamber, turn the release bolt counter-
clockwise to release the spring brake.
(2) Apply a position mark R or L to make clear the side where the
chamber was installed.
SAPH068020200126

NOTICE
Before disassembling, put aligning marks to the clamp band, ser-
vice brake chamber, bulkhead and spring brake chamber.
SAPH068020200127
1. DISASSEMBLING THE SPRING BRAKE CHAMBER

(1) Remove the piston follower and then remove the dust cover,
spring pin and release bolt.
SAPH068020200128
(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)
SAPH068020200129
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
SAPH068020200130
2. ASSEMBLING THE SPRING BRAKE CHAMBER

(1) Attach guide bolts to align the holes.
NOTICE
Align the aligning marks of the spring brake chamber and bulk-
head.
SAPH068020200131
(2) Use a press or special tool to compress the spring then tighten
the chamber cover with the bolts.
SAPH068020200132
(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.
SAPH068020200133
(4) Install the piston follower on the piston.

NOTICE
Apply locking adhesive (LOCTITE 242 or equivalent) to the thread
of the piston follower.
SAPH068020200134
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.
SAPH068020200135
(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.
SAPH068020200136
(4) Turn the release bolt clockwise to release the spring of the spring
brake chamber.
SAPH068020200137

(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.
SAPH068020200138

(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.
S4785-02920/ -02930/ -02940/ -02950/
-03030/ -03040/ -04370/ -04380
SAPH068020200139
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.
SAPH068020200140
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.
SAPH068020200126
(2) After mounting, the release bolt must be set at the specified
torque.

EN0680202H300023

Piston: — — Replace, Visual check
Chamber: — — Replace, Visual check

Spring and compression spring: — — Replace, Visual check

SPRING BRAKE CHAMBER (MODELS: GH, FM)

[FOR REAR BRAKE (S-CAM TYPE)]
EN0680202I200021
Spring and piston type brake chamber combined with diaphragm type chamber
Type
with breather tube
DESCRIPTION
EN0680202C100022
SAPH068020200144
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
EN0680202D100021
SAPH068020200146
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
EN0680202H200020
1. DISMOUNTING THE CHAMBER ASSEMBLY

(1) Before dismounting the chamber, turn the release bolt counter-
clockwise to release the spring brake.
(2) Apply a position mark R or L to make clear the side where the
chamber was installed.
SAPH068020200147

NOTICE
Before disassembling, put aligning marks to the clamp band, ser-
vice brake chamber, bulkhead and spring brake chamber.
SAPH068020200148
1. DISASSEMBLING THE SPRING BRAKE CHAMBER

(1) Remove the piston follower and then remove the dust cover,
spring pin and release bolt.
SAPH068020200149
(2) Use a press or special tool to hold the spring in compression then
remove the chamber cover bolt.
SAPH068020200150
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
SAPH068020200151
2. ASSEMBLING THE SPRING BRAKE CHAMBER

(1) Attach guide bolts to align the holes.
NOTICE
Align the aligning marks of the spring brake chamber and bulk-
head.
SAPH068020200152
(2) Use a press or special tool to compress the spring then tighten
the chamber cover with the bolts.
SAPH068020200153
(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.
SAPH068020200154
(4) Install the piston follower on the piston.

NOTICE
Apply locking adhesive (LOCTITE 242 or equivalent) to the thread
of the piston follower.
SAPH068020200155
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.
SAPH068020200156
(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.
SAPH068020200157
(4) Turn the release bolt clockwise to release the spring of the spring
brake chamber.
SAPH068020200158

(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.
SAPH068020200159

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.}
S4785 -01890/ -01900/ -01971/ -01981/ -02530/
-02540/ -02551/ -02561/ -02570/ -02580/
-02590/ -02600/ -02650/ -02660/ -02670/
-02680/ -02720/ -02730/ -02810/ -02820/
-02830/ -02840/ -02850/ -02860/ -02870/
SAPH068020200160 -02880/ -02890/ -02900/ -02990/ -03000/
-03230/ -03240/ -04410/ -04420
: 52 mm {2.05 in.}
S4785 -02920/ -02930/ -02940
-02950/ -03030/ -03040
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.
SAPH068020200161
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.
SAPH068020200162
torque.

EN0680202H300024

Piston: — — Replace, Visual check
Chamber: — — Replace, Visual check

Spring and compression spring: — — Replace, Visual check

BRAKE CHAMBER (MODEL: GD)

[FOR FRONT BRAKE (WEDGE TYPE)]
Type Diaphragm type
DESCRIPTION
6 5
1 3 2 4
SAPH068020200166
1 Pressure plate 4 Push rod

2 Clamp ring 5 Base
3 Diaphragm 6 Push rod guide
SPECIAL TOOL
Prior to starting a brake chamber overhaul, it is necessary to have this special tool.
WEDGE CHAMBER STROKE

S0971-41030
TOOL
COMPONENT LOCATOR
SAPH068020200168
1 Pressure plate 8 Oil seal

2 Clamp ring 9 Tolerance ring
3 Diaphragm 10 Washer
4 Push rod 11 Guide
5 Base 12 Plate
6 Push rod guide 13 Bushing
7 Snap ring

A 25-30 {260-310, 18.8-22.4}
OVERHAUL

CLAMP RING
1. REMOVAL OF PRESSURE PLATE
MARK (1) Make a matching mark to base, clamp ring and pressure plate.
PRESSURE PLATE BASE

SAPH068020200169
(2) Mark clamp ring not to forget the inserting direction of clamp ring
bolt and remove clamp ring.
NOTICE
When removing clamp ring, do not expand the inserting portion of
clamp ring bolt by more than 80 mm {3.15 in.}.
DO NOT EXPAND MORE THAN 80 mm {3.15 in.}.

SAPH068020200170
(3) Remove pressure plate from base.
SAPH068020200171
2. REMOVAL OF DIAPHRAGM AND PUSH ROD

(1) Remove diaphragm and push rod from base.
NOTICE
• Push rod should be removed out, holding plate and repeating
to push and pull it straightly for a few times.
• When removing, push rod should not be pulled out up or
downward, toward right or left, not hammering from the
square flange side.
SAPH068020200172
3. REMOVAL OF PUSH ROD GUIDE

(1) Take out push rod guide out of the square flange.
NOTICE
When removing push rod guide, do not drop off a washer in it.
SAPH068020200173
4. REMOVAL OF GUIDE
(1) Remove snap ring, plate and oil seal with snap ring pliers.
NOTICE
Make sure not to jump out a snap ring.
(2) Remove guide, using a pipe having outer diameter of about 37
mm {1.46 in.} and tapping with plastic hammer by making the
square flange of base upside.
SAPH068020200174
5. DISASSEMBLY OF PUSH ROD GUIDE ASSEMBLY

(1) Remove bushing and tolerance ring from push rod guide.
TOLERANCE RING
NOTICE
WASHER • Keep it surely as washer in the push rod guide may be
BUSHING reused when assembling it.
• There is a case that tolerance ring may be in the fitting hole
at the tip of push rod, in case of which, pick it up with screw-
driver, etc.
PUSH ROD GUIDE
SAPH068020200175
1. INSTALLATION OF GUIDE, OIL SEAL AND PLATE

(1) Apply lightly grease (stored in the repair kit) at moving portion of
push rod guide on base.
NOTICE
Never fail to use the grease, stored in the "REPAIR KIT".
SAPH068020200176
(2) Facing the flat side of new guide to diaphragm side, insert it until it
RING TYPE SPRING RETAINER touches down to base by tapping lightly with stick having an outer
diameter of about 37 mm {1.46 in.} or box-socket.
NOTICE
• Confirm that ring type spring is installed on oil seal.
• Confirm that retainer is in its groove.
PLATE
OIL SEAL
GUIDE
SAPH068020200177
2. INSTALLATION OF PUSH ROD AND DIAPHRAGM

(1) Insert it to base by applying grease (stored in the "REPAIR KIT")
at the rod portion of push rod.
NOTICE
• Never fail to use grease, stored in the "REPAIR KIT".
• When installing push rod, make sure not to damage oil seal.
SAPH068020200178
3. INSTALLATION OF PRESSURE PLATE

(1) Putting pressure plate on base, align those matching marks.
SAPH068020200179
4. INSTALLATION OF CLAMP RING

(1) Matching clamp ring with the fitting mark, catch the both end at
bolt inserting portion of clamp ring with the vice gradually and
make its both end of ring come closer to approx. 15-20 mm {0.60-
0.78 in.} in the distance. After that, removing the vice, tighten tem-
MATCHING MARK
porally them toward inserting direction with the bolt and nut.
(2) Tap all periphery of clamp ring with plastic hammer and tighten
15-20 mm securely the nut. Repeat this 2-3 times for gradual tightening.
{0.60-0.78 in.} CATCH IT IN THE VICE.
SAPH068020200180
5. INSTALLATION OF PUSH ROD GUIDE

(1) Putting new bush into pushing rod guide, insert it deeply to base
SPECIAL TOOL
until push rod guide contacts with the internal hole of push rod
guide by special tool.
SST: Wedge Chamber Stroke Tool (S0971-41030)
NOTICE
In this case, do not install tolerance ring and washer.
THE SURFACE TO
CHECK THE DIMENSION
SAPH068020200181
(2) Under the status that the special tool remains pushed against
138 Unit: mm push rod guide, piling washers on the depression for adjustment
at the end-face of special tool and picking out one top washer
102.1
piled up, determine Max. quantity of washers, installable in the
30
internal diameter of base.
NOTICE
37
30
The washer quantity at this time is adjusted one for setting dimen-
sion of push rod guide. Accordingly, keep them securely.
13
THE SURFACE TO CHECK DIMENSION HINT

DEPRESSION FOR WASHER ADJUSTMENT • Do not mind to use the washers picked out in dismounting.
SAPH068020200182 • Target for washer quantity: 0-4 pcs.
• Washer thickness (1 pierce): 0.5 mm {0.02 in.}
(3) Picking out special tool and push rod guide for a while and install-
ing the washer of quantities determined in the above (3) and new
tolerance ring on push rod guide, insert it deeply with special tool
again until push rod guide contacts with the bottom.
NOTICE
• Be careful not to drop off the washers.
• After installing, confirm that, under the status that the spe-
cial tool remains pushed against push rod guide, the end-
face of base side is almost identical with the surface to check
setting dimension of special tool.
(4) Apply grease at the depression portion of push rod guide.
Using grease:
COSMO Heat-resistant grease B No.2 or equivalent
6. INSPECTION AFTER INSTALLATION

(1) When adding air of 700-800 kPa {7.2-8.2 kgf/cm2, 102-116 lbf/
SERVICE BRAKE PORT in.2} to service brake port, check that push rod moves smoothly.
(2) Make sure not to leak air from diaphragm.
SAPH068020200183
Pressure plate, clamp, — — Replace, Visual check

push rod, diaphragm and if necessary.
base:
Wear and damage
BRAKE CHAMBER (MODEL: GH)

[FOR FRONT BRAKE (S-CAM TYPE)]
EN0680202I200023
Type Diaphragm type
DESCRIPTION
EN0680202C100024
SAPH068020200185
1 Push rod 5 Diaphragm

2 Return spring 6 Chamber cover
3 Chamber A Inlet
4 Clamp B Drain hole
COMPONENT LOCATOR
EN0680202D100023
SAPH068020200186
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
EN0680202H200022
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.
SAPH068020200187
1. ASSEMBLING THE BRAKE CHAMBER

(1) Replace the diaphragm with new one.
(2) Align 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 the specified torque.
SAPH068020200188
2. CHECKING FOR AIR LEAKAGE

(1) Apply soapy water to the chamber as shown and charge with
compressed air of 830 kPa {8.5 kgf/cm2, 121 lbf/in.2} from the inlet
port A then check for leakage.
SAPH068020200189
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.
SAPH068020200190
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.

EN0680202H300026
Cover, clamp, push rod, — — Replace, Visual check

return spring and cham- if necessary.
ber:
Wear and damage
BRAKE CHAMBER (MODEL: FM)

[FOR REAR (REARWARD) BRAKE (S-CAM TYPE)]
EN0680202I200024
Type Diaphragm type
DESCRIPTION
EN0680202C100025
SAPH068020200192
1 Push rod 7 Diaphragm

2 Holder 8 Chamber cover
3 Dust seal 9 Retainer
4 Return spring A Inlet
5 Chamber B Drain hole
6 Clamp
COMPONENT LOCATOR
EN0680202D100024
SAPH068020200193
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
EN0680202H200023
1. DISMOUNTING OF THE BRAKE CHAMBER

(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.
SAPH068020200194
1. ASSEMBLING THE BRAKE CHAMBER

(1) Replace the diaphragm with new one.
(2) Align 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 the specified torque.
SAPH068020200195
2. CHECKING FOR AIR LEAKAGE

(1) Apply soapy water to the chamber as shown and charge with
compressed air of 830 kPa {8.5 kgf/cm2, 121 lbf/in.2} from the inlet
port A then check for leakage.
SAPH068020200196
3. INSTALLING CLEVIS
(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

SAPH068020200197 1. INSTALLING THE BRAKE CHAMBER
(1) The chamber must be mounted on the side as marked when dis-
mounting.
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.

EN0680202H300027
Cover, clamp, push rod, — — Replace, Visual check

return spring, if necessary.
retainer, dust seal, holder
and chamber:
Wear and damage
WHEEL BRAKE (WEDGE TYPE)

Drum brake with internally expanding, leading-trailing shoes operating by

Type
expander in all wheels.
Brake drum inside diameter 370 mm {14.57 in.} for both front and rear.
Brake lining Front 120 x 15 mm {4.72 x 0.59 in.}

Width x Thickness Rear 150 x 15 mm {5.9 x 0.59 in.}
DESCRIPTION
FRONT (MODEL: GD)
SAPH068020200199
1 Brake shoe return spring 7 Brake chamber

2 Expander 8 Brake lining
3 Brake shoe 9 Anchor pin retainer
4 Anchor pin 10 Lock plate
5 Brake spider A Front
6 Brake drum
REAR
SAPH068020200200
1 Brake shoe return spring 7 Spring brake chamber

2 Expander 8 Brake lining
3 Brake shoe 9 Anchor pin retainer
4 Anchor pin 10 Lock plate
5 Brake spider A Front
6 Brake drum
SPECIAL TOOL
Prior to starting a wheel brake overhaul, it is necessary to have these special tools.
S0968-31090 SPRING PULL BACK TOOL
S0942-02000 ANCHOR PIN PULLER

COMPONENT LOCATOR
FRONT
SAPH068020200203
1 Brake chamber 14 Rivet

2 O-ring 15 Brake lining
3 Hole plug 16 Retainer spring
4 Brake spider 17 Return spring pin
5 Anchor pin 18 Bushing
6 Anchor pin retainer 19 Wheel sensor
7 Lock plate 20 Clamping bushing
8 Brake shoe assembly (Leading) 21 Grommet
9 Brake shoe assembly (Trailing) 22 Wear indicator sensor
10 Expander 23 Clip
11 Brake shoe return spring 24 O-ring
12 Brake drum cover 25 Dust seal
13 Brake drum

A 20.1-33.9 {205-345, 14.9-24.9} D 20.1-33.9 {205-345, 14.9-24.9}
B 36.2-51.8 {369-528, 26.7-38.2} E 148-196 {1,520-2,000, 109-144}
C 14.1-23.9 {144-243, 10.4-17.6}
REAR
SAPH068020200204
1 Spring brake chamber 10 Expander 19 O-ring

2 O-ring 11 Brake shoe return spring 20 Seal
3 Hole plug 12 Brake drum cover 21 Wheel sensor
4 Brake spider 13 Brake drum 22 Clamping bushing
5 Anchor pin 14 Rivet 23 Holder
6 Anchor pin retainer 15 Brake lining 24 Grommet
7 Lock plate 16 Retainer spring 25 Wear indicator sensor
8 Brake shoe assembly (Leading) 17 Return spring pin 26 Clip
9 Brake shoe assembly (Trailing) 18 Bushing

A 36.2-51.8 {369-528, 26.7-38.2} D 34.5-51.5 {352-525, 25.5-37.9}
B 14.1-23.9 {144-243, 10.4-17.6} E 148-196 {1,510-1,998, 109-144}
C 20.1-33.9 {205-345, 14.9-24.9}
OVERHAUL
1. REMOVAL OF TIRE
(1) Refer to the chapter "WHEEL & TIRE".
2. REMOVAL OF BRAKE DRUM, WHEEL HUB AND WHEEL HUB

BEARINGS
(1) Refer to the chapter "FRONT AXLE" and "REAR AXLE".
3. COMPRESSION OF SPRING IN SPRING BRAKE CHAMBER

BY RELEASE BOLT
(1) Remove the release bolt, washer and release nut from the cham-
ber.
SAPH068020200205
(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
SAPH068020200206
(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 85 mm {3.346 in.}.
NOTICE
Do not turn the release nut at the strong torque (68.7 Nm {700
kgfcm, 51 lbfft} or more).
SAPH068020200207
4. REMOVAL OF BRAKE SHOE RETURN SPRING

(1) Using the special tool, remove the return spring.
(FRONT WHEEL)
SST: Spring pull back tool (S0968-31090)
SAPH068020200208
(2) Using the special tool, remove the outer return spring.
(REAR WHEEL)
SAPH068020200209
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.
SST: Anchor pin puller (S0942-02000)
SAPH068020200210
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.
SAPH068020200211
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
At this time, be careful not to scratch the brake shoe.
SAPH068020200212
b. After drilling, remove the remaining portion of the rivet with a

fine chisel or a riveting machine.
SAPH068020200213
(2) Install the brake lining to the brake shoe.

a. Set the lining on the shoe and insert the rivets into all holes,
then hold them in place with adhesive tape "A".
SAPH068020200214
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: 18.63-20.59 kN
{1,900-2,000 kgf}.
c. Remove adhesive tape.
ø15
ø8.5 +0.5
-0
ø6.5
60˚
2
45˚
0.75
R 0.2
R
1
SAPH068020200215
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.
SAPH068020200216
(2) Using a hexagon wrench, install the expander to the brake spider.
NOTICE
Pay attention to assembling way.
(3) Install the new O-ring and brake chamber to the brake spider.
SAPH068020200217
3. INSTALLATION OF BRAKE SHOE ASSEMBLY

(1) Apply adequate amount of heat resistance grease on the brake
shoe bushing, O-ring and anchor pin.
(2) Set the brake shoe assembly in place, then insert the anchor pins.
(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.
SAPH068020200218
4. INSTALLATION OF BRAKE SHOE RETURN SPRING

(1) Use the special tool to install the return spring.
NOTICE
The folded part of the spring cover must be placed in the upper
side.
SAPH068020200219
5. ASSEMBLY OF 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
1. The drums, 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.
SAPH068020200220
(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. (For JIS type wheel only)
Tightening Torque:
393-470 Nm {4,000-4,800 kgfcm, 290-347 lbfft}
SAPH068020200221

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:
SAPH068020200222 13.7-15.7 Nm {140-160 kgfcm, 10.2-11.5 lbfft}
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
1. REMAINING THICKNESS OF THE BRAKE LINING

(1) Check remaining thickness of lining through the inspection hole of
the brake drum cover. If the lining has been worn to the limit mark-
ing 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.
SAPH068020200223
2. AIR PRESSURE IN THE AIR TANK

(1) Operate the engine and obtain an air pressure of the 790-880 kPa
{8.0-9.0 kgf/cm2, 115-127 lbf/in.2}
NOTICE
The specified air pressure in the air tank should be maintained
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.
SAPH068020200224
(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.
(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.
SAPH068020200225 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.
SAPH068020200226
(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.
SAPH068020200225

Unit: mm {in.}
Brake drum: — — Regrind or Visual check

Cracks and damage replace, if
necessary.
Brake drum: 370 {14.567} 372 {14.645} 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, if Visual check

Cracks and damage necessary.
Brake lining: 15 {0.590} 5.0 {0.197} Replace. Measure

Thickness
Clearance between brake 0.082-0.165 0.165 {0.006} Replace the Measure

shoe bushing and anchor {0.003-0.006} brake shoe
pin bushing and/
or anchor
pin.
Brake shoe return spring — — Replace, if Visual check

and spring cover: necessary.
Damage, lacking elastic
strength distortion
WHEEL BRAKE (S-CAM TYPE)

EN0680202I200028
Drum brake with internally expanding, leading-trailing

Type shoes operating by cam shaft and slack adjuster in all
wheels.
Brake drum inside diameter 406.4 mm {16.0 in.} for both front and rear.
Front 127 x 15.5 mm {5.0 x 0.61 in.}

Model: GH
Brake lining Rear 203 x 15.5 mm {8.0 x 0.61 in.}
Width x Thickness Front 152 x 15.5 mm {6.0 x 0.61 in.}
Model: FM
Rear 216 x 15.5 mm {8.5 x 0.61 in.}
DESCRIPTION
EN0680202C100029
FRONT [MODEL: GH]
SAPH068020200234
1 Brake shoe return spring 9 Brake chamber bracket

2 Lubrication fitting 10 Brake chamber
3 Auto slack adjuster 11 Hole plug
4 Cam shaft 12 Brake shoe
5 Anchor pin 13 Brake lining
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)
SAPH068020200235
1 Brake shoe return spring 9 Brake chamber bracket

2 Lubrication fitting 10 Spring brake chamber
3 Auto slack adjuster 11 Hole plug
5 Anchor pin 13 Brake lining
6 Brake spider 14 Wheel sensor
7 Brake drum 15 Sensor ring
8 Brake drum cover A Front
REAR (MODEL: GH)
SAPH068020200236
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 Auto slack adjuster 14 Wheel sensor
7 Spring brake chamber 15 Sensor ring
8 Brake chamber bracket A Front
REAR (Frontward) (MODEL: FM)
SAPH068020200237
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 Auto slack adjuster 14 Wheel sensor
7 Spring brake chamber 15 Sensor ring
8 Brake chamber bracket A Front
REAR (Rearward) (MODEL: FM)
SAPH068020200238
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 Auto slack adjuster A Front
SPECIAL TOOL
EN0680202K100004
Prior to starting a wheel brake overhaul, it is necessary to have these special tools.
S0942-01510 ANCHOR PIN PULLER
S0968-41010 ANCHOR PIN TOOL

COMPONENT LOCATOR
EN0680202D100028
FRONT (MODEL: GH)
SAPH068020200242
1 Retainer ring 15 Retainer 29 Brake lining

2 Auto 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
10 Brake chamber bracket 24 Cam shaft 38 Spacer
11 Brake chamber 25 Collar 39 O-ring
12 Hole plug 26 O-ring 40 Wheel sensor
13 Brake drum cover 27 Bushing 41 Sleeve
14 Brake spider 28 Rivet

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)
SAPH068020200243
1 Auto slack adjuster 15 Retainer 29 Rivet

2 Pin 16 Lock plate 30 Brake lining
3 Spacer 17 Anchor pin 31 Spring hanger
4 Collar 18 Brake shoe assembly (Trailing) 32 Retainer ring
5 Plate 19 Brake drum 33 Seal
6 Brake chamber bracket 20 Spring cover 34 Roller
7 Pin 21 Brake shoe return spring 35 Brake shoe
8 Washer 22 Brake shoe assembly (Leading) 36 Bracket
9 Cotter pin 23 Cam shaft 37 Indicator
10 Clevis 24 Collar 38 Lock washer
11 Spring brake chamber 25 O-ring 39 Wheel sensor
12 Hole plug 26 Bushing 40 Sleeve
13 Brake drum cover 27 Lubrication fitting
14 Brake spider 28 Spacer

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}
REAR (MODEL: GH)
SAPH068020200244
1 Auto slack adjuster 18 Spacer 35 Sleeve

2 Bracket 19 Bushing 36 Lock washer
3 Thrust washer 20 O-ring 37 Holder
4 Collar 21 Collar 38 Spring hanger
5 Oil seal 22 Cam shaft 39 Rivet
6 Pin 23 Anchor pin 40 Brake lining
7 Bracket 24 Brake spider 41 Brake shoe
8 Cotter pin 25 Retainer 42 Rivet pin
9 Washer 26 Lock plate 43 Bushing
10 Spring brake chamber 27 Brake shoe assembly (Trailing) 44 Clamp
11 Pin 28 Spring hanger 45 Retainer ring
12 Brake chamber bracket 29 Brake shoe return spring 46 Pin
(Inner)
13 Plate 30 Brake shoe return spring 47 Seal
(Outer)
14 Brake drum cover 31 Spring cover 48 Roller
15 Hole plug 32 Brake shoe assembly (Leading) 49 Lock washer
16 Lubrication fitting 33 Brake drum 50 Indicator
17 Joint 34 Wheel sensor

A 109-147 {1,100-1,500, 80-108} D 168-226 {1,710-2,300, 124-166}
B 119-225 {1,200-2,300, 81-166} E 21-39 {200-400, 15-28}
C 34.5-51.5 {351-527, 26-38}
REAR (Frontward) (MODEL: FM)
SAPH068020200245
1 Retainer ring 19 Lock plate 37 Holder

2 Bracket 20 Brake shoe assembly (Trailing) 38 Lock washer
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 Auto slack adjuster 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
13 Cotter pin 31 Brake spider 49 Indicator
14 Pivot pin 32 Spacer 50 Spacer
15 Hole plug 33 Connector 51 Pin
16 Brake drum cover 34 Lubrication fitting 52 Plate
17 Anchor pin 35 Wheel sensor
18 Retainer 36 Sleeve

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)
SAPH068020200246
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 Auto slack adjuster 22 Lock plate 38 Retainer ring
7 Plate 23 Brake shoe assembly (Leading) 39 Pin
8 Bracket 24 Brake shoe return spring 40 Seal
(Inner)
9 Collar 25 Brake shoe return spring 41 Roller
(Outer)
10 Pin 26 Brake shoe assembly (Trailing) 42 Lock washer
11 Bushing 27 Spring hanger 43 Indicator
12 O-ring 28 Brake drum 44 Spacer
13 Spacer 29 Brake lining 45 Wheel sensor
14 Hole plug 30 Cotter pin 46 Sleeve
15 Brake drum cover 31 Washer 47 Holder
16 O-ring 32 Clamp 48 Lock washer

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}
OVERHAUL
EN0680202H200027
1. REMOVAL OF TIRE
2. REMOVAL OF BRAKE DRUM WITH WHEEL HUB AND WHEEL

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).
SAPH068020200247
(2) Turn the pivot pin and pull out the spring hanger then remove the
return spring, inner (REAR WHEEL).
SAPH068020200248
4. REMOVAL OF ANCHOR PIN

(1) Using the special tool, remove the pin and the brake shoe assem-
bly.
SST: Anchor pin puller (S0942-01510)
SAPH068020200249
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.
SAPH068020200250
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
At this time, be careful not to scratch the brake shoe.
SAPH068020200251
b. After drilling, remove the remaining portion of the rivet with a

fine chisel or a riveting machine.
SAPH068020200252
(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.
SAPH068020200253
a. Set the lining on the shoe and insert the rivets into all holes,
then hold them in place with adhesive tape "A".
SAPH068020200254
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.
SAPH068020200255
2. 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.
SAPH068020200256
3. 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.
SAPH068020200257
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.
SAPH068020200258
(3) Apply adequate amount of chassis grease on the O-ring, oil seal
and busing before installing the cam shaft.
(4) If the clearance 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.
SAPH068020200259
(5) 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.
(6) If the clevis pin-hole and auto slack adjuster pin-hole are mis-
aligned, turn the set screw of auto slack adjuster for clockwise.
SAPH068020200260
(7) Rotate by hand, the control arm as for as possible in the direction
of the arrow on the adjuster point.
(8) Make sure that clearance between set bolt and control arm is cor-
rect, and tighten the nut.
SAPH068020200261
(9) 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).
SAPH068020200262
5. INSTALLATION OF BRAKE SHOE ASSEMBLY

(1) Apply adequate amount of heat resistance grease on the bushing
of the brake shoe.
(2) Set the brake shoe assembly in place, then insert the anchor pins.
SAPH068020200263
(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)
SAPH068020200264
(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.
SAPH068020200265
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.
SAPH068020200248
(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.
SAPH068020200266
7. 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 bushing 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.
SAPH068020200267
(3) Arrange the wire harness.
SAPH068020200268
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.
With R: Install in right side.
With L: Install in left side.
• The drums, with no R or L.
New drums: Install in any side.
Reused drums: Install in the side originally installed.
SAPH068020200269
(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).
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
EN0680202H300032
1. REMAINING THICKNESS OF THE BRAKE LINING

(1) Check remaining thickness of lining through the inspection hole of
the brake drum cover. If the lining has been worn to the limit mark-
ing 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.
SAPH068020200270
2. AIR PRESSURE IN THE AIR TANK

(1) Operate the engine and obtain an air pressure of the 690 kPa {7.0
kgf/cm2, 99.54 lbf/in.2}
NOTICE
The specified air pressure in the air tank should be maintained
when making the adjustment.
SAPH068020200271
3. ADJUST THE BRAKE CHAMBER STROKE

(1) Lift the wheel to be adjusted off the ground.
(2) Turn the set screw clockwise until the brake lining slightly contacts
the drum, and then turn back the screw by 1. With this, the brake
chamber stroke will become approx. 55 to 60 mm {2.166 to 2.362
in.} under the air pressure of 690 kPa {7.0 kgf/cm, 99.54 lbf/in.2}.
NOTICE
In the case of spring brake chamber, set the spring brake control
valve to the "OFF" position.
SAPH068020200272
(3) Final adjustment after completion of vehicle building up start the

engine, and push in the brake pedal repeatedly. That is, first push
in the pedal lightly and rapidly with rather long interval, and later
do it deeply and slowly in proportion to decreasing of the chamber
stroke amount. The set screw and the indicator automatically
rotate at the initial pushing-in actions. By repetition of pushing-in,
however, the chamber stroke gets close to a steady value, the set
screw and the indicator coming to stop rotating. In case that the
set screw has been adjusted by 1 back turn as the above (2), the
chamber stroke will become certain steady value after repetitive
pushing of approx. 50 times.
SAPH068020200273
(4) Depress the brake pedal fully and measure the brake chamber
push rod stroke "A".
Repair limit: Brake chamber: 40 mm {1.57 in.}
Spring brake chamber: 45 mm {1.77 in.}
SAPH068020200274
(5) Make sure that there is no dragging, when turning the wheel by
hand. If there is any dragging, repeat the operation over again
from (2).
NOTICE
In accordance with the same procedure as above, adjust the
stroke for all wheels.
SAPH068020200275

EN0680202H300033
Unit: mm {in.}
Slack adjuster body: — — Replace, Visual check

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
EN0680202C100031
SAPH068020200289
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
EN0680202D100030
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).
SAPH068020200294
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
EN0680202H200029
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.
SAPH068020200295
(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.
SAPH068020200296
(5) Remove the screw and then remove the sleeve assembly.
SAPH068020200297
(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.
SAPH068020200298
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.}
SAPH068020200299
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})

SAPH068020200300
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
SAPH068020200301 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
SAPH068020200299 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.
SAPH068020200302
(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.
SAPH068020200298
(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.
SAPH068020200297
(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)
SAPH068020200303
(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.
SAPH068020200304
(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.
SAPH068020200305

EN0680202H300035
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 mm {0.45 in.} 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 mm 29.8 lbf}
{4.17 in.}
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}
WHEEL BRAKE SLACK ADJUSTER (AUTO ADJUSTER)

(MODELS WITH S-CAM TYPE BRAKE)
DESCRIPTION
EN0680202C100032
SAPH068020200310
1 Body 5 Worm gear

2 Worm shaft 6 Holder
3 Front retainer 7 Control arm
4 Lubrication fitting 8 Rear retainer
SPECIAL TOOL
EN0680202K100006
Prior to starting an auto slack adjuster overhaul, it is necessary to have this special tool.
S0963-02350 SPECIAL PARTS ASSEMBLY
COMPONENTS IN THE SPECIAL PARTS ASSEMBLY
Illustration Tool name Remarks
PEG SPANNER
SPACER
END LOAD TESTER
GREASE TOOL
IMPACT SCREWDRIVER
DRIVER TIP
TORX SCREWDRIVER
MANDREL
Illustration Tool name Remarks
THICKNESS GAUGE
CONTROL ARM BUSHING

INSTALLATION TOOL
UNIVERSAL SPLINE KEY
DIAL GAUGE
HEXAGONAL WRENCH
COMPONENT LOCATOR
EN0680202D100031
SAPH068020200325
1 Rear retainer 10 Spring 19 Worm gear

2 Spring 11 Inner cap 20 O-ring
3 Thrust washer 12 Thrust bearing 21 Gasket
4 Body 13 Front retainer 22 Holder
5 Bushing 14 Spring 23 Rivet
6 Worm shaft 15 Spring 24 Plug
7 O-ring 16 Plug 25 Torx screw
8 Bearing 17 Rack 26 Lubrication fitting
9 Drive gear 18 O-ring

A 50 {510, 37} D TYPE-A: S4748-01471/ -01791,
S4749-01031/ -01181:
B 50 {510, 37} 3.92-9.81 {40-100, 2.90-7.23}
C 4 {41, 2.96} TYPE-B: S4748-01631/ -01641/ -01801/ -01811
9.81-29.4 {100-300, 7.24-21.69}
OVERHAUL
EN0680202H200030
1. REMOVING THE AUTO SLACK ADJUSTER

(1) Remove the auto slack adjuster from the wheel brake.
2. DISASSEMBLING OF RACK AND SPRING SECTION

(1) Remove the six torx screws with the special tool.
NOTICE
When the torx screws have been tightened strongly, use the spe-
cial impact screwdriver and a hammer.
SST: Special parts assembly (S0963-02350)
• Torx screwdriver
• Impact screwdriver
(2) Remove the holder and the gasket.
SAPH068020200326
(3) Remove the rack using a screwdriver.
SAPH068020200327
(4) Push and shrink the spring with a screwdriver and bring a tapping
rod into contact with the plug.
(5) Remove the plug using a tapping rod and hammer.
(6) Remove the spring.
SAPH068020200328
3. DISASSEMBLING OF WORM SHAFT AND WORM GEAR SEC-

TION
(1) Loosen the rear retainer in counterclockwise direction with a hex-
agonal wrench to remove it.
(2) Remove the spring and the thrust washer.
SAPH068020200329
(3) Turn the front retainer in counterclockwise direction using the spe-
cial tool to remove it.
NOTICE
When the retainer has been tightened strongly, use the special
impact screwdriver and a hammer.
• Peg spanner
• Impact screwdriver
SAPH068020200330
(4) Remove the thrust bearing, the O-ring, the inner cap, the spring
and the drive gear.
SAPH068020200331
(5) Install the special tool mandrel and the special tool spacer.
• Mandrel
• Spacer
SAPH068020200332
(6) Using a vice, turn it slowly until the bearing and the worm shaft
are removed.
(7) Remove the bearing and the worm shaft.
SAPH068020200333
(8) Remove the worm gear.

(9) Remove the O-ring from the outer surface of the worm gear.
SAPH068020200334
4. CLEANING OF EACH PART

(1) Clean each part shown in the figure.
SAPH068020200335

NOTICE
At the time of assembly, apply a sufficient amount of grease
(Alexol RCF2, made by AB Axel Christiernsson or equivalent or
LITHIUM/CALCIUM-basis with EP additives viscosity NLG12) to
each part.
1. ASSEMBLING OF WORM SHAFT AND WORM GEAR SEC-

TION
(1) Apply grease (Alexol RCF2, made by AB Axel Christiernsson or
equivalent or LITHIUM/CALCIUM-basis with EP additives viscos-
ity NLG12) to the inside of the body and to the entire worm gear.
(2) Install O-rings on both sides of the worm gear and insert the
worm gear with the projecting part to the front into the body.
SAPH068020200336

ity NLG12) to the worm shaft and the bearing.
(4) Install them with the hexagonal adjustment part to the front from
the front retainer direction all the way to the inside.
SAPH068020200337
(5) Insert the special tool until it comes into contact with the bearing.
• Mandrel
(6) Install the worm shaft and bearing by using a vice to press-fit
them completely.
SAPH068020200338
(7) Use a wrench to turn the worm shaft about 22 times, and confirm
smooth rotation of the worm shaft and the worm gear.
NOTICE
The worm gear performs approximately one revolution when the
worm shaft is turned 22 times.
SAPH068020200339
(8) Assemble the inner cap, the spring and the drive gear.
ity NLG12) to the parts assembled in step (7) and to the O-ring,
the thrust bearing, and the front retainer. Then install them in
sequence from the front retainer direction.
SAPH068020200340
(10) Install the body in a vice and tighten the front retainer using the
special tool and a torque wrench.
NOTICE
Do not use an impact wrench.
• Peg spanner
Tightening Torque:
50 Nm {510 kgfcm, 37 lbfft}
(11) Use a wrench to confirm smooth rotation of worm shaft and worm
SAPH068020200341 gear.
(12) Insert the special tool dial gauge into the rear retainer and insert
the special tool universal spline key into the worm gear spline sec-
tion.
• Dial gauge
• Universal spline key
(13) Turn the special tool universal spline key to the left and right and
measure the play of the worm shaft indicated by the dial gauge.
Play: 0.15-0.60 mm {0.0060-0.0236 in.}
(14) Replace the body if the play is outside the standard range.
SAPH068020200342
2. ASSEMBLING OF THE RACK AND SPRING SECTION

ity NLG12) to the spring and the rack and install them to the body.
SAPH068020200343
(2) Install the rack using the special tool while pushing the spring.
Visually confirm that the rack and the spring are fitted as shown in
the figure.
• Universal spline key
SAPH068020200344
(3) Use a tapping rod and hammer to close the opening with a new
plug.
NOTICE
Pay attention to the direction of the plug.
SAPH068020200345

ity NLG12) to the thrust washer, the spring, and the rear retainer
and install them.
NOTICE
Pay attention to the direction of the thrust washer.
SAPH068020200346
(5) Using an hexagonal wrench, tighten the rear retainer about four
turns in the clockwise direction.
NOTICE
Do not use an impact wrench.
SAPH068020200347

ity NLG12) to the gasket, and then install it together with the
holder in the body.
NOTICE
Confirm that the notch of the holder matches the claw of the rack.
(7) Tighten the torx screws.
Tightening Torque:
4 Nm {41 kgfcm, 3 lbfft}
(8) Install the lubrication fitting.

SAPH068020200348
3. GREASE FILLING
(1) Use a grease gun to apply grease until it escapes through the
holder gap.
SAPH068020200349
1. INSPECTION OF THE SLACK ADJUSTER ASSEMBLY

(1) Fix the special tool end load tester to a vice with a width of at least
215 mm {8.465 in.}
(2) Apply the special tool hexagonal wrench to the rear retainer and
fix it to the special tool end load tester.
• End load tester

• Hexagonal wrench
SAPH068020200350
(3) Secure the body, and confirm at this time that the gauge indicator
is in the condition shown in the figure.
SAPH068020200351
(4) Confirm that the control arm part of the holder can be moved for-
ward and back by hand.
(5) Push the control arm part of the holder with your thumb lightly in
the direction of the rear retainer. Turn the vice in clockwise direc-
tion and confirm that the control arm part of the holder moves in
the direction of the rear retainer within the specified range of the
gauge indicator. Or confirm that the control arm of the holder
moves lightly.
Specified value: 3,530-3,730 N {360-380 kgf, 794-837 lbf}
SAPH068020200352
(6) If the control arm part of the holder moves outside the range of
3,530-3,730 N {360-380 kgf, 794-837 lbf} of the gauge indicator,
adjust assembly by tightening or loosening the special tool hexag-
onal wrench with a spanner.
Under 3,530 N {360 kgf, 794 lbf}: Turn in clockwise direction
Over 3,730 N {380 kgf, 837 lbf}: Turn in counterclockwise
direction
(7) For confirmation of correct assembly, again perform the inspec-

tion after assembly.
SAPH068020200353
2. FINISHING THE INSPECTION

(1) Use a punch and a hammer to drive the rivet into the retainer.
(2) Confirm the inner diameter of the bushing and use a vice to press-
fit it into the body.
NOTICE
Confirm the inner diameter of the bushing as the repair kit con-
tains several types of bushings.
SAPH068020200354
(3) Remove the used plug and use the special tool to install a new
plug.
• Control arm bushing installation tool
SAPH068020200355

EN0680202H300036
Unit: mm {in.}
Inner diameter of the body — 62.20 Replace. Measure.
{2.4488}
Gap between worm shaft and body — 0.25 Replace the Measure.
(at the time of inspection, a new {0.0098} body.
worm shaft should be used) using
special thickness gauge
Outer diameter of the worm gear — 61.87 Replace. Measure.

{2.4358}
Holder gear part — 0.40 Replace. Measure.

{0.0157}
Holder gear part: — — Replace, Visual check

No play if necessary.
Body: — — Replace, Visual check

No traces of scuffing on the inside if necessary.

Worm gear: — — Replace, Visual check
No uneven wear on the outside if necessary.
Worm gear: — — Replace, Visual check

No damage to the spline part if necessary.
ABS & ASR (WABCO MAKE) BR03–1
BR03 ABS & ASR (WABCO MAKE) BR03-001
ABS ...........................................................BR03-2
OVERVIEW...................................................... BR03-2
COMPOSITION AND OPERATION ................. BR03-4
FUNCTION ...................................................... BR03-7
OVERVIEW AND FUNCTION.......................... BR03-7
ASR .........................................................BR03-12
OVERVIEW.................................................... BR03-12
COMPOSITION AND OPERATION ............... BR03-14
OVERVIEW AND FUNCTION........................ BR03-17
FRONT WHEEL BRAKE.........................BR03-20

OVERHAUL ................................................... BR03-21
REAR WHEEL BRAKE...........................BR03-25

OVERHAUL ................................................... BR03-26
BR03–2 ABS & ASR (WABCO MAKE)
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.
1. BRAKING ON SLIPPERY CURB ROAD SURFACE.

• Once vehicle not equipped with ABS device locked on slippery curb road by applying brake, the vehicle direction will
be lost although attempting to steer correctly and skid off the course.
VEHICLE NOT EQUIPPED

WITH ABS
VEHICLE EQUIPPED
WITH ABS
SAPH06Z080300001
2. BRAKING ON ROAD SURFACE WITH DIFFERENT FRICTION COEFFICIENT ON LH AND RH PART (RORD
SURFACE COMPOSED OF A SLIPPERY SURFACE ON ONE SIDE AND NOT SLIPPERY ONE ON ANOTHER).
• When vehicle not equipped with ABS device applying brake, a wheel on a side of slippery road surface will be locked
earlier than another one on not slippery surface.
• One the wheel locked, braking will not be effective, which means braking application on only one side. And the steer-
ing will be lost and spun some times.
VEHICLE NOT
EQUIPPED WITH ABS
NOT SLIPPERY ROAD SURFACE

VEHICLE EQUIPPED
(SUCH AS DRY ROAD, ETC.).
WITH ABS
SAPH06Z080300002
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
6 2
3 7 2 6
FROM 3
AIR TANK
4
5
4
8 8
4 FROM AIR TANK
3
3
6 2 6
2
AIR CIRCUIT ABS/ASR SECTION

ELECTRICAL CIRCUIT
BRAKE SECTION
SAPH06Z080300003
1 Brake valve 5 ABS/ASR ECU

2 Wheel brake 6 Wheel sensor
3 Brake chamber 7 ABS warning light
4 ABS control valve 8 Relay valve
ABS CONTROL FLOWCHART
INPUT SIGNAL ABS ECU OUTPUT SIGNAL
Front left wheel sensor ABS control valve for

front left wheel
Front right wheel sensor ABS control valve for

front right wheel
ABS control function
(ABS control valve control ABS control valve for

Rear left wheel sensor function) rear left wheel
ABS control valve for

Rear right wheel sensor
rear right wheel
ASR control function
Exhaust brake cut relay

Exhaust brake control
function
Malfunction code
Malfunction diagnostic (diagnostic code)
function
Switches off ABS to allow

normal brake operation
Fail-safe function
(safety function)
ABS warning light
SAPH06Z080300004
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.
Slip ratio = Vehicle's speed- Wheels rotational speed
x 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-
1 NON-SLIPPERY
tion coefficient of the tires and of the road surface and the slip
FRICTION COEFFICIENT
ROAD SURFACE
ratio.
BETWEEN TIRES AND
• In an ABS-equipped vehicle, the brake force is controlled to

ROAD SURFACE
ensure that it is within the range where the friction coefficient is

high (shaded portion of the graph) without locking the wheels.
SLIPPERY ROAD This ensures efficient braking performance.
SURFACE
0 50 100
SLIP RATIO
SAPH06Z080300005
OPERATION
OUTLET AIR PRESSURE WHEEL DECELERATION SPEED
1. The ABS control characteristics line graph at left illustrates how

the vehicle's speed, the wheels' rotational speed, the wheel accel-
VEHICLE'S SPEED 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'
WHEEL'S ROTATIONAL
rotational speed drop and at the same time, the wheel accelera-
SPEED 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
ABS CONTROL VALVE
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.
T1T2 T3 T4 T5 4. At point T5, the wheels' rotational speed and the vehicle's speed
TIME
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.
SAPH06Z080300006 5. The above processes is repeated over and over until the vehicle
comes to a complete stop.
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 sub brake while ABS is operating.
• If the sub brake is applied independently or together with the service brake on a road surface with very low friction
coefficient, the driving wheels may lock. This ABS system prevents the driven wheels from locking in such cases by
automatically releasing the sub brake, if necessary, during ABS operation.
CLUTCH ACCELERATOR EXHAUST

SWITCH PEDAL SWITCH BRAKE SWITCH
+ 24V
EXHAUST BRAKE MAGNETIC VALVE
+ 24V
EXHAUST BRAKE CUT RELAY ABS/ASR ECU
SAPH06Z080300007
OVERVIEW AND FUNCTION

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.
SAPH06Z080300008
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.
SAPH06Z080300009
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
SAPH06Z080300010
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
VALVE OPERATING STATUS
10 (5), passes through outlet port (9), and flows into the brake
9
chamber. At this point, solenoid coil (1) is not energized, so
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
1
up diaphragm (11) and closes exhaust valve (13).
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
SAPH06Z080300011
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.
2
4
15 11 12

ON
STATUS
valve 3

ON
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SAPH06Z080300012
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
SAPH06Z080300013
3. WHEEL SENSORS
WHEEL SENSOR
• These sensors are mounted, facing the sensor rings on each
SENSOR RING 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.
FRONT
SAPH06Z080300014
SAPH06Z080300015
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.
FOR FRONT FOR REAR
SAPH06Z080300016
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.
SAPH06Z080300017
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.
SAPH06Z080300018
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 goes 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 {4.3-6.2 mile/h}.
• Then, note that even when the warning light is lit, the ABS system,
unaffected by the malfunction, continues to operate. Also, the
SAPH06Z080300019
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 sub brake is
shut down, and the sub brake is released.
ASR
OVERVIEW
EN06Z0803C100005
1. ASR
• ASR, when a torque is loaded on the driving wheels on the slippery road, is a device to serve for steady starting,
acceleration, straight line drive-ability and turning stability by controlling properly a slip rate between tires and road
surface.
• By maintaining a driving force of the driving wheels, it serves for vehicle stability and prevents from fishtailing when
accelerating.
• With a driving performance corresponding to the change of friction force between tires of driving wheels and road
surface, it serves to improve the starter-ability and the acceleration performance.
2. STARTING AT SLIPPERY CLIMBING SLOPE, SNOWY ROAD AND ROAD WHOSE FRICTION RATE IS DIFFER-
ENT IN LH AND RH.
• When the vehicle nit equipped with ASR starting on the slippery climbing slope, snowy road or a road whose friction
rate is different in LH and RH by loading an excessive torque on the wheels, a possibility is that smooth starting can
not be made due to the wheel spinning.
• The comparison of starter-ability by vehicle with ASR device or without it, will be listed below:

WITH ASR
Once the wheels spun, the case is that driving wheels are caught on snowy
roads and sinking into the snow.
VEHICLE EQUIPPED
WITH ASR
When one side of driving wheels spinning, it will serve for smooth starting by
applying a brake to the spinning wheel automatically and limiting differential
gear action of rear axle.
When both sides of driving wheels spinning, it will work to start smoothly by
controlling automatically engine output to be reduces and driving wheels not
to be spun.
SAPH06Z080300020
3. CURB WITH SLIPPERY ROAD SURFACE.

• When the model not equipped with ASR running at the curb of slippery road with a load on the driving wheels and
spins them, the driving wheels may slip, which will cause a fishtailing and skid off the course.
• Comparison of steering stability between vehicles with ASR device and without it, will be listed below.
Fishtailing

WITH ASR
The vehicle will go out of course.
VEHICLE EQUIPPED Going out

WITH ASR of course.
The vehicle will turn a curb by controlling
engine output not to spin the driving wheel
and not to make a fishtailing.
SAPH06Z080300021
COMPOSITION AND OPERATION

EN06Z0803C100006
• The system of ASR is composed of ECU for ABS/ASR, which will output controlling signal of proper braking force and
engine speed (rpm) by using sensor ring, wheel sensor and ABS control valve in common with ABS, ASR valve
which brakes LH and RH driving wheels by controlling signal, ASR indicator light to show its system operation and
piping, wire harness to connect those units.
• Once vehicle begins to run, LH and RH driving wheels speed will be monitored in comparison with that of front
wheels. When one side of driving wheels starts to spin and exceeds a limit value of slip rate, immediately ABS/ASR
ECU will control ASR valve and ABS control valve to apply a brake (Differential Brake) on the spinning wheel.
• When traction force not recovering regardless of the differential brake applied, it will send more signal to engine ECU
to reduce engine output and to prevent a slip of driving wheels.
• When LH and RH driving wheels slipping, immediately ABS/ASR ECU will send its signal to engine ECU to reduce
engine output and to prevent the slip of driving wheels.
• When you want to stop the operation of ASR intentionally during maintenance service, etc., ASR cut switch is avail-
able for it.
SYSTEM COMPOSITION DIAGRAM
ENGINE
ECU
SUPPLY PUMP
1
2 FROM AIR TANK

6
3 7 8 2 6
9
FROM AIR TANK 3
12 4
5
4 10
11 11
4 FROM AIR TANK
3
3
6 2 6
2
AIR CIRCUIT ABS SECTION ABS/ASR SECTION

ELECTRICAL
ASR SECTION BRAKE SECTION
CIRCUIT
SAPH06Z080300022
1 Brake valve 7 ABS warning light

2 Wheel brake 8 ASR indicator light
3 Brake chamber 9 ASR valve (Differential brake control valve)
4 ABS control valve 10 Double check valve
5 ABS/ASR ECU 11 Relay valve
6 Wheel sensor 12 ASR cut switch
ABS/ASR CONTROL FLOWCHART
INPUT SIGNAL ABS/ASR ECU OUTPUT SIGNAL

Front left wheel sensor
front left wheel

Front right wheel sensor
ABS control function front right wheel
(ABS control valve control

Rear left wheel sensor function) ABS control valve for
rear left wheel

Rear right wheel sensor
rear right wheel
ASR control function ASR valve
Differential brake
ASR indicator light
control
ASR OFF indicator light
ASR cut switch

Engine control
Engine ECU
Sub brake control Sub brake cut relay

function
Malfunction diagnostic Malfunction code

function (diagnostic code)
Switches off ABS to allow

normal brake operation
Fail-safe function
(safety function)
ABS warning light
SAPH06Z080300023
BASIC PRINCIPLE
• ASR, by monitoring a speed difference (Driving wheel slipping) between that of front wheels and of rear driving
wheels and another speed difference (One side spinning) between that of LH and RH driving wheels through wheel
sensor while vehicle starting, running and accelerating, will control engine or make differential brake control when the
slip rate exceeds the standard Value.
Differential brake control Engine control
One side of driving wheels slipping. To be controlled. Not controlled.
Both sides of driving wheels slipping. To be controlled. To be controlled.
OPERATION
1. DIFFERENTIAL BRAKE CONTROL

• When one side of driving wheels slips and exceeds T2, ABS/ASR ECU will control ASR valve and ABS control valve
to apply brake on the slipping wheel. When the slip rate becomes T3, within the standard valve, the brake will be
released.
REAR RH WHEEL REAR LH WHEEL

SLIP
SPEED
DESIGNATED SLIP RATE
VEHICLE SPEED
PRESSURE
BRAKE CHAMBER ON REAR RH WHEEL
T1 T2 T3 T4
SAPH06Z080300024
2. ENGINE CONTROL
• When both LH/RH sides of driving wheels slipping and exceeding T2, ABS/ASR ECU will work to CAN communica-
tion to reduce engine revolution speed, regardless of acceleration pedal.
When the slip rate comes back to T3, within standard value, CAN communication will be stopped and the engine rev-
olution corresponding to acceleration pedal depression volume will be recovered.
REAR RH WHEEL
SLIP
SPEED
DESIGNATED SLIP RATE
VEHICLE SPEED
REAR
REVOLUTION
ACCELERATOR PEDAL DEPRESSION

INJECTION VOLUME OF SUPPLY PUMP
ENGINE
T1 T2 T3 T4
SAPH06Z080300025
OVERVIEW AND FUNCTION

EN06Z0803C100007
1. ASR VALVE (DIFFERENTIAL BRAKE CONTROL VALVE)

1. OVERVIEW
• ASR valve (Differential brake control valve) is installed between ABS control valve of driving wheels and air tank.
Double check valve is installed at side of ABS control valve, to which ASR valve send air regardless of accelerating
pedal depression by signal from ABS/ASR ECU.
• Brake chamber air pressure of slipping driving wheels is adjusted through ABS control valve and controlled until slip-
ping is stopped.
FROM AIR TANK

INLET PORT4
ABS CONTROL VALVE
RELAY VALVE
VALVE 1
OUTLET TO BRAKE
PORT 3 CHAMBER
SOLENOID
VALVE
SOLENOID
COIL EXHAUST PORT 5 DOUBLE
VALVE 2 FROM BRAKE VALVE CHECK VALVE
ASR VALVE
(DIFFERENTIAL BRAKE CONTROL VALVE)
SAPH06Z080300026
2. OPERATION
.
a. NON-OPERATION MODE
.
1. Due to the fact that solenoid coil is not turning on electricity, valve (1) is closed and air from air tank is shut off in
inlet port (4).
2. At the same time, as outlet port (3) is passed to exhaust port (5) through open valve (2), air is sent out to open air.
4
1
2 5
SAPH06Z080300027
b. PRESSURE INCREASE MODE

.
1. Once solenoid coil is turned on electricity, the valve (1) is opened, by which air will flow into chamber through inlet
port (4) and outlet port (3), passing through double check valve and ABS control valve.
2. At this moment, valve (2) is closed. Therefore, outlet port (3) and exhaust port (5) are shut off.
4
1
2 5
SAPH06Z080300028
c. PRESSURE REDUCTION MODE

.
1. Solenoid coil is not turned on electricity and valve (1) is closed and air from air tank is shut off inlet port (4).
2. At the same time, outlet port (3) passes through exhaust port (5) by opening valve (2), air from chamber is sent
out to open air, which will reduce pressure.
4
1
2 5
SAPH06Z080300029
2. ASR CUT SWITCH

• Once turned on ASR cut switch, indicator light is lit and ASR will not function. Use it when using speed meter test in
maintenance service, etc. When vehicle normally running, check that the same switch is returned back to original
position (Indicator light at the meter is not lit).
SAPH06Z080300030
3. ASR INDICATOR LIGHT

• When, at least, one of driving wheels slipping and ASR operating, driver will be warned with ASR indicator light lit
(Amber color).
SAPH06Z080300031
FRONT WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100001
FRONT AXLE
SAPH06Z080300032
1 Knuckle 5 Wear indicator

2 Wheel sensor 6 Sensor ring
3 Clamping bushing 7 Brake drum
4 Brake spider 8 Wheel hub
OVERHAUL
EN06Z0803H200001
1. REMOVE THE WHEEL HUB, WHEEL HUB BEARINGS AND

BRAKE DRUM.
(1) Refer to the chapter "FRONT AXLE".
SAPH06Z080300033
SAPH06Z080300034
2. REMOVE THE WHEEL SENSOR.

(1) Remove the brake drum cover.
(2) Pull out the wheel sensor from the brake spider.
NOTICE
• Pull out the wheel sensor by hand.
• 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.
SAPH06Z080300035
3. REMOVE THE SENSOR RING.

(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.
• Do not remove the sensor ring unless it is required.
• Do not reuse the removed sensor ring, be sure to replace it
with new one.
SAPH06Z080300036
1. INSPECTION OF ONLY WHEEL SENSOR.

(1) With a tester, measure the resistance of wheel sensor.
Standard: 1.0-1.3 k
(2) When the measured value is out of the basic standard, change
the wheel sensor as it might be considered presumably to be
abnormal.
SAPH06Z080300037
2. INSPECTION OF 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.
SAPH06Z080300038
3. INSPECTION OF 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 lightly force.
SAPH06Z080300039
1. 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
SAPH06Z080300040 the axle direction.
Assembly standard: 0.2 mm {0.0078 in.} or less
2. MOUNT THE WHEEL SENSOR.

the knuckle's wheel sensor holder.
SAPH06Z080300041
(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
or attempt to pry it into place with a screwdriver, or the like. Doing
so could damage the wheel sensor.
(3) Slowly turn the wheel hub and brake drum and confirm that they
move smoothly.
(4) Mount the brake drum cover.
SAPH06Z080300042
3. MOUNT THE WHEEL HUB AND BRAKE DRUM.
(1) Refer to the chapter "FRONT AXLE".
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.
4. ADJUST 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 brake drum by one time for 5 seconds)
Standard: 150-1,999 mV
(Range of Alternating Current Voltage)
(3) In case of out of the standard range at (2), push the wheel sensor
PUSH softly by fingers until the sensor contacts with the sensor ring,
then inspect again from (1).
WHEEL SENSOR
SAPH06Z080300043
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.
SAPH06Z080300044
REAR WHEEL BRAKE

COMPONENT LOCATOR
EN06Z0803D100002
REAR AXLE
SAPH06Z080300045
1 Wheel sensor 6 Wear indicator

2 Clamping bushing 7 Sensor ring
3 Wheel sensor holder 8 Wheel hub
4 Axle housing assembly 9 Axle shaft
5 Brake spider 10 Brake drum

A 34.5-51.5 {352-51.5, 26-37}
OVERHAUL
EN06Z0803H200002
1. REMOVING THE WHEEL HUB, WHEEL HUB BEARINGS AND

BRAKE DRUM.
(1) Refer to the chapter "REAR AXLE".
SAPH06Z080300046
SAPH06Z080300047
2. REMOVE THE SENSOR RING.

(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.
• Do not remove the sensor ring unless it is required.
• Do not reuse the removed sensor ring, be sure to replace it
with new one.
SAPH06Z080300048
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.
SAPH06Z080300049
4. REMOVE THE CLAMPING BUSHING.

(1) Remove the clamping bushing out of the wheel sensor holder.
SAPH06Z080300050
1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 1.0-1.3 k
(2) When the measured value is out of the basic standard, change
the wheel sensor as it might be considered presumably to be
abnormal.
SAPH06Z080300051
2. INSPECTION OF 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 a press to pressure mount it again.
SAPH06Z080300052
3. INSPECTION OF THE CLAMPING BUSHING

(1) Make sure that the wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed
in with a weak force.
SAPH06Z080300053
1. MOUNT THE WHEEL SENSOR.

the wheel sensor holder.
SAPH06Z080300054
(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 using a screwdriver, or the like.
Doing so could damage the wheel sensor.
SAPH06Z080300055
2. 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.}
SAPH06Z080300056
3. MOUNT THE WHEEL HUB AND BRAKE DRUM.

(1) Refer to the chapter "REAR AXLE".
NOTICE
• 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.
• 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 with a lock nut.
4. ADJUST THE WHEEL SENSOR.

(2) With a circuit tester, confirm the output voltage of the wheel sen-
PUSH sor (By rotating the tire by one time for 5 seconds)
Standard: 150-1,999 mV
(Range of Alternating Current Voltage)
(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
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.
SAPH06Z080300057 This may damage the wheel sensor.
(4) Mount the axle shaft to the wheel hub and tighten the bolt on the
axle shaft.
Refer to the chapter "REAR AXLE".
5. ABS WIRE HARNESSES

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.
EXHAUST BRAKE BR05–1
EXHAUST BRAKE
BR05
BR05-001
EXHAUST BRAKE SYSTEM ....................BR05-2

SYSTEM DIAGRAM ........................................ BR05-2
TROUBLESHOOTING ..................................... BR05-3
ADJUSTMENT................................................. BR05-3
BRAKE CYLINDER...................................BR05-4
DATA AND SPECIFICATION............................ BR05-4
DESCRIPTION ................................................ BR05-4
COMPONENT LOCATOR................................ BR05-5
OVERHAUL ..................................................... BR05-6
INSPECTION AND REPAIR ............................ BR05-6
ADJUSTMENT................................................. BR05-7
BR05–2 EXHAUST BRAKE
EXHAUST BRAKE SYSTEM

SYSTEM DIAGRAM
EN06Z0805J100001
SAPH06Z080500001
1 Clutch switch 5 Magnetic valve

2 Accelerator switch 6 Exhaust brake control cylinder
3 Exhaust brake switch A From power source
4 Indicator light B From air tank
NOTICE
Figure shown above is a typical diagram; refer to Electric Wiring Diagram in the ELECTRIC WIRE chapter and
Brake Piping Diagram in the BRAKE EQUIPMENT chapter for details.
TROUBLESHOOTING
EN06Z0805F300001

Switch does not work Defective contacts Check and correct.
Open circuit in harness Check and correct.
Valve does not close Valve clogged with carbon Remove carbon.
Burnt shaft Check and correct.
ADJUSTMENT
EN06Z0805H300001
ACCELERATOR SWITCH ADJUSTMENT

(EXAMPLE)
OFF 1. ADJUSTMENT OF THE EXHAUST BRAKE ACCORDING TO
THE ENGINE SPEED
(1) Adjust the engine idling speed by turning the throttle knob.
(2) The accelerator switch should turn on (continuity) when the
engine speed is lower than the following, and off (no continuity)
ON when the engine speed is higher.
NOTICE
Use the accelerator pedal to change engine speeds.
SAPH06Z080500002
(3) Adjust the accelerator switch position if it is out of position.

Assembly standard: 0-0.5 mm {0-0.020 in.}
SAPH06Z080500003
CLUTCH PEDAL SWITCH ADJUSTMENT

The clutch pedal switch should not be knocked against.
When the clutch pedal is depressed, the clearance "A" (between the
buffer and the switch body tip) should have 0.5-1.5 mm {0.020-0.059
in.}.
SAPH06Z080500004
BRAKE CYLINDER
EN06Z0805I200001
Type Butterfly valve
DESCRIPTION
EN06Z0805C100001
SAPH06Z080500005
1 Blind plate 5 Seal ring

2 Bushing 6 Plate
3 Valve 7 Lever
4 Shaft 8 Control cylinder
COMPONENT LOCATOR
EN06Z0805D100001
SAPH06Z080500006
1 Arm 8 Lever
2 Bushing 9 Cover
3 Seal ring 10 Valve
4 Plate 11 Shaft
5 Control cylinder 12 Stud
6 Pin 13 Body
7 Clevis

A 22.6-28.4 {240-280, 18-20} C 19.6-24.5 {200-240, 15-17}
B 10.8-16.7 {120-170, 9-12}
OVERHAUL
EN06Z0805H200001

! CAUTION
Do not work on the exhaust brake cylinder while it is still hot. This
1. INSTALLATION OF THE PLATE

(1) Before assembling the brake cylinder, remove the carbon with a
scraper or emery paper (recommended: No.150).
(2) Beveled edge of blind plate is fitted outward as shown in the fig-
ure.
SAPH06Z080500007
2. INSTALLATION OF THE SEAL RINGS

(1) The small and large seal rings must be installed alternately as
SAPH06Z080500008
3. INSTALLATION OF THE VALVE

(1) Apply lithium molybdenum grease to the bolt seat surface and bolt
threads.
1 2 (2) Tighten the bolts in order shown in the figure to the specified
60˚ torque below.
Tightening Torque:
9.81 Nm {100 kgfcm, 7 lbfft}
9.81 N·m (3) Mark the bolt heads and shaft in the same direction with paint.
SHAFT
(4) Tighten the bolts 60 (1/6 turn) as in step 2.
(5) Make sure that the paint marks face the same direction.
PAINT MARK
SAPH06Z080500009 NOTICE
When adding torque, never untighten the nuts, even if they have
been overtightened.

EN06Z0805H300002
Brake cylinder, bush- — — Replace, if necessary. Visual check

ing and seal ring:
Wear, any other dam-
ages
ADJUSTMENT
EN06Z0805H300003
1. CLOSE SIDE ADJUSTMENT

(1) Adjust the clearance between the cylinder and the butterfly valve
with the adjusting screw "A".
SAPH06Z080500011
Limit: B = 0.1 mm {0.0039 in.}

(2) Lock the adjusting screw "A" with a lock nut.
SAPH06Z080500012
2. OPEN SIDE ADJUSTMENT

(1) Set the lever to the open position.
(2) Adjust the butterfly valve may be right angle (90) to the cylinder
with the adjusting screw "C".
(3) Lock the adjusting screw "C" with a lock nut.
SAPH06Z080500013
SAPH06Z080500014
STEERING EQUIPMENT SR01–1
STEERING EQUIPMENT
SR01
SR01-001
STEERING SYSTEM................................. SR01-2

TROUBLESHOOTING ..................................... SR01-2
SR01–2 STEERING EQUIPMENT
STEERING SYSTEM
TROUBLESHOOTING
EN07Z0701F300001
STEERING WHEEL
Shimmy of steering wheel Looseness in steering system or link Tighten with the specified tightening
system torque.
Excessive play or wear of steering Replace.
system
(spline and ball joint)
Other faults in front axle Inspect and adjust wheel alignment.
Improper meshing of power steering Adjust.
gear
Unbalance of right and left tires Adjust.
Excessive tire run-out Correct.
Imbalance of tire inflation pressure Adjust.
between right and left tires or insuffi-
cient tire inflation pressure
Deflection in disc wheel Inspect and replace.
Symptom Trouble shooting and repair
Stiff steering wheel on either side

(excessive steering force)
Stiff steering wheel on both sides Reference: STEERING EQUIPMENT, TROUBLESHOOTING, STEERING IS
(excessive steering force) HEAVY (Page SR01-3)
Stiff steering wheel at start of vehicle

operation (excessive steering force)
Stiff steering wheel or unresponsive Reference: STEERING EQUIPMENT, TROUBLESHOOTING, STEERING

returning RETURN IS RELUCTANT (Page SR01-4)
Oil leakage Reference: STEERING EQUIPMENT, TROUBLESHOOTING, OIL LEAKAGE

(Page SR01-5)
Abnormal noise Reference: STEERING EQUIPMENT, TROUBLESHOOTING, ABNORMAL

NOISE (Page SR01-6)
STEERING IS HEAVY
1. CHECK AND CONFIRM THE FOLLOWING POINTS AND TAKE COUNTERMEASURE.

(1) Check the front tire pressure, and supply compressed air with the specified pressure if insufficient.
(2) Check the tire for abnormal wear and improper groove depth, if any problem found, replace the tire.
(3) Measure the front axle loading, if it exceeds the specified value, correct or empty the cargo.
(4) If frontward cargo causes the excessive front axle loading, correct it by reviewing the weight balance.
(5) If superstructure causes the excessive front axle loading, refurbish the superstructure to reduce loading.
(6) Check the power steering fluid level and replenish if insufficient.
In spite of the above check and countermeasure taken, if the troubles still remain, pursue the true cause with the following
procedures, and repair the troubles.
Steering is always
heavy
YES
Steering is heavy with NO Steering is heavy NO Steering by full NO Confirm by

normal operation with quick turning is heavy recurring the
operation phenomenon
YES YES
Steering to both right NO Replace the power Power assisting NO Replace the power
and left turn is heavy steering gear fluid pressure is steering pump
normal
YES YES
YES
Power assisting fluid NO Replace the power Replace the power

pressure is normal steering pump steering gear
YES
Abnormal gear noise NO Replace the power It is possible to NO Replace the power
is heard steering gear steer the handle, steering pump
one rotation per
second
YES
YES
Bleed air from power Replace the power

steering system steering gear
SAPH07Z070100001
STEERING RETURN IS RELUCTANT

Steering return is reluctant
YES
Universal joint swaying torque is normal NO Replace the corresponding

part
YES
There is no chafing between the NO Repair or replace the

steering shaft and column dust boots corresponding part
There is no awkward movement in ball NO Replace the corresponding

joint part
YES
The rolling resistance of the bevel gear NO Replace the corresponding

is normal. part
YES
There is no awkward rotation in NO Replace the corresponding

intermediate shaft bearing part
YES
There is no awkward movement in king NO Replace the corresponding

pin part
YES
Replace the power steering gear
SAPH07Z070100002
OIL LEAKAGE
Oil leakage
YES
No oil leakage from the power steering NO Replace power steering pump
pump installation area O-ring in installation
YES
No oil leakage from the power steering NO Replace the power steering
pump (cover, plug, suction pipe, flange) pump
YES
No oil leakage from the power steering NO Replace the oil seal
pump (input shaft oil seal)
YES
pump (rest area) gear
YES
No oil leakage from the power steering NO Replace the gasket, hose
pipe joints band and O-ring
YES
No oil leakage from other area NO Replace the parts causing oil
leakage
YES
Repair finish
SAPH07Z070100003
ABNORMAL NOISE
Abnormal noise
YES
Groaning sound is NO Abnormal sound is NO Squealing sound is NO Confirm by

heard when steering heard from the PS heard when recurring the
pump when steering phenomenon
steered by full
turning
YES YES
YES
Bleed air from power Noise is louder NO Leave and watch Lubricate linkage
steering system than other vehicle on
YES
Replace the power

YES
steering pump and
flow control valve
Groaning sound is NO Squealing sound is NO Replace the power

gone out different when steering pump
steering to right or
left
YES
YES
Repair finish Replace the power

steering gear
SAPH07Z070100004
STEERING UNIT SR02–1
STEERING UNIT
SR02
SR02-001
STEERING LINKAGE ............................... SR02-2

DESCRIPTION ................................................ SR02-2
SPECIAL TOOL ............................................... SR02-3
COMPONENT LOCATOR................................ SR02-4
OVERHAUL ..................................................... SR02-5
INSPECTION AND REPAIR .......................... SR02-10
SR02–2 STEERING UNIT
STEERING LINKAGE
DESCRIPTION
EN07Z0702C100001
(REPRESENTATIVE TYPE)
1
3
SAPH07Z070200001
1 Steering wheel 5 Steering gear unit

2 Horn button 6 Pitman arm
3 Steering column assembly 7 Drag link
4 Dust cover
SPECIAL TOOL
EN07Z0702K100001
Prior to starting a steering linkage overhaul, it is necessary to have these special tools.
S0965-01341 STEERING WHEEL PULLER
S0965-72050 GUIDE Model: GD
2 pieces
S0965-71790 DUST COVER GUIDE INNER
Models: GH, FM
S0965-71800 DUST COVER GUIDE OUTER Models: GH, FM
SZ179-20001 DUST COVER GUIDE NUT Models: GH, FM
S0965-01260 PITMAN ARM PULLER

COMPONENT LOCATOR
EN07Z0702D100001
(REPRESENTATIVE TYPE) 2
G
16
4
6 5 17
3
18
9 19
7
8 20
10
A
F
15 14
13
D
12
C B
11
SAPH07Z070200008
1 Steering wheel 8 Dust seal 15 Steering gear bracket

2 Horn button 9 Dust cover 16 Flange nut
3 Combination switch 10 Sliding yoke 17 Column upper cover
4 Spiral cable 11 Steering gear unit 18 Column lower cover
5 Light control switch 12 Pitman arm 19 Column lower boot
6 Windshield wiper switch 13 Drag link 20 Column lower tube
7 Steering column assembly 14 Lubrication fitting

A 48.5-57.5 {500-600, 37-43} D 27: 211-289 {2,200-3,000, 156-213}
B 16: 146-224 {1,500-2,300, 109-167} 30: 341-439 {3,500-4,500, 251-323}
18: 277-423 {2,830-4,310, 206-315} 36: 391-489 {4,000-5,000, 289-360}
C 146-244 {1,500-2,500, 109-180} E 146-244 {1,500-2,500, 109-180}
F 206-284 {2,100-2,900, 152-209}
G 48.5-77.5 {500-800, 37-57}
NOTICE
When removing the nut "F", because the nut "F" is coated with friction coefficient stabilizer be sure to replace the
nut with new one.
OVERHAUL
EN07Z0702H200001
1. REMOVE THE STEERING WHEEL.

(1) Loosen the torx bolt for fixing the horn button using torx wrench.
(2) Remove the horn button from the steering wheel.
SAPH07Z070200009
(3) Remove the connector for the horn.
CONNECTOR FOR HORN
SAPH07Z070200010
(4) Remove the steering wheel lock nut.

(EXAMPLE) (5) Use the special tool or commercial tool to remove the steering
wheel as shown in the figure.
SST: Steering Wheel Puller (S0965-01341)
NOTICE
• Before removing the steering wheel from the steering shaft,
make aligning marks on both so that they can be assembled
in the same position.
• Because the puller hole is made of aluminum and it is easily
damaged, screw the puller bolt deeply.
SAPH07Z070200011 (6) Fix the rotating part of spiral cable with tape etc. to prevent the
spiral cable from rotating.
2. REMOVE THE PITMAN ARM.

(1) Remove the nut, lock washer and plain washer from the sector
shaft.
(2) Using the special tool, remove the pitman arm.
SST: Pitman Arm Puller (S0965-01260)
NOTICE
Do not use wedges or hit with a hammer.
SAPH07Z070200012
1. ASSEMBLE THE STEERING SHAFT.
2. INSTALL THE DUST COVER.

(1) The dust cover must be fitted with two bolts facing the relief mark
"REAR" rearward. After tightening, make certain that the white
paint mark will be faced frontward.
3. ASSEMBLE THE STEERING SHAFT.

LUBRICATION FITTING (1) Before assembling, apply chassis grease to the spline of the slid-
SAPH07Z070200013
ing yoke, and after assembling also fill grease through lubrication
fitting.
When replacing parts: 30g (1.1 oz.)
When replenishing parts: 15g (0.5 oz.)
NOTICE
When assembling, take care not to damage the steering shaft
spline.
4. INSTALL THE STEERING WHEEL.

(1) Set front axles toward rectilinear direction.
(2) Tighten the set screw for fixing the horn button after pushing it in
by using a torx wrench.
Tightening Torque:
6.5-13.5 Nm {66-138 kgfcm, 4.8-9.9 lbfft}
SAPH07Z070200009
5. IF NECESSARY, REPLACE THE DRAG LINK DUST SEAL.

(MODEL: GD)
(1) Using a flat blade screwdriver etc., remove the clamp and then
remove the dust seal.
DUST SEAL NOTICE
CLAMP If dust etc. is adhered to the socket groove, remove it.
(2) Set up the ball stud vertically to the end.
(3) Apply grease to the dust seal lip part.
SAPH07Z070200014
(4) Put a dust seal on the end and fit it into the groove. Screw in a
A clamp mounting special tool so that its end plane "A" is located 5
5 mm mm {0.1969 in.} above the upper end of the ball stud screw. At
{0.1969 in.} this moment, make sure that the pointed end of the tool is posi-
tioned to the seal groove as the illustration to the left shows.
B
SPECIAL TOOL SST: Guide (S0965-72050)
(5) Insert a clamp from "A" side of the tool and move it to the direction
of B down to the plane "C". Then drop the clamp slowly into the
C
dust seal groove.
(6) After mounting the clamp, make sure that there is no deformation
SAPH07Z070200015 under torsion or running off the edge of the clamp. If such defor-
mation or running out is found, touch it up by using a flat head
screw driver or its equivalent.
NOTICE
• If the dust seal is damaged or the clamp is deformed, replace
them with new one.
• Do not reuse the clamp once used.
(7) After mounting the clamp, fill the lubrication fitting of the drag link
ball joint with chassis grease.
NOTICE
Fill with grease until it flows out from the hole of dust seal.
6. IF NECESSARY, REPLACE THE DRUG LINK DUST SEAL AND
RELAY ROD. (MODELS: GH, FM)
(1) Observe the following procedure when changing the dust seal.
a. Pry off the dust seal with a screw driver.
b. Put 6.5 g {0.23 oz.} of lithium molybdenum grease in the seal.
c. Use the special tools to install the dust seal onto the socket
without damaging it.
SST:
Dust Cover Guide Inner (S0965-71790)
Dust Cover Guide Outer (S0965-71800)
Dust Cover Guide Nut (SZ179-20001)
SAPH07Z070200016
7. INSTALL THE PITMAN ARM.

(1) Through the pitman arm, install the plain washer and lock washer
to the sector shaft.
(2) Tighten the nut to the specified torque.
NOTICE
SAPH07Z070200017
8. INSTALL THE DRAG LINK.

(1) Connect the drag link with the pitman arm and with the knuckle
arm.
NOTICE
• At this time, make sure that the arrow "FRONT" or numeral
on the drag link is positioned toward the front of vehicle.
• When handling the drag link, take care not to damage the
dust seal.
(2) Tighten the slotted nuts of the ball studs at both ends of the link to
the specified torque, and then secure the nuts with the cotter pins.
SAPH07Z070200018
9. INSPECT THE STEERING SYSTEM FOR OPERATING ABIL-

ITY.
(1) Place the front wheels on turn tables.
(2) Make sure that the steering wheel turns smoothly without any jolts
or abnormal resistance when the steering wheel is turned full
range.
SAPH07Z070200019
(3) Check the steering wheel free play while engine is idling.
FREE PLAY Wheel Free Play: 15-35 mm {0.591-1.377 in.}
(4) If wheel free play exceeds 15-35 mm {0.591-1.377 in.}, turn the
set screw clockwise to decrease wheel free play and counter-
clockwise to increase it.
! CAUTION
Excessive steering wheel free play may adversely affect vehicle
handling. This can result in personal injury and/or property dam-
age.
SAPH07Z070200020
(5) Measure the steering wheel turning force. Use a spring balancer
to measure the steering wheel turning force.
NOTICE
Measure the steering wheel turning force while the engine is
idling.
Turning force: 20 N {2.0 kgf, 4.4 lbf}
SAPH07Z070200021
(6) The steering wheel must be locked securely in any position up,
down, forward and backward.
! CAUTION
Before moving the vehicle, tighten the lever securely and try to
ADJUSTING
LEVER move the steering wheel up and down, and forward and backward
to make sure that it is locked securely. Never try to adjust the
RELEASE steering wheel position while the vehicle is moving. Any adjust-
ment of the steering wheel while driving can cause the driver to
lose control, and result in personal injury and/or property dam-
LOCK age.
SAPH07Z070200022
(7) Check to see that the combination switch is operating properly.

EN07Z0702H300001
Steering wheel: — — Replace, Visual check

Cracks, distortion and if necessary.
damage
Steering wheel serration: — — Replace, Visual check

Steering column assem- — — Replace, Visual check

bly: Bent, oscillation and if necessary
cracks
Drag link: Cracks and — — Replace the Visual check

damage whole drag link
Ball joint: Play assembly or
Dust seal: Damage replace only
dust cover.
POWER STEERING SR03–1
POWER STEERING
SR03
SR03-001
POWER STEERING SYSTEM .................. SR03-2

TROUBLESHOOTING ..................................... SR03-2
AIR BLEEDING................................................ SR03-7
HYDRAULIC TEST .......................................... SR03-9
POWER STEERING GEAR UNIT ........... SR03-12

DATA AND SPECIFICATIONS ....................... SR03-12
DESCRIPTION .............................................. SR03-12
OPERATION .................................................. SR03-13
SPECIAL TOOL ............................................. SR03-14
COMPONENT LOCATOR.............................. SR03-16
OVERHAUL ................................................... SR03-18
POWER STEERING PUMP .................... SR03-34

DATA AND SPECIFICATIONS ....................... SR03-34
DESCRIPTION .............................................. SR03-34
OPERATION .................................................. SR03-35
OVERHAUL ................................................... SR03-37
OIL RESERVOIR (MODEL: GD)............. SR03-42

DESCRIPTION .............................................. SR03-42
OVERHAUL ................................................... SR03-43
OIL RESERVOIR (MODELS: GH, FM) ... SR03-45

DESCRIPTION .............................................. SR03-45
OVERHAUL ................................................... SR03-47
SR03–2 POWER STEERING
POWER STEERING SYSTEM

TROUBLESHOOTING
EN07Z0703F300001
STEERING WHEEL
Shimmy of steering wheel Looseness in steering system or link Tighten with the specified tightening
system torque.
Excessive play or wear of steering Replace.
system
(spline and ball joint)
Other faults in front axle Inspect and adjust wheel alignment.
Improper meshing of power steering Adjust.
gear
Unbalance of right and left tires Adjust.
Excessive tire run-out Correct.
Imbalance of tire inflation pressure Adjust.
between right and left tires or insuffi-
cient tire inflation pressure
Deflection in disc wheel Inspect and replace.
Symptom Trouble shooting and repair
Stiff steering wheel on either side

(excessive steering force)
Stiff steering wheel on both sides Reference: POWER STEERING, TROUBLESHOOTING, STEERING IS
(excessive steering force) HEAVY (Page SR03-3)
Stiff steering wheel at start of vehicle

operation (excessive steering force)
Stiff steering wheel or unresponsive Reference: POWER STEERING, TROUBLESHOOTING, STEERING

returning RETURN IS RELUCTANT (Page SR03-4)
Oil leakage Reference: POWER STEERING, TROUBLESHOOTING, OIL LEAKAGE

(Page SR03-5)
Abnormal noise Reference: POWER STEERING, TROUBLESHOOTING, ABNORMAL NOISE

(Page SR03-6)
STEERING IS HEAVY

Steering is always
heavy
YES
Steering is heavy with NO Steering is heavy NO Steering by full NO Confirm by

normal operation with quick turning is heavy recurring the
operation phenomenon
YES YES
Steering to both right NO Replace the power Power assisting NO Replace the power
and left turn is heavy steering gear fluid pressure is steering pump
normal
YES YES
YES
Power assisting fluid NO Replace the power Replace the power

pressure is normal steering pump steering gear
YES
Abnormal gear noise NO Replace the power It is possible to NO Replace the power
is heard steering gear steer the handle, steering pump
one rotation per
second
YES
YES
Bleed air from power Replace the power

steering system steering gear
SAPH07Z070300001
STEERING RETURN IS RELUCTANT

Steering return is reluctant
YES
Universal joint swaying torque is normal NO Replace the corresponding

part
YES
There is no chafing between the NO Repair or replace the

steering shaft and column dust boots corresponding part
There is no awkward movement in ball NO Replace the corresponding

joint part
YES
The rolling resistance of the bevel gear NO Replace the corresponding

is normal. part
YES
There is no awkward rotation in NO Replace the corresponding

intermediate shaft bearing part
YES
There is no awkward movement in king NO Replace the corresponding

pin part
YES
Replace the power steering gear
SAPH07Z070300002
OIL LEAKAGE
Oil leakage
YES
No oil leakage from the power steering NO Replace power steering pump
pump installation area O-ring in installation
YES
pump (cover, plug, suction pipe, flange) pump
YES
No oil leakage from the power steering NO Replace the oil seal
pump (input shaft oil seal)
YES
pump (rest area) gear
YES
No oil leakage from the power steering NO Replace the gasket, hose
pipe joints band and O-ring
YES
No oil leakage from other area NO Replace the parts causing oil
leakage
YES
Repair finish
SAPH07Z070300003
ABNORMAL NOISE
Abnormal noise
YES
Groaning sound is NO Abnormal sound is NO Squealing sound is NO Confirm by

heard when steering heard from the PS heard when recurring the
pump when steering phenomenon
steered by full
turning
YES YES
YES
Bleed air from power Noise is louder NO Leave and watch Lubricate linkage
steering system than other vehicle on
YES
Replace the power

YES
steering pump and
flow control valve
Groaning sound is NO Squealing sound is NO Replace the power

gone out different when steering pump
steering to right or
left
YES
YES
Repair finish Replace the power

steering gear
SAPH07Z070300004
AIR BLEEDING
EN07Z0703H200001
1. FILL THE OIL RESERVOIR WITH POWER STEERING FLUID.

NOTICE
• Use only specified fluid.
• Do not overfill the oil reservoir.
• Replace old fluid with new fluid after overhauling power
steering gear unit or power steering pump.
• Specified fluid....Refer to recommended lubricant list.
2. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.
SAPH07Z070300005
3. TURN THE STEERING WHEEL FULLY IN BOTH DIRECTIONS

SEVERAL TIMES.
4. CHECK THE FLUID LEVEL IN THE OIL RESERVOIR.

(1) Add the fluid, if necessary.
SAPH07Z070300006
5. START THE ENGINE AND TURN THE STEERING WHEEL

FULLY IN BOTH DIRECTIONS SEVERAL TIMES WITH
ENGINE IDLING.
NOTICE
The fluid in the oil reservoir should be continuously replenished
while air bleeding so that the oil reservoir never become empty.
6. RETURN THE STEERING WHEEL TO STRAIGHT AHEAD.
SAPH07Z070300007
7. RECHECK THE FLUID LEVEL WHEN THE ENGINE IS

STOPPED.
(1) If necessary, add or decrease the power steering fluid to match
the between "MAX" and "MIN" line.
SAPH07Z070300008
NORMAL
MODELS: GH, FM
SAPH07Z070300009
HYDRAULIC TEST
EN07Z0703H300001
SAPH07Z070300010
HYDRAULIC TEST
1. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME

WITH STANDS.
NOTICE
Block the rear wheels.
SAPH07Z070300005
2. SET THE STOP VALVE AND OIL PRESSURE GAUGE AS

SHOWN IN THE FIGURE.
NOTICE
After setting the stop valve and oil pressure gauge, perform the air
bleeding in the system according to "AIR BLEEDING".
SAPH07Z070300011
3. CHECK THE FLOW CONTROL VALVE OPERATION.

(1) Start the engine and idle then close the stop valve until the fluid
pressure is at 5.0 MPa {51 kgf/cm2, 725 lbf/in.2}.
(2) Run the engine up to 1,500 r/min, then reduce the engine speed
suddenly.
NOTICE
This operation should be repeated more than 5 times.
(3) Good, if the set pressure of 5.0 MPa {51 kgf/cm2, 725 lbf/in.2} is
recovered immediately.
If the set pressure is not recovered immediately, stop the engine
and replace the flow control valve assembly.
SAPH07Z070300012
(4) Open the stop valve fully.
4. CHECK THE RELIEF VALVE OPERATION.

(1) Run the engine up to 2,000 r/min.
(2) Close the stop valve until the fluid pressure is at “A”.
MODEL "A"
GD 13.7 MPa {140 kgf/cm2, 1,992 lbf/in.2}
GH, FM 12.8 MPa {131 kgf/cm2, 1,861 lbf/in.2}
NOTICE
Be careful not to exceed “A”.
SAPH07Z070300013 (3) Good, if the fluid pressure is maintained at “B”.
MODEL "B"
13.0-13.7 MPa
GD
{133-140 kgf/cm2, 1,890-1,992 lbf/in.2}
12.1-12.8 MPa
GH, FM
{124-131 kgf/cm2, 1,759-1,861 lbf/in.2}
(4) If pressure is higher, stop the engine and replace the flow control
valve assembly.
5. MEASURE THE SYSTEM HYDRAULIC PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and then turn the steering wheel to a full
stop.
(3) Apply a force of approx. 147.1 N {15 kgf, 33 lbf} to the steering
wheel and measure the hydraulic pressure.
(4) Repeat the measurement by fully turning the steering wheel in the
opposite direction.
Hydraulic pressure: “B”
(5) If the above pressure is not attained, measure the discharge pres-
sure or stop the engine and repair the power steering gear unit.
SAPH07Z070300014
6. MEASURE THE DISCHARGE PRESSURE.

(1) Make sure that the stop valve is fully open.
(2) Start the engine and idle and measure the discharge pressure
with the stop valve fully close.
Discharge pressure: “B”
NOTICE
Do not allow the stop valve to remain closed for more than 15 sec-
onds.
(3) Open the stop valve fully.
SAPH07Z070300013
7. REMOVE THE STOP VALVE AND OIL PRESSURE GAUGE.

(1) Stop the engine and remove the stop valve and oil pressure
gauge.
NOTICE
After removing stop valve and oil pressure gauge, perform the air
bleeding in according to "AIR BLEEDING".
SAPH07Z070300015
8. INSPECT THE STEERING SYSTEM FOR OPERATION ABIL-

ITY.
(1) Place the front wheels on turn tables then start the engine and
idle.
(2) Check to see that the steering wheel turned smoothly without any
jolts or abnormal resistance, when it is turned fully in both direc-
tions.
(3) Measure the steering wheel turning force.
Turning force: Less than 20 N {2 kgf, 4.41 lbf}
SAPH07Z070300016
POWER STEERING GEAR UNIT

EN07Z0703I200001
Type Integral type power steering
Gear ratio GD 19.0: 1

Models:
Gear ratio GH, FM 20.2: 1
Cylinder inside diameter GD 90 mm {3.543 in.}

Models:
Cylinder inside diameter GH, FM 100 mm {3.937 in.}
DESCRIPTION
EN07Z0703C100001
4 3 2 1
6 7 8 9 10
SAPH07Z070300017
1 Valve housing assembly 6 Dust cover

2 Worm valve assembly 7 Needle roller bearing
3 Steel ball 8 Oil seal
4 Ball nut assembly 9 Adjusting screw
5 Sector shaft 10 Adjusting screw lock nut
OPERATION
EN07Z0703C100002
SAPH07Z070300018
SPECIAL TOOL
EN07Z0703K100001
Prior to starting a power steering gear unit overhaul, it is necessary to have the following special tools.
Tool and accessory set: S0903-04180
TOOL ASSEMBLY
S0965-71870
• For 85 mm {3.346 in.}
• For 90-110 mm
{3.544-4.330 in.}
(Used together with tool assem-
bly)
S0965-91400 ATTACHMENT ASSEMBLY
S0960-31560 WRENCH ASSEMBLY
INSERTER ASSEMBLY
A:
For 40 mm {1.575 in.}
S0965-71860
For 45 mm {1.772 in.}
For 48 mm {1.890 in.}
For 53 mm {2.087 in.}
For 58 mm {2.283 in.}
(Used together with inserter
assembly)
A
S0965-91410 PRESS FITTER
S0969-91360 NEEDLE
S0965-71840 INSERTER
S0969-41020 CAULKING TOOL
S0965-71850 INSERTER
S0971-21130 BAR
COMPONENT LOCATOR
EN07Z0703D100001
(EXAMPLE) 1
A
2
7
8
7 7
7
9
C 10
9
11
7
12
3 17
13
14
15 18 E
16 22
19
D
20 14 13 17
7
21
F
SAPH07Z070300029
1 Dust cover 12 Tube clip

2 Plug and seal assembly 13 Back-up ring
3 Oil seal 14 Y-packing
4 Ball bearing 15 Steering body
5 Bearing cage and steel ball 16 Tapered plug
6 Worm shaft assembly 17 Needle roller bearing
7 O-ring 18 Sector shaft
8 Valve housing 19 Adjusting screw
9 Seal ring 20 Retainer
10 Power piston (Ball nut) 21 Side cover
11 Ball tube 22 Lock nut

A 226-245 {2,300-2,500, 167-180} D 8.9-12.7 {90-130, 6.5-9.4}
B 98.1-107.9 {1,000-1,100, 73-79} (GD) E 117.7-127.5 {1,200-1,300, 87-94}
117.7-127.5 {1,200-1,300, 87-94} (GH, FM)
C 4.41-5.39 {45-55, 3.2-3.9} F 49.1-53.9 {500-550, 36-40} (GD)
73.6-83.4 {750-850, 55-61} (GH, FM)
OVERHAUL
EN07Z0703H200002
NOTICE
Observe the following instructions before disassembly and
assembly.
1. All functional parts should be clean. Blow dirty parts off with
dry compressed air, then clean them with volatile metal
cleanser. Never use brushes or cloth.
2. Handle rubber parts, seals, etc., in clean condition. Any worn
part should be replaced immediately.
Volatile metal cleanser may attack rubber parts, so they
should never be used. Always use fluid.
3. For disassembling and assembling, only use the specified
fluid.
4. Never use standard tools in place of special tools and when
using the special tools, read the instruction carefully.
1. BEFORE DISASSEMBLY, SECURE THE POWER STEERING IN

A VISE.
SAPH07Z070300030
2. REMOVE THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
(1) Loosen and remove the nut fixing the adjusting screw to the side
cover.
BOLT
(2) Remove the eight bolts and washers fitting the side cover to the
steering body.
NUT
SAPH07Z070300031
(3) Confirm that the power piston is located in the center, and then
gently tap the output end of the sector shaft with a plastic (or
wooden) hammer to remove the sector shaft assembly and the
side cover together from the steering body.
NOTICE
Never use a steel hammer when removing the sector shaft (as the
PLASTIC HAMMER threads will be damaged).
SAPH07Z070300032
(4) Turn the adjusting screw clockwise using a screwdriver to raise

and separate the side cover assembly from the sector shaft
SCREWDRIVER assembly.
ADJUSTING SCREW
SIDE COVER NOTICE
• Do not secure the sector shaft directly in a vise.
• Always use a cloth etc. to protect the sector shaft.
SECTOR SHAFT
SAPH07Z070300033
(5) Remove the O-ring from the groove around the outside of the side
BACK-UP RING cover using the special tool. Then remove the Y-packing from
behind the needle roller bearing and the back-up ring using the
Y-PACKING special tool.
NOTICE
O-RING
It is not necessary to remove the needle bearing unless it is dam-
aged.
SIDE COVER SST: Needle (S0969-91360)
SAPH07Z070300034
3. REMOVE THE VALVE HOUSING AND BALL NUT ASSEMBLY.

(1) Remove the dust cover from the valve housing.
WRENCH ASSEMBLY (2) Loosen the plug and seal assembly in the valve housing section
using the special tool. At this time, only back off the plug and seal
assembly 180. Do not remove it.
NOTICE
If the plug and seal assembly is removed, the steel balls (bearing)
in the valve housing may spring out.
SST: Wrench assembly (S0960-31560)
SAPH07Z070300035
(3) Remove the bolts to remove the worm shaft assembly and valve
housing assembly from the steering body.
NOTICE
• Do not damage the internal surface of the steering body
when removing the worm shaft assembly and valve housing
assembly.
• Do not let the steel balls spring out.
• Never damage the power piston.
BOLT
SAPH07Z070300036
4. REMOVE THE ADJUSTING SCREW AND SECTOR SHAFT.

(1) Uncaulk the retainer at two caulked positions.
NOTICE
RETAINER
• Do not disassemble the sector shaft assembly unless it is
damaged.
SECTOR
SHAFT • Do not secure the sector shaft directly in a vise. Always use a
cloth etc. to protect the sector shaft.
SAPH07Z070300037
(2) Remove the retainer using the special tool. Remove the adjusting
RETAINER screw at the same time.
BAR SST: Bar (S0971-21130)
ADJUSTING SCREW
SAPH07Z070300038
5. REMOVE THE WORM SHAFT ASSEMBLY, VALVE HOUSING

STUB SHAFT AND POWER PISTON ASSEMBLY.
(1) Place the assembly on the work bench with the power piston side
VALVE
down. Turn the stub shaft while holding the valve housing, and
HOUSING remove the worm shaft from the power piston.
(2) Let the steel balls assembled in the power piston and ball race of
the worm shaft drop into the power piston.
WORM SHAFT POWER PISTON
NOTICE
Do not tilt the piston as it contains the steel balls. Do not lose the
steel balls.
SAPH07Z070300039
(3) Secure the special tool in a vise.

SST: Attachment assembly (S0965-91400)
WRENCH (4) Remove the O-rings fitted on the contact surfaces of the steering
ASSEMBLY
ATTACHMENT body of the valve housing.
ASSEMBLY (5) Attach the valve housing to the attachment assembly, and remove
the previously loosened plug and seal assembly.
SST: Wrench assembly (S0960-31560)
SAPH07Z070300040
(6) Remove the ball bearing and oil seal from the plug and seal
BEARING assembly.
OIL SEAL
PLUG AND
SEAL ASSEMBLY
SAPH07Z070300041
6. REMOVE THE WORM SHAFT ASSEMBLY AND VALVE HOUS-

VALVE HOUSING ING.
(1) Prepare a plastic box, etc. Hold the valve housing over the box
BEARING CAGE
and remove the worm shaft assembly by pushing it from the
STEEL BALLS power piston side as shown in figure. The side race, steel balls,
SIDE RACE and bearing cage will come apart and fall into the box.
NOTICE
• Do not lose any steel balls.
• If only one side race and/or steel ball is lost, the worm shaft
and valve housing assembly must be replaced.
Number of the steel balls: 18 pieces.
SAPH07Z070300042
(2) Remove the rotor from the worm shaft assembly, and then remove
the seal ring from the rotor using the special tool.
SEAL RING SST: Needle (S0969-91360)
ROTOR
SAPH07Z070300043
(3) Remove the three seal rings and three O-rings from the valve
SEAL RING (3) housing using the special tool.
SST: Needle (S0969-91360)
O-RING (3)
VALVE HOUSING
SAPH07Z070300044
7. REMOVE THE POWER PISTON.

BALL TUBE SCREW (1) Place the piston's steel balls in a separate container.
WASHER (2) Loosen the screw of the tube clip securing the ball tube using a
PISTON wrench. Remove the ball tube from the power piston by pinching it
CLIP with your fingers and shaking it.
NOTICE
• Never insert a screwdriver etc., between the ball tube and the
piston to pry them apart.
• Check for any steel balls remaining in the ball tube.
Number of the steel balls: 32 pieces.
SAPH07Z070300045
(3) Remove the seal ring and O-ring from the power piston using the
PISTON
special tool.
SEAL RING SST: Needle (S0969-91360)
O-RING
SAPH07Z070300046
8. REMOVE THE STEERING BODY.

OIL SEAL (1) Remove the oil seal, back-up ring, and Y-packing from the section
BACK-UP RING of the steering body contacting the sector shaft.
Y-PACKING
NOTICE
STEERING BODY
Do not remove the needle roller bearing and tapered plug unless
they are damaged.
SAPH07Z070300047

RETAINER 1. INSTALL THE SECTOR SHAFT.
(1) Secure the sector shaft in a vise while protecting the geared base
BAR
of the shaft with a rag.
ADJUSTING
SCREW
(2) Fill the assembly with grease through the adjusting screw hole.
Then, insert the adjusting screw, and fix the retainer using the
special tool.
SST: Bar (S0971-21130)
SAPH07Z070300048
NOTICE
How to tighten the retainer; After fully tightening, back off the
CAULKING TOOL
retainer 180 and then, after retightening it to 4 kgfm, back it off
20. Ensure the adjusting screw rotates smoothly.
(3) After tightening the retainer, securely caulk it at two positions

using the special tool.
SST: Caulking tool (S0969-41020)
SAPH07Z070300049
2. INSTALL THE SIDE COVER.

O-RING (1) Insert the Y-packing and back-up ring in the bottom of the needle
BACK-UP RING
roller bearing press fitted inside the side cover.
NOTICE
Y-PACKING
• The back-up ring can be assembled easily if inserted by
pinching it with the fingers.
SIDE COVER • After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing side.
SAPH07Z070300050
(2) Form the back-up ring using the special tool.

SST: Inserter assembly (S0965-71860)
NOTICE
INSERTER ASSEMBLY There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 48 mm {1.890 in.}.
INSERTER
SIDE COVER
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SAPH07Z070300051
48 {1.890}
53 {2.087}
58 {2.283}
3. INSTALL THE VALVE HOUSING.

O-RING (1) Insert an O-ring and a seal ring into each of the three narrower
grooves of the five grooves in the valve housing.
(2) Then, form the seal ring using the special tool.
INSERTER
SST: Inserter (S0965-71850)
SEAL RING
SAPH07Z070300052
4. INSTALL THE PLUG AND SEAL ASSEMBLY.

(1) Press fit the oil seal into the inside of the plug and seal assembly
HAND PRESS
using the special tool.
OIL SEAL NOTICE
PRESS FITTER Always use a hand press when press fitting the oil seal.
PLUG SST: Press fitter (S0965-91410)
SAPH07Z070300053
(2) Apply grease to the oil seal and then install the ball bearing.
OIL SEAL
GREASE
SAPH07Z070300054
5. INSTALL THE WORM SHAFT AND THE VALVE HOUSING.

(1) Form the seal ring using the special tool after assembling the seal
INSERTER ring in the outer groove of the rotor.
SEAL RING
ROTOR
SAPH07Z070300055
(2) Insert the rotor between the stub shaft and the worm shaft. At this
ROTOR time, assemble it so that the straight pin in the bottom fits in the
rotor notch.
ROTOR NOTCH
WORM SHAFT STRAIGHT PIN
SAPH07Z070300056
(3) Fit the guide into the special tool and insert the previously assem-
bled worm shaft assembly into the guide with the input side down.
SST: Tool assembly (S0965-71870)
WORM SHAFT
BEARING CAGE NOTICE
GUIDE
There are two kinds of guide as below, and install worm shaft
STEEL BALL
assembly using the guide for power piston diameter 90-110 mm
TOOL {3.544-4.330 in.}.
ASSEMBLY
Unit: mm {in.}
POWER PISTON DIAMETER
SAPH07Z070300057
85 {3.346}
90-110 {3.544-4.330}
(4) Install the race of bearing side (one side), the bearing cage and
the steel balls, and allow the tool assembly to slide down and set
the balls in position.
(5) Remove the guide and fit the other side race.
SIDE RACE
SIDE RACE
BEARING CAGE
STEEL BALL
SAPH07Z070300058
(6) Assemble the valve housing to the worm shaft assembly and pre-
viously assembled bearing sub-assembly by inserting it from the
worm shaft side.
NOTICE
VALVE HOUSING
• When fitting the valve housing, do not damage the seal ring
in the valve housing.
• Inserter (S0965-71850) can be used to form the seal rings of
the valve housing part.
SAPH07Z070300059
(7) Secure the special tool in a vise.

PLUG AND SECTION ON SST: Attachment assembly (S0965-91400)
SEAL ASSEMBLY WITH LIQUID
GASKET IS (8) Fit the previously assembled worm shaft assembly and valve
O-RING APPLIED
(SEE NOTICE)
housing onto the attachment assembly, place the O-ring in the
inner groove of the valve housing, and screw the plug and seal
assembly into the valve housing.
NOTICE
ATTACHMENT • Apply liquid gasket (equivalent to ThreeBond 1102) to the
ASSEMBLY screw section of the plug and seal assembly.
• The O-ring must not be fitted in the thread escape groove of
SAPH07Z070300060 the valve housing.
• When assembling the plug and seal assembly, do not let the
stub shaft serration damage the oil seal.
(9) Tighten the plug and seal assembly using the special tool.
LOOSEN THE PLUG SST: Wrench assembly (S0960-31560)
AND SEAL ASSEMBLY
BY 180 FOR STUB SHAFT
SUBSEQUENT WORK NOTICE
Check that the stub shaft rotates smoothly and uniformly while
holding the valve housing.
(10) Loosen the plug and seal assembly by approx 180.
SAPH07Z070300061
(11) Install O-rings in the groove around the outside of the valve hous-
ing and in the oil port recess.
NOTICE
Do not twist the O-rings.
O-RING
O-RING
SAPH07Z070300062
6. INSTALL THE POWER PISTON.

(1) Fit the O-ring and seal ring in the groove around the outside of the
power piston and form the seal ring using the special tool.
O-RING NOTICE
INSERTER SEAL RING Do not twist the O-ring or stretch the seal ring.
PISTON
SAPH07Z070300063
(2) Place the power piston on the bench.

(3) Fill the ball tube with grease, lay 10-11 steel balls in the tube, and
BALL TUBE place the other side of the ball tube on top.
NOTICE
Never fix the piston in a vise.
STEEL BALL
SAPH07Z070300064
(4) Insert the worm shaft and valve housing assembly in the center
PUNCH STEEL BALL hole of the power piston, align the power piston and worm shaft
STUB SHAFT ball races, and drop the remaining steel balls one by one through
PISTON the piston's ball tube hole.
NOTICE
• Drop the steel balls while turning the stub shaft to facilitate
assembly.
• Steel balls sometimes come out of the hole on the other side
of the ball tube after a certain number are inserted. Plug the
hole with a punch to prevent the steel balls from coming out.
• When installing the steel balls, the worm shaft and valve
SAPH07Z070300065 housing assembly must not be drawn out to its extreme posi-
tion, as the steel balls may drop outside the ball race.
(5) After inserting the steel balls in the power piston, insert the ball
BALL TUBE tube into the power piston and fix it using the clip, washer, and
screw.
NOTICE
Always push in the ball tube by hand. Never force or strike it. If
forced or struck, the ball tube may be deformed, the edge may be
nipped, or otherwise damaged, causing malfunctions.
(6) Tighten the screw to the specified torque.
CLIP
SAPH07Z070300066
(7) Measure the axial play between the power piston and the worm
B (AXIAL PLAY) shaft assembly.
2 mm (0.079 in.) A (point of application) 20 mm {0.787 in.}

F (force) 5 kg
B (axial play) 0.5 mm {0.0197 in.} or less
A
NEUTRAL POSITION F
SAPH07Z070300067
7. INSTALL THE STEERING BODY.

(1) Fit the Y-packing and back-up ring in the groove in front of the
BACK-UP RING Y-PACKING needle roller bearing (in the hole for the steering body output
shaft).
NOTICE
• Back-up ring installation is facilitated by pinching the ring
with the fingers as shown in figure.
• After filling the groove with grease, assemble the Y-packing
so that the lip faces to the needle roller bearing.
STEERING BODY
SAPH07Z070300068
(2) Form the back-up ring using the special tool.

INSERTER ASSEMBLY
NOTICE
INSERTER There are five kinds of inserters as below, and install the back-up
ring using the inserter for the diameter 58 mm {2.283 in.}.
Unit: mm {in.}
INSERTER DIAMETER
40 {1.575}
45 {1.772}
SAPH07Z070300069
48 {1.890}
53 {2.087}
58 {2.283}
(3) Press fit the oil seal into the steering body using the special tool.
INSERTER ASSEMBLY
OIL SEAL (4) Fill the oil seal with grease.
SAPH07Z070300070
8. INSTALL THE VALVE HOUSING AND BALL NUT ASSEMBLY.

STEERING BODY (1) Secure the steering body in the vise.
PISTON (2) Fit the worm shaft and valve housing assembly by inserting it into
the steering body with the power piston gear placed on the side of
the sector shaft. Hold the power piston lightly by hand so that it
does not rotate.
NOTICE
• When inserting the worm shaft and valve housing assembly,
do not damage the piston seal ring.
• Be careful that the O-ring does not fall out.
SAPH07Z070300071
(3) Align the steering body and valve housing oil passage holes and
tighten the bolt to the specified torque.
NOTICE
Insert a bar into the bolt hole to align the body and housing oil
passage holes. Prevent housing rotation to prevent the O-ring
from being cut or dislodged.
SAPH07Z070300072
(4) Tighten the plug and seal assembly (which was previously loos-
ened through 180) to the specified torque using the wrench
assembly.
WRENCH ASSEMBLY SST: Wrench assembly (S0960-31560)
NOTICE
After applying a thin and uniform coat of liquid gasket to 3-5 whole
threads of the screw part of the plug and seal assembly and tight-
ening it with the indicated torque, apply turning stopper punches
every 180.
Liquid gasket: Equivalent to ThreeBond 1102

SAPH07Z070300073
(5) Attach the dust cover to the valve housing.
DUST COVER
NUT
SAPH07Z070300074
9. INSTALL THE SIDE COVER ASSEMBLY AND SECTOR

SHAFT.
SCREWDRIVER ADJUSTING SCREW (1) Assemble the side cover assembly to the sector shaft assembly
by aligning the screw hole in the center of the side cover with the
SIDE COVER
adjusting screw and turning the adjusting screw.
Install the O-ring around the outside of the side cover.
SECTOR SHAFT
SAPH07Z070300075
(2) Insert the sector shaft into the steering body so that its gear and
the power piston gear engage in the center.
NOTICE
When inserting the sector shaft, do not let the sector shaft serra-
tion damage the lip of the Y-packing. Damage may affect oil tight-
ness.
SAPH07Z070300076
(3) Assemble the side cover to the steering body using the bolts.
STEERING BODY
Tighten them to the specified torque.
SIDE COVER
SAPH07Z070300077
10. MEAUSURE THE WORM VALVE ASSEMBLY TURNING

TORQUE. (MODEL: GD)
TURNING TORQUE
Assembly standard: Unit: Nm {kgfcm, lbfft}
A B
Less than 0.1-0.39
B 0.98 {10, 0.73} {1-4, 0.07-0.29}
A
NEUTRAL
POSITION
SAPH07Z070300078
NOTICE
If measurement is not within specification, readjust the backlash
with adjusting screw.
SAPH07Z070300079
11. MEASURE THE SECTOR SHAFT BACKLASH. (MODELS: GH,

FM)
(1) Align the marks on the sector shaft with pitman arm.
(2) Install the pitman arm and tighten the nut finger-tight.
SAPH07Z070300080
(3) Use a dial gauge to check to see that the sector shaft backlash in
neutral position.
L Backlash
0.05-0.25 mm
270 mm {10.63 in.}
{0.002-0.009 in.}
(4) If measurement is not within specification, readjust the backlash

with adjusting screw.
SAPH07Z070300081
12. INSPECT THE WORM VALVE ASSEMBLY ROTATING CONDI-

TION.
(1) Check to see that the worm valve assembly rotate smoothly with-
out any shocks, abnormal resistance, noise and drag, when the
worm valve assembly rotates full lock in both direction.
13. TIGHTEN THE PITMAN ARM LOCK NUT.
SAPH07Z070300082

EN07Z0703H300002
METALLIC PARTS
Inspection item Location Remedy
Steering body • The internal surface of the cyl- Repair or replace the steering body if there is evi-
inder dence of abrasion or stepped wear. Check visu-
ally and by touch for any flaws that may affect
smooth piston stroke.
• Side cover assembly surface Repair or replace the steering body if there is evi-
dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
• Y-packing groove in the sector Repair or replace the steering body if there is evi-
shaft hole dence of any flaws, rust or gouging that may
affect oil tightness (check visually and by touch).
Sector shaft • Gear Replace the gear if it is severely flawed or worn.

Chipped gears must also be replaced. (Check
visually and by touch)
• Gear shaft and serrations Check for cracks using magnetic-particle test
equipment and a color penetration test. Replace
any cracked parts.
• Needle roller bearing contact Check for wear, flaws or gouging (visually and by
surface touch). Repair or replace if necessary.
• Y-packing contact surface Repair or replace if any flaws, rust or gouging

affecting oil tightness are found (check visually
and by touch).
• Adjusting screw Measure the axial clearance of the adjusting

screw with a dial gauge.
0.01-0.1 mm is acceptable, but if excessive, the
screw must be disassembled for inspection. Also
check whether the adjusting screw rotates
smoothly. If not, the screw must be disassembled
and inspected.
Power piston • Cylinder contact surface Any wear or abrasion that affects smooth piston
stroke must be corrected, or the power piston
must be replaced.
• Rack gear Replace the rack gear if severely flawed, worn or

chipped.
• Steel ball race surface Any wear or flaw that disturbs smooth rotation
and movement of steel balls must be corrected,
or the race must be replaced. (Visual inspection)
• Seal ring and O-ring Replace the seal ring or O-ring if any flaws or
tears affecting oil tightness are found.
Ball tube • Steel ball rotation surface Replace the ball tube if any wear, flaws or goug-
ing that affect smooth ball rotation are found on
the inside at the tube.
• Tang (end) Replace the ball tube if any warping, bending,

flaws or pits that affect smooth ball rotation are
found on the tang.
Inspection item Location Remedy
Worm shaft • Steel ball race surface Repair or replace the race if any wear, flaws or
(stub shaft) pits that affect smooth ball rotation are found.
• Seal ring Any wear, flaw, or gouge affecting oil tightness

must be corrected or the seal ring must be
replaced.
• Y-packing contact surface Any wear, flaw, rust, or gouge which may affect
oil tightness must be corrected or the packing
must be replaced.
• Thrust bearing (steel ball) con- Check the bearing for wear, flaws or pits if shaft
tact surface rotation is stiff or uneven. Repair or replace if
found.
Thrust bearing • Bearing race and steel ball Check the bearing for wear, flaws or pits if shaft
(steel ball) rotation is stiff or uneven. Repair or replace if
and bearing cage found.
• Bearing cage Replace the cage if any flaws or damage affecting

smooth rotation are found.
Rotor • External surface Repair or replace the rotor if any wear, flaws or
gouging affecting smooth rotation are found.
• Chamber Replace the chamber if any flaws, breaks, or

chips affecting steering characteristics are
found.
• Seal ring groove Replace the seal ring if any flaws or tears affect-
ing oil tightness are found.
Side cover • Steering body contact surface Repair or replace the side cover if any flaws,
gouging or rust affecting oil tightness are found.
• Y-packing groove Repair or replace the side cover if any flaws,

• O-ring groove Repair or replace the side cover if any flaws,

Plug and seal • Thrust bearing side race con- Repair or replace the plug and seal assembly if
assembly tact surface any flaws, rust or gouging affecting uniform tight-
ening are found.
• Y-packing press fitted section Replace the plug and seal assembly if any flaws,
rust or gouging affecting oil tightness are found.
• O-ring contact surface Replace the plug and assembly if any flaws, rust
or gouging affecting oil tightness are found.
Bearings Check that the bearing rotates smoothly. Replace

the bearing if rotation is stiff or uneven.
POWER STEERING PUMP

EN07Z0703I200002
Type Vane type
GD 715-4,901 r/min
Speed range Models:
GH, FM 715-5,239 r/min
GD 13.0-13.7 MPa {133-139 kgf/cm2, 1,886-1,987 lbf/in.2}

Relief pressure Models:
GH, FM 12.1-12.8 MPa {123-130 kgf/cm2, 1,750-1,849 lbf/in.2}
GD 12.0 L/min. {3.17 U.S.gal, 2.64 lmp.gal} at 2,000 r/min.

Flow rate Models:
GH, FM 17.0-20.0 L/min. {4.50-5.28 U.S.gal, 3.74-4.39 lmp.gal} at 2,000 r/min.
DESCRIPTION
EN07Z0703C100003
SAPH07Z070300083
1 Flow control valve assembly 6 Vane 11 Pump body sub-assembly

2 Relief valve 7 Drive gear 12 Spring
3 Flow control spring 8 Oil seal 13 Dowel
4 Rotor 9 Ball bearing 14 Side plate
5 Cam ring 10 Pump shaft 15 Body cover
OPERATION
EN07Z0703C100004
SAPH07Z070300084
1 Oil reservoir 5 Flow control valve assembly

2 Vane 6 Relief valve
3 Cam ring A To power steering gear unit
4 Rotor B From power steering gear unit
COMPONENT LOCATOR
EN07Z0703D100002
SAPH07Z070300085
1 Flow control valve assembly 7 Ball bearing 13 Vane

2 Flow control valve spring 8 Oil seal 14 Rotor
3 Drive gear 9 Pump body sub-assembly 15 Cam ring
4 Snap ring 10 Spring 16 Dowel
5 Plug 11 O-ring 17 Body cover
6 Pump shaft 12 Side plate 18 Shaft sub assembly

A 49-69 {500-700, 37-50} B 34-44 {350-450, 26-32}
OVERHAUL
EN07Z0703H200003
1. REMOVE THE FLOW CONTROL VALVE ASSEMBLY.

(1) Remove the plug, flow control valve assembly and spring.
NOTICE
Be careful not to drop, scratch or nick the flow control valve
assembly.
SAPH07Z070300086
2. REMOVE THE BODY COVER.

(1) Loosen the four fixing bolts that secure the body cover, then
remove the cover.
SAPH07Z070300087
3. REMOVE THE VANE PUMP CORE.

(1) As shown in the figure, face the vane pump core side downward
and remove the vane pump core. The vane pump core consists of
the cam ring, rotor and vane. Since dimensional checks of these
parts have been completed, handle the vane pump core carefully.
Remove the side plate and spring.
SAPH07Z070300088
4. DISASSEMBLE THE PUMP SHAFT ASSEMBLY.

(1) Remove the snap ring from the pump body, and push and remove
the spline edge surface of the pump shaft by hand or by using a
plastic hammer. Be careful not to damage the oil seal lip. This pro-
cess completes disassembly. Carry out inspection.
SAPH07Z070300089
REPLACEMENT
1. REPLACE THE BALL BEARING, IF NECESSARY.

(1) Use a pair of snap ring pliers to remove the retainer ring.
SAPH07Z070300090
(2) Use a press, press out the ball bearing.
SAPH07Z070300091
(3) Use a press, press in the ball bearing.
SAPH07Z070300092
(4) Use a pair of snap ring pliers, install the retainer ring.
SAPH07Z070300093
2. REPLACE THE OIL SEAL, IF NECESSARY.

(1) Use a screw driver, remove the oil seal.
NOTICE
Do not scrape or damage the inside of pump body.
SAPH07Z070300094
(2) Insert the oil seal as shown in the figure.

NOTICE
To prevent oil leakage from oil seal due to lip wear, apply lithium
base grease to A and B.
(3) Using a press, press in the oil seal into the pump body.
SAPH07Z070300095

JIG 1. INSTALL THE PUMP SHAFT.
(1) Apply grease to the oil seal lip.
BODY Recommended: Lithium grease

GROOVE
(2) Use a jig to install the shaft assembly.
(3) Install the snap ring into the groove completely.
OIL SEAL
SAPH07Z070300096
2. INSTALL THE VANE PUMP CORE.

(1) Press-fit the dowel pin into the pump body, then install in the
order: O-ring, spring, side plate, rotor, cam ring, and vane. Install
the cam ring so that the oval dowel hole is positioned at the valve
side of the body and that the rotation direction is correct. Install
the rotor so that the chamfer side of the spline faces the side
plate. Install the vane so that the radius edge contacts the inner
surface of the cam ring.
SAPH07Z070300097
3. INSTALL THE BODY COVER.

(1) Fit the O-ring and the body cover onto the pump body. Align the
dowel hole in the cover with the dowel pin, press the cover to the
edge surface of the body manually. Temporary tighten the bolts by
hand, then retighten to the specified torque.
SAPH07Z070300098
4. INSTALL THE FLOW CONTROL VALVE.

(1) Insert the flow control valve spring. Install the flow control valve
assembly into the body so that the pin side faces the plug side.
Tighten the plug.
5. INSPECT PUMP SHAFT ROTATING CONDITION.

(1) Check to see that the pump shaft rotates smoothly without abnor-
mal noise.
SAPH07Z070300099

EN07Z0703H300003
Pump shaft: — — Replace, Visual check

Damage if necessary.
Side plate: — — Replace, Visual check

Abrasion and flaw if necessary.
Flow control valve assembly: — — Replace, Visual check

Pump shaft bearing: — — Replace, Visual check

Scratched and damage if necessary.
Cam ring inner surface: — — Replace the Visual check

Rotor surface: vane pump core,
Vane surface: if necessary.
Wear, scratches and scoring
Oil seal: — — Replace, Visual check

OIL RESERVOIR (MODEL: GD)

DESCRIPTION
EN07Z0703C100005
SAPH07Z070300106
1 Oil reservoir cap 5 Filter cover seal

2 Oil seal 6 Filter cover
3 Oil strainer 7 Oil filter
4 Spring 8 Filter gasket
COMPONENT LOCATOR
EN07Z0703D100003
SAPH07Z070300107
1 Oil reservoir cap 3 Oil reservoir

2 Oil strainer
OVERHAUL
EN07Z0703H200004

NOTICE
• Use only compressed air to clean the oil filter.
• The oil filter is made of synthetic resin, so never wash it with
hot water, solvent or detergent.
• Before assembling, clean all the parts.

EN07Z0703H300004
Oil strainer: — — Clean or replace, Visual check

Clogged and damage if necessary.
Oil reservoir: — — Replace,

OIL RESERVOIR (MODELS: GH, FM)

DESCRIPTION
EN07Z0703C100014
SAPH07Z070300109
1 Oil reservoir cap 5 Filter cover

2 Oil strainer 6 Filter cover seal
3 Spring 7 Filter seal
4 Oil filter 8 Oil filter gasket
COMPONENT LOCATOR
EN07Z0703D100008
SAPH07Z070300110
1 Oil reservoir cap 6 Filter cover seal

2 Oil strainer 7 Filter seal
3 Spring 8 Oil filter gasket
4 Oil filter 9 Oil reservoir
5 Filter cover
OVERHAUL
EN07Z0703H200009

NOTICE
• Use only compressed air to clean the oil filter.
• The oil filter is made of synthetic resin, so never wash it with
hot water, solvent or detergent.
• Before assembling, clean all the parts.

EN07Z0703H300009
Oil strainer: — — Clean or replace, Visual check

Clogged and damage if necessary.
Oil reservoir: — — Replace,

Pub. No. S1-MGDE01A ’07-12

S1-MGDE01B ’11-11
S1-MGDE01C 1/2 ’12-5

S1-MGDE01C 1-2 For GD8J, GH8J & FM8J

Uploaded by

Copyright:

S1-MGDE01C 1-2 For GD8J, GH8J & FM8J

Uploaded by

Document Information

Original Title

Copyright

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

S1-MGDE01C 1-2 For GD8J, GH8J & FM8J

Uploaded by

Copyright:

S1-MGDE01C-1.

book 1 ページ ２０１２年５月２９日 火曜日 午後３時５６分

Manual Name Pub. No.

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MANUAL NO. S1-MGDE01C 1/2

GENERAL INTRODUCTION GN02-001

CLUTCH MAIN UNIT CL02-001 (CS380)

CLUTCH CONTROL CL03-001

TR05-001 TR05-002 TR05-003

PP02-002 PP02-003 PP02-004

DIFFERENTIAL CARRIER DF02-001 (SH14) DF02-002 (SH18) DF02-003 (THD17)

BRAKE EQUIPMENT BR01-001

SERVICE BRAKE BR02-001

ABS & ASR BR03-001 (ABS & ASR: WABCO MAKE)

EXHAUST BRAKE BR05-001

STEERING EQUIPMENT SR01-001

STEERING UNIT SR02-001

POWER STEERING SR03-001

INDEX: CHASSIS GROUP 1/4

CLUTCH MAIN UNIT

WORKSHOP CLUTCH CONTROL

MANUAL TRANSMISSION EQUIPMENT

TRANSMISSION MAIN UNIT

TRANSFER MAIN UNIT

PTO (POWER TAKE-OFF)

TRANSMISSION / TRANSFER CONTROL

PROPELLER SHAFT EQUIPMENT

ABS & ASR

ES START (EASY & SMOOTH START SYSTEM)

INDEX: CHASSIS GROUP 2/4

WHEEL & TIRE

COUPLER (5TH WHEEL)

INDEX: CHASSIS GROUP 3/4

INDEX: CHASSIS GROUP 4/4

CAB EQUIPMENT CONTROL

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

Conven- Conversion value*1 Conven- Conversion value*1

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

book 1 ページ２０１２年５月２９日火曜日午後３時５６分

Conven- Conversion value1 Conven- Conversion value1