ISUZU COMMERCIAL TRUCK

FORWARD
TILTMASTER

NPR/NPR HD/NQR
W3500/W4500/W5500
(DIESEL)
SERVICE MANUAL
CHASSIS
(1999-2001)
 FOREWORD
This service manual contains diagnosis, on-vehicle service, wiring diagrams, and component
unit repair for Medium Duty Steel Cab Vehicles.

Keep this manual in a handy place for ready reference. If properly used, it will enable the
technician to serve the owners of these vehicles.

CAUTION:
This service manual is intended for use by professional, qualified technicians.
Attempting repairs or service without the appropriate training, tools, and equipment could
cause injury to you or others and damage to your vehicle that may cause it not to operate
properly.
These vehicles contain parts dimensioned in the metric system as weil as in the customary
system. Some fasteners are metric and are very close in dimension to familiar customary
fasteners in the inch system. It is important to note that, during any vehicle maintenance
procedures, replacement fasteners must have the same measurements and strength as those
removed, whether metric or customary. (Numbers on the heads of metric bolts and on
surfaces of metric nuts indicate their strength. Customary bolts use radial lines for this
purpose, while most customary nuts do not have strength markings.) Mismaiched or incorrect
fasteners can result in vehicle damage or malfunction, or possibly personal injury. Therefore,
fasteners removed from the vehicle should be saved for re-use in the same location
whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken
to select a replacement that matches the original. For information and assistance, see your
Authorized dealer.
 CAUTION
To reduce the chance of personal injury and/or property damage, the following instructions
must be carefully observed.

Proper service and repair are important to the safety of the service technician and the safe,
reliable operation of all motor vehicles. If a part replacement is necessary, the part must be
replaced with one of the same part number or with a part of the same quality. Do not use an
incorrect or a replacement part of lesser quality.

The service procedures recommended and described in this service manual are effective
methods of performing service and repair. Some of these procedures require the use of tools
specially designed for the purpose.

Accordingly, anyone who intends to use a replacement part, service procedure or tool, which
is not recommended by the vehicle manufacturer, must first determine that neither technician
safety nor the safe operation of the vehicle will be jeopardized by the replacement part,
service procedure or toal selected.

It is important to note that this manual contains various Cautions and Notices that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. itis
also important to understand that these ‘Cautions’ and ‘Notices’ are not exhaustive, because
it is impossible to warn of all the possible hazardous consequences that might result from
failure to follow these instructions.
 1999-2001
SERVICE
ANUAL
CHASSIS
NPR/NPR HD/NQR
W3500/W4500/W5500
MODELS
Any reference to brand names in this manual is intended merely as an example of types of
lubricants, tools, materials, etc., recommended for use. In all cases, an equivalent may be
used.

All information, illustrations, and specifications contained in this manual are based on the
latest product information available at the time of publication approval. The right is reserved
to make changes at any time without notice.

PUBLICATION NO.
Isuzu Motors Limited NPDO1-WSM-CO1
©2000 Isuzu Motors Limited
Printed in U.S.A. January 2000

No part of this publication may be reproduced, stored in any retrieval system, or transmitted,
in any form or by any means, including but not limited to electronic, mechanical,
photocopying, recording or otherwise, without the prior written permission of
isuzu Motors Limited. This includes all text, illustrations, tables, and charts.
 NPR/NPR HD/NQR
W3500/W4500/W5500
TABLE OF CONTENTS
The table of contents on this page indicates the sections covered in this manual. At the beginning of each
individual section is a table of contents which gives the page number on which each major subject begins.

SECTION SUBJECT CONTENTS

0 GENERAL OA GENERAL OB MAINTENANCE AND

INFORMATION INFORMATION LUBRICATION

1 HEATING AND AIR ; 1A HEATING AND 1B AIR CONDITIONING

CONDITIONING VENTILATION

2A FRAME AND BODY 2C SHEET METAL

2 FRAME AND CAB MOUNTS
2B CAB MAINTENANCE

STEERING 3A FRONT END ALIGNMENT 3G FRONT AXLE AND

3 SUSPENSION 3B1 STEERING LINKAGE SUSPENSION
WHEELS AND 3B3 POWER STEERING 3D REAR SUSPENSION
TIRES 3B4 STEERING COLUMN 3E WHEELS AND TIRES

REAR AXLE AND | 4A1 REAR AXLE 4B PROPELLER SHAFT

4 PROPELLER
SHAFT

5A HYDRAULIC BRAKES 5A3 HYDRAULIC FOUNDATION

5A1 VACUUM BOOSTER BRAKES
5 BRAKES BRAKE SYSTEM 5A4 ANTI-LOCK BRAKE SYSTEM
5A2 HYDRAULIC BOOSTER (ABS)
BRAKE SYSTEM 5C PARKING BRAKE

7A AUTOMATIC 7C1 CLUTCH

TRANSMISSION (FOR MXA TRANSMISSION)
, TRANSMISSION | 7B1 MANUAL TRANSMISSION (MXA) 7C2 CLUTCH
7B2 MANUAL TRANSMISSION (MBP) (FOR MBP TRANSMISSION)

8 CAB AND CHASSIS | 8 CAB AND CHASSIS

ELECTRICAL ELECTRICAL

METRIC AND SAE | 9 METRIC AND SAE FASTENER

9 FASTENER INFORMATION
INFORMATION

10 STEEL TILT CAB | 10D STEEL TILT CAB

 NPR/NPR HD/NQR
W3500/W4500/W5500
MODEL DATA

Models for Manual Transmission

Truck Modei Engine Clutch Front Axle Rear Axle Transmission

Standard Standard Standard Standard Standard

NPR/W3500 4HE1-TON 11.8 inch Reverse Elliott Single Speed MXA5C

|-Beam Banjo, Full
NPR HD/W4500 | 4HE1-TCN Floating
4HE1-TCS

NQR/W5500 4HE1-TCS 12.8 inch MBP6P

Models for Automatic Transmission

Truck Model Engine Giutch Front Axle Rear Axle Transmission

Standard — Standard Standard Standard

NPR/NPR HD/ 4HE1-TCN — Reverse Elliott, Single Speed AISIN

NQR 4HE1-TCS |-Beam Banjo, Full 450-43LE
W3500/W4500/ Floating
W5500

Models for Manual / Automatic Transmission

Truck Model Brake

NPR/NPR HD Vacuum Assist + ABS

W3500/W4500

NQR HBB + ABS

W5500

+ HBB: Hydraulic Brake Booster

ABS : Anti-lock Brake System
MEMO
 GENERAL INFORMATION 0A-1

SECTION 0

CONTENTS
SUBJECT PAGE

General Information ...........cecceccsssecsssssescensarenescansesousrassenenesetiseeses cutsansentenusuasecetanusdeesetnnesteusaneusenueauseusesuscanonaese 0A

Maintenance and Lubrication ............s:cessssnsenssnrsssnsntenconsseeesnesstaersvonenuneusssastaeaenesansuneusieuneanearauevseevavenoansengetoas OB

SECTION 0A

CONTENTS

SUBJECT PAGE

Handling Electrostatic Discharge (ESD) Sensitive Parts ...........:ccsscsssesenseesscasasessessssneeccuenressanaeosenmnentegs OA- 2

Model Designation ...........:cscssesssssssesessesssenusrseranesenatsssanensensenseaentarsnacnesesensinsseeeasannavedseasecasaneaseusendseaanassens OA- 2
VIN (Vehicle Identification Number) and Weight Rating Plate...........-..0scesecsssecsssessssersesesemuracenonsecsatseens OA- 2
GVWR (Gross Vehicle Weight Rating) ...........:sssessssserssnseresseateesansaneansennesnsntensesnneananneeaneniuareaueraniacenates OA- 3
Service Parts Identification Label ............cccsscccsssenesteesesercoensneuneaesonsasasestansoneerageconedsaueninuseqeausunessaneneeseuseroes OA- 3
Regular Production Options (RPO) Code List .....-...::csssssssesensseneneene euanuassuvocanneeuaneeessnoaaeansonnttenqaaanennus OA- 4
Engine Serial NUMDET .........c.:scecscsesssrseeenesenseessnencensensantenaonenennaanantcarsessunseunusvovensunaeasacanansesnent staneceneneuseansaeens OA- 5
Graphic Symbols. ........ccsccsceseerenecenmnanseernenerenseenectenssersenrarisermenereunnoenianes senecaatentasseensnsuanseeseussousceaaunesernense OA- 5
Action SyMboIs ......ccssceescccsssessneanesenacenensanieseueresseanssmneeuiecuurorastsnneneanessennenens nevadenauvonsaaussenseausversarensereatass OA: 5
Emergency Starting a Vehicle Due to a Discharged Battery .............:scssssscsssssssssenseeseesesseesanesensceseesantetes OA- 5
Towing Procedure ......csccrresnenarcens naunesnsvoneoesausnansvscecsmeqanetoaeenecoussssnsatansracusnesesserssascenseusaecassnasensuasensueausnens OA- 6
Vehicle Lifting Points .........:.csensssessnssencansensceecensmnennsstneeneneesunnnsssimenesanneevaunnnens suseaueseuaseonenecuaventsavenseastansese OA- 7
Abbreviations Charts .........cccccscscessecssacesrsessenceseenesesnersoaraneusenteseuseunsesnenmnauacersaiercostenneasueesnusaneceantansneensnenreaeenae OA- 8
Essential Service TOONS .....cccc:esccesseoccnscccssssessensnsessusuesceeeoeusneensoontquosetyaevouscspeunsaueceanesseeacesaraaueeaeunanananeraanaaeanees OA-10
0A-2 GENERAL INFORMATION

HANDLING ELECTROSTATIC DISCHARGE

(ESD) SENSITIVE PARTS
Model
When handling an electronic part that has an ESD
sensitive sticker (figure 1), the service technician
should follow these guidelines to reduce any
NPR/NPR
possible electrostatic charge build-up on the
HD/NQR
service technician’s body and the electronic part in
W3500
the dealership:
W4500
1. Do not open the package until it is time to install
the part.
4x2
2. Avoid touching the electrical terminals of the
part.
3. Before removing the part from its package,
ground the package to a known good ground on Figure 3. Model identification
the vehicle.
4, Always touch a known good ground before
VIN (VEHICLE IDENTIFICATION NUMBER)
AND WEIGHT RATING PLATE
handling the part. This should be repeated
while handling the part and more frequently
The VIN and Weight Rating Plate (figure 4) lists
after sliding across the seat, sitting down from a
the manufacturer, gross vehicle weight for the
standing position or waiking a distance.
vehicle, maximum front end weight at ground,
maximum rear end weight at ground, and the VIN
(vehicle identification number). This plate is
NOTICE
s
attached to the inner face of the cab side panel on
the driver side.
The vehicle identification number is a legal
identifier of your vehicle. It not only appears on the
VIN plate, but also on the Vehicle Certificates of
Title and Registration. The vehicle identification
number specifically identifies a vehicle by code.
Figure 5 displays the codes and descriptions for the
model covered in this manual.
TO
STATIC ELECTRICITY

Figure 1. Electrostatic Discharge Symbol / - ~

O | (MANUFACTURER) | QO)
MODEL DESIGNATION WARRANTY MAY BE VOIOED ud oe ores ANY OF RATINGS SHOWN GROSS
VEHICLE WEIGHT INCLUDESWEIGHT OF BASE VEHICLE, Ati ADDED EQUIPMENT, CRIVER
ANO PASSENGERS, AND ALL PROPERTY LOADED INTO OR ONTO VEHICLE

The model designation for this vehicle is HATINGS IN POUNDS AG MANUFACTURED

NPR/W4S042. Refer to fiqure 2 for the model HIGHWAY GFE HIGHWAY

explanation and figure 3 for the model identification. GORE VERCLE EMME HOR Foe VERE E
as | ie
Cw
CODE DESCRIPTION £40 ene weet AF GRUUNE [ 4 __ ~ ~ __]

Ww Steel Tilt Gab

4 GVW Range - 10,001~16,000 Ibs
lO CU ~— lO,
5 GVW Range - 16,001—19,500 Ibs
$ Cab Style-68.0 in BBC Steel Cab Figure 4. VIN Weight Rating Plate
0 Constant - For Future Expansion

42 Chassis Type-4x2

Figure 2. Model Explanation

 GENERAL INFORMATION 0A-3

Gab Type Code Model Year Gode

GVWA and Engine
_Brake System Code
- Series Chassis Gheck Piant
Sequential Numbers

iooooe
identifiers Geode _ | Type Code Digit Code

aoaaapgagga
Code Description Code Piant Location
J Japanese Built 7 Fujisawa

Code Model Year

Code Description X 1999
A Isuzu Motors Y 2000
8 Isuzu Motors 1 2001

Code Description Code Description

4 Isuzu 4HE1-TCS
B Chevrolet Incomplete
D GMC Incomplete 5 isuzu 4HE1-TCN
L isuzu Incomplete
Code Description
| 4x2
Code Description
B 10001 - 14000 Ibs.
Code Description
Cc 14001 - 16000 lbs.
E 16001 - 19500 Ibs. B Stee! Tilt Cab
Hydraulic Brake System 67.8 inch BBC*
Gode Series
4 NPR/NPR HD *: Bumper to Back of Cab
5 NQR

Figure 5. VIN Chart

GVWR (GROSS VEHICLE WEIGHT

RATING) {SUZU MOTORS LTD. JAPAN

The GVWR is the weight of a vehicle plus the VIN. [~ JaLB4B1K6s7000001 |

weight of a vehicle’s load. For the gross vehicle
weight rating and the gross vehicle combined
a
ENGINE
a a RR AXLE [|
weight rating, refer to Model Explanation (figure 2). TRANS PINAL [
For the gross vehicle weight rating range refer to TIRE
the VIN Chart (figure 5).
B.COLOR/TRIM [___|
SERVICE PARTS IDENTIFICATION LABEL OPTION

The “Service Parts Identification” label (figure 6)

lists major components and their part numbers plus
vehicle options and their codes. The information on
_/
the label was printed at the factory; therefore, it XY
represents only the equipment on the vehicle when
it was shipped from the factory. Always refer to this Figure 6. Service Parts Identification Label
label when ordering replacement service parts.
(Refer to the “NOTICE” on the label.)
The service parts identification label is attached
to the inner face of the cab side panel on the
Passenger side.
0A-4 GENERAL INFORMATION

REGULAR PRODUCTION
OPTIONS (RPO) CODE LIST
The RPO list (figure 7) contains RPQs available
on this model. Also, refer to the “Service Parts
Identification” label (figure 6) for a list of the RPOs Note; F=Front
used on each specific vehicle. R=Rear
w/=With
OPTION OPTION OPTION OPTION
CODE DESCRIPTION CODE DESCRIPTION
100 INTERIOR-TRIM COLOR COMBI(IN WHITE) RNJ AUTOMATIC TRANSMISSION 4-SPEED (AISIN}
153 INTERIOR-TRIM COLOR COMBI.(GRAY) RNL MANUAL TRANSMISSION-5 SPEED (MXA-5C)
729 BODY COLOR CODE-ARC WHITE (W301-P801) M11 SHIFT-FLOOR (REMOTE)
730 BODY COLOR CODE-ADRIATIC BLUE V66 POWER TAKE OFF-PROVISIONS FOR
(B302-P801) NL7 FUEL TANK-125L, 33GAL
800 BODY COLOR CODE-IN WHITE 6HU FUEL SEDIMENTER-WITH HEATER
979 BODY COLOR CODE-HEILING MAYERS GREEN N33 STEERING COLUMN-TILT TYPE
De4 PAINT-TOUCH-UP, ONE COLOR (WITH TELESCOPIC)
VG1 WAX-PROTECTIVE UNDERBODY N40 STEERING-POWER
RWC | CANADIAN EQUIPMENT ASQ | F/TIRE215/85R16-E, R/TIRE215/85R16-E
6SH BUDGET PACKAGE F&R/DISC 16X6K-127 w/DOT MARK
7VH OFFICE DEPOT PACKAGE WHITE DISC, (BS BRAND, R187)
YL3 FRIGID ZONE KIT AVE | F&R/TIRE 225/70R19.5
6JJ DEALER INSTALLATION OPTION F&R/DISC 19.5X6.00-127, WHITE
6FM US TERRITORY (FT HIGHWAY, RR MUD & SNOW)
RQF | GVWR CLASS-3 (10001-14000 LBS) AVU F&R/TIRE 225/70R19.5
RQG | GVWR CLASS-4 (14001-16000 LBS) F&R/DISC 19.5X6.00-127, WHITE
RQH | GVWR CLASS-5 (16001-19500 LBS) (FT & RR HIGHWAY)
7NQ_ | VEHICLE CATEGORY-NQR AVZ F&A/TIRE 225/70R19.5 (FOR BUDGET)
6FZ FENDER GOVER F&R/DISC 19.5X6.00-127, WHITE
RWZ | CAB-TILT, MANUAL (FT & RR MUD & SNOW)
EK7 MARK-VEHICLE NAME AZF F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
aus SEAT BELT EXTENSION F&R/DISC 16X6K-128 w/DOT MARK
p20 SUNVISOR-CO-DRIVER SIDE WHITE DISC (ALL SEASON)
C41 HEATER & DEFROSTER gYY F/TIRE 215/85R16-E, R/TIRE 215/85R16-E JU019
C60 AIR CONDITIONER-MANUAL CONTROL F&R/DISC 16X6K-127 w/DOT MARK
C55 VENTILATOR-ROOF WHITE DISC
v92 TRAILER PROVISIONS 9Yz F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
F59 STABILIZER SHAFT-FRONT F&R/DISC 16X6K-127 w/DOT MARK
G73 AXLE REAR-HEAVY DUTY WHITE DISC, FOR BUDGET
6CP AXLE REAR-HEAVY DUTY VAR.2 9ZB F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
GT5 FINAL DRIVE GEAR RATIO-4.100 (41/10) | F&R/DISC 16X6K-127 w/DOT MARK
HC6 FINAL DRIVE GEAR RATIO-4.556 (41/9) | WHITE DISC (ALL SEASON)
R40 FINAL DRIVE GEAR RATIO-5.375 (43/8) 9ZC F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
R41 FINAL DRIVE GEAR RATIO-5.857 (41/7) F&R/DISC 16X6K-127 w/DOT MARK
7QQ_ | BRAKE SYSTEM-HYDRO BRAKE BOOSTER WHITE DISC FOR BUDGET (ALL SEASON)
NFS EXHAUST-BRAKE 9zD F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
J52 BRAKES-FT DISK, MULTIPLE PISTON F&R/DISC 16X6K-127 w/DOT MARK
6PH BRAKE-WHEEL LOCK CONTROL, (L.S.P.V) WHITE DISC, (RR ALL SEASON)
JES ANTI LOCK BRAKE SYSTEM 9zV F/TIRE 215/85R16-E, R/TIRE 215/85R16-E
RLY ENGINE-DIESEL 4CYL L 4.8L (4HE1) F&R/DISC 16X6K-127 w/DOT MARK, WHITE
EE2 GOVERNOR-ENGINE, WITH HIGH ALTITUDE US DISC (ALL SEASON, US GOODYEAR)
COMPENSATOR R46 SPARE TIRE & DISC WHEEL VAR.1
K51 TURBO CHARGER 7NC SPARE TIRE & DISC WHEEL-LESS
Kd3 AIR INTAKE SYSTEM; RR VERTICAL P10 CARRIER-SPARE WHEEL (TRUCK)
6PL INTERCOOLER uot LAMPS-FIVE, ROOF MARKER
7QV ENGINE POWER N-SPEC 6GZ RADIO-AM/FM STEREO ETR 2-SPEAKERS
BAA LONG LIFE COOLANT (50%) 6VL AM/FM w/CASSETTE 2SP 31N-1
6HT HEATER-OIL PAN u73 ANTENNA
KOS HEATER-ENGINE BLOCK 7FK SPEAKER OPTION: 2-SPEAKER
RNC | MANUAL TRANSMISSION-6 SPEED (MBP-6P) C13 WIPER-WITH INTERMITTENT

Figure 7. Regular Production Option List

 GENERAL INFORMATION 0A-5

ENGINE SERIAL NUMBER ..Disassembie

eee
The engine serial number is machined on the left
side of the engine just above the oil pan. ..Assemble

GRAPHIC SYMBOLS

R
..Glean

Graphic symbols are used on some controls and

displays on the vehicle (figure 8). Many of these inspect

eB &
symbols are used internationally.

SE
... Measure

s é od

7 -O-||2D Adjust
a

me
é i x real
—
LMT
COOLANT ENGINE OM. FUEL MASTER Ligier .. Tighten to specified torque

GT
am FD

5002| aed} | HL
s %

oe
te .. important
e

TEREE| Pees | [eae | Se)

WONORRRELD
ae
EMERGENCY STARTING A VEHICLE DUE
TO DISCHARGED BATTERY
a
Rr
WOLE SPEED
If your vehicle will not start due to a discharged
battery, it can often be started by using energy from
DOME UGHT BODY INTERIOR ALUMINA TION
LIGHT SWITCH CONTROL CONTROL
SWITCH

AED | 00 [ESI] #
another battery—a procedure called “jump starting.”
This vehicle has a 12volt starting system and a
ue

Lidl
oaee
ame negative ground electrical system. Be sure that the
MAzARD wAgHING HIGH BEAM Show PLUG Mi
——aarieny
Almac FACE other vehicle also has a 12volt starting system, and
that it is the negative (black “~”) terminal which is
grounded (attached to the engine biock, chassis or
we GY (G} frame rail). Its owner’s manual may give you that
us upd
information. DO NOT TRY TO JUMP START IF
BrLEVEL Foor SEPROSTER DEFROSTER pecancULATION YOU ARE UNSURE OF THE OTHER VEHICLE’S
VOLTAGE OR GROUND (OR IF THE OTHER

A BO VEHICLE’S VOLTAGE AND GROUND ARE

on 6

DIFFERENT FROM YOUR VEHICLE).

FRESH AI LIGA TEER: HOR muwnina rast
Podeng Soko
[ara eaneg rt
Some diesel engine vehicles have more than one
battery because of higher torque required to start a
diesel engine. This procedure can be used to start
Figure 8. International Symbols a single battery vehicle from any of the diesel
vehicle's batteries. However, it may not be possible
ACTION SYMBOLS to start a diesel engine from a single battery in
another vehicle, at low temperatures.
In this manual, much of the general narrative has
been replaced with step-by- step procedures and NOTICE: Never tow the vehicle to start, because
the addition of “Action Symbols.” To improve the surge forward when the engine starts could
readability and to provide emphasis where cause a collision with the tow vehicle. Also, this
necessary, the following symbols are used in the vehicle has 12volt batteries. Be sure the vehicle or
manual. equipment used to jump start your engine is also
a 12volt Use of any other system may damage the
| Remove or Disconnect vehicle’s electrical components.

foe] install or Connect

0A-6 GENERAL INFORMATION

Jump Starting Instructions

CAUTION: Batteries produce explosive gases, Make Connections in Numberical Order
contain corrosive acid, and supply levels of DO NOT Allow the Vehicles Charged
electrical current high enough to cause burns. To Touch a Battery
Therefore, to reduce the risk of personal injury steed, a 2
when working near a battery:
- Always shield your eyes and avoid leaning Discharged
over a battery whenever possible. Battery ‘
« Do not expose a battery to open flames or
L e ——_—
sparks. 4m
» Be sure any batteries that have filler caps are
properly filled with fluid.
* Do not allow battery acid to contact eyes or = Cc
skin. Flush any contacted area with water
immediately and thoroughly, and get medical
Make last connection on frame away from
help.
the battery.
¢ Follow each step in the jump starting
instructions.
1. Position the vehicle with the good (charged) Figure 9. Jump Starting Diagram
battery so that the booster (jumper) cables will
reach but never let the vehicles touch. Aiso, be
TOWING PROCEDURE
sure the booster cables to be used do not have Proper equipment must be used to prevent
loose or missing insulation. damage to vehicles during any towing. State
2. In both vehicles: (provincial in Canada) and local laws that apply to
« Turn off the engine control switch and ail vehicles in tow must be followed.
lights and accessories except the hazard » Vehicles should not be towed at speeds in excess
flasher or any lights needed for the work area. of 5&8 mph (90 km/h).
* Apply the parking brake firmly, and shift the * Connect to the main structural parts of the
automatic transmission to Park or manual vehicle.
transmission to Neutral. * DO NOT attach to bumpers, tow hooks or
3. Make sure the cable clamps do not touch any brackets.
other metal parts. Clamp one end of the first > Use only equipment designed for this purpose.
booster cable to the positive “+"terminal on one * Follow the instructions of the wrecker
battery, and the other end to the positive manufacturer.
terminal on the other battery. Never connect “+” * Asatety chain system must be used.
to “—" (figure 9). « The procedures below must be followed when
4. Clamp one end of the second cable to the towing, to prevent possible damage.
negative “—” terminal of the good (charged) Front End Towing
battery and the final connection (to any solid, (Front Wheels Off The Ground)
stationary metallic object) on the engine at least
Before Towing
450 mm (18 in) from the discharged battery; or
the frame rail, chassis or some other well- To prepare a disabled vehicle for front end towing
grounded point, if the battery is mounted with front wheels raised off the ground, the
following steps are necessary:
outside the engine compartment. Make sure the
* Block the rear wheels of the disabled vehicle.
cables are not on or near pulleys, fans, or other
Manual Transmission Models
parts that will move when the engine is started.
* Shift into neutral position.
5. Start the engine of the vehicle with the good
* If there is damage or suspected damage to the
(charged) battery and run the engine at a
transmission, disconnect the propeller shafts at
moderate speed for several minutes. Then, start
the rear axle.
the engine of the vehicle that has the
Secure the propeller shafts to the frame or
discharged battery.
crossmember,
6. Remove the jumper cables by reversing the
Automatic Transmission Models
above installation sequence exactly. While
» Disconnect the propeller shafts at the rear axle.
removing each clamp, take care that it does not
Secure the propeller shafts to the frame or
touch any other metal while the other end
crossmember.
remains attached.
NOTICE: Never tow the vehicle with propeller
 GENERAL INFORMATION 0A-7

shafts is connected, as this may cause damage to ahead position. Make certain that the front axle is
the automatic transmission. not loaded above the front axle Gross Axle Weight
Rating (GAWR) as indicated on the vehicle’s VIN
* Provide wood blocking to prevent towing chain
and Weight Rating Plate.
and bar from contacting the bumper.
° If there is damage or suspected damage to the Special Towing Instructions
rear axle, remove the axle shafts. Cover the hub 1. All state and local laws regarding such items as
openings to prevent the loss of lubricant or entry warning signals, night illumination, speed, etc.,
of dirt or foreign objects. must be followed.
After Towing 2. Safety chains must be used.
« Block the rear wheels and install the axle and 3. No vehicle should ever be towed at over 55
propeller shafts if removed. mph (90 km/h).
+ Apply the parking brake before disconnecting 4. Loose or protruding parts of damaged vehicles
from the towing vehicle. should be secured prior to moving.
» Check and fill rear axie with oil if required. 5. A safety chain system completely independent
of the primary lifting and towing attachment
Front End Towing must be used.
(All Wheels On The Ground) 6. Operators should not go under a vehicle that is
Before Towing being lifted by the towing equipment unless the
Your vehicle may be towed on all wheels provided vehicle is adequately supported by safety
the steering is operable. Remember that power stands.
steering and brakes will not power assist. There 7. No towing operation that for any reason
must be a tow bar installed between the towing jeopardizes the safety of the wrecker operator
vehicle and the disabled vehicle. or any bystanders or other motorists should be
To prepare a disabled vehicle for front end towing attempted.
with all wheels on the ground, the following steps VEHICLE LIFTING POINTS
are necessary:
» Block the rear wheels of the disabled vehicle. Figure 10 shows the jack stand placement points.
Manual Transmission Models CAUTION: To help avoid personal injury when a
« Shift into neutral position. vehicle is on a jackstand, provide additional
- If there is damage or suspected damage to the support for the vehicle at the opposite end from
transmission, disconnect the propeller shafts at. which components are being removed. This will
the rear axle. reduce the possibility of the vehicle falling off of
Secure the propeller shafts to the frame or the stand.
crossmember.
Automatic Transmission Models
- Disconnect the propelier shafts at the rear axle.
Secure the propeiler shafts to the frame or
crossmember.
@il

NOTICE: Never tow the vehicle with propeller

shafts connected, as this may cause damage to
the automatic transmission.
indicates Area
* Provide wood blocking to prevent towing chain
for Jackstand
and bar from contacting the bumper. Placement, etc.
: If there is damage or suspected damage to the
rear axle, remove the axle shafts. Cover the hub
openings to prevent the loss of lubricant or entry
of dirt or foreign objects.
After Towing
» Block the rear wheels and install the axle and
propeller shafts if removed.
» Apply the parking brake before disconnecting
from the towing vehicle.
* Check and fill rear axle with oil if required.
Rear End Towing
Figure 10. Vehicle Lifting Points
When towing a vehicle with rear wheels raised,
secure the steering wheel to maintain straight-
0A-8 GENERAL INFORMATION

ABBREVIATIONS CHARTS
For abbreviations of emission system, refer to the section GE.

LIST OF AUTOMOTIVE ABBRIVIATIONS WHICH MAY BE USED IN THIS MANUAL

A — Ampere (s) DVM - Digital Voitmeter (10 meg.)
ABS ~ Antilock Brake System DVOM — Digital Volt Onmmeter
AC ~ Alternating Current EBCM — Electronic Brake Control Module
A/C — Air Conditioning ECM — Engine Control Module
ACCEL -— Accelerator ECT ~ Engine Coolant Temperature
ACC - Accessary EEPROM - Electronically Erasable Programmable
ACL - Air Cleaner Read Only Memory
Adj — Adjust EGR — Exhaust Gas Recirculation
A/F — Air Fuel Ratio El ~ Electronic ignition
AIR — Secondary Air Injection System ESD ~ Electrostatic Discharge
Alt — Altitude ETR — Electronically Tuned Receiver
AMP — Ampere (s) EVAP -- Evaporation Emission
ANT — Antenna Exh — Exhaust
ASM -— Assembly °F ~ Degrees Fahrenheit
A/T — Automatic Transmission Fed — Federal (All States Except Calif.)
ATDC - After Top Dead Center FF - Front Drive Front Engine
ATF — Automatic Transmission Fluid FICD ~ Fast idle Control Device
Auth ~— Authority FL -~ Fusible Link
Auto — Automatic ~ Front Lett
BARO - Barometric Pressure FLW ~ Fusible Link Wire
Bat — Battery FP — Fuel Pump
B+ — Battery Positive Voltage FR ~ Front Right
Bb! ~ Barrel FRT ~ Frant
BHP — Brake Horsepower ft ~ Foot
BPT ~ Back Pressure Transducer FWD — Front Wheel Drive
BTDC — Before Top Dead Center 4x 4, 4WD — Four Wheel Drive
°C — Degrees Celsuis 4 A/T - Four Speed Automatic Transmission
CAC — Charge Air Cooler Gal — Gallon (3.7858 }
Calif - California GEN — Generator
cc — Cubic Centimeter GND ~ Ground
CID — Cubic inch Deplacement Gov — Governor
CKP — Crankshaft Position g ~ Gram
CKT — Circuit Harn — Harness
CL —- Closed Loop HBB -- Hydraulic Brake Booster
CLCC ~ Closed Loop Carburetor Control HC — Hydrocarbons
CMP — Camshaft Position HD ~ Heavy Duty
CO — Carbon Monoxide Hg -- Hydrargyrum (Mercury)
Coax — Coaxial HiAlt — High Altitude
Conn — Connector HO2S ~ Heated Oxygen Sensor
Conv — Coverter HU — Hydraulic Unit
Cu.in. — Cubic Inch HVAC ~— Heater-Vent-Air Conditioning
CV — Constant Velocity IAC ~ Idle Air Control
DI —- Distributor Ignition IAT ~ Intake Air Temperature
Diff — Differential IC — Integrated Circuit
Dist — Distributor ID — identification
DLC -— Data Link Connector -- Inside Diameter
DOHC — Doubte (or Dual) Overhead Camshaft IGN — Ignition
DRL ~ Daytime Running Light int -- Intake
DTC — Diagnostic Trouble Code IP — Instrument Panel
DTM ~— Diagnostic Test Mode IPC ~ instrument Panel Cluster
DTT ~ Diagnostic Test Terminal iSC — Idle Speed Control
 GENERAL INFORMATION 0A-9

J/B — Junction Block QWS — Quick Warming-up System

kg — Kilograms REF ~ Reference
km — Kilometers RF — Right Front
km/h — Kilometer per Hour RFI ~ Radio Frequency interference
kPa — KiloPascals RH — Right Hand
KS — Knock sensor RL -~ Rear Left
kV — Kilovolts (Thousands of Volts) RPM — Revolutions per Minute
kW — Kilowatts RPS -- Revolution per Second
L. — Liter RPM Sensor — Engine Speed Sensor
lb-ft - Foot Pounds RPO — Regular Production Option
ib-in — Inch Pounds RR -- Right Rear
LF — Left Front RS - Right Side
LH — Left Hand RTV — Room Temperature Vulcanizing
LR —- Left Rear RWAL — Rear Wheel Antilock Brake
LS — Left Side RWD — Rear Wheel Drive
LWB — Long Wheel Base SAE - Society of Automotive Engineers
L-4 — In-line Four Cylinder Engine Sec — Secondary
MAF — Mass Air Flow SFI — Sequential Multiport Fuel Injection
MAN — Manual $1 —- System International
MAP — Manifoid Absolute Pressure SIR — Supplemental Inflatable Restraint System
Max — Maximum SOHC — Single Overhead Camshaft
MC — Mixture Control Sol - Solenoid
MFI — Multiport Fuel Injection SPEC - Specification
MIL — Malfunction Indicator Lamp Speedo - Speedometer
Min — Minimum SRS ~ Supplemental Restraint Systern
mm — Millimeter ST ~- Start
MPG — Miles per Gallon ~ Scan Tool
MPH ~ Miles per Hour Sw ~ Switch
M/T — Manual Transmission/Transaxle SWB - Short Wheel Base
MV — Millivoit SYN — Synchronize
NA ~ Natural Aspirated Tach - Tachometer
NC -- Normally Closed TB — Throttle Body
N-m — Newton Meter TBI -- Throttle Body Fuel injection
NO — Normally Open TCC — Torque Converter Clutch
NOx — Nitrogen, Oxides of TCM - Transmission Control Module
OBD — On-Board Diagnostic TDC ~ Top Dead Center
OD — Outside Diameter Term — Terminal
O/D — Over Drive TEMP — Temperaure
OHC — Overhead Camshaft TP — Throttle Position
OL — Open Loop TRANS — Transmission
O2 — Oxygen TURBO ~ Tubocharger
02S — Oxygen Sensor TVRS — Television & Radio Suppression
PAIR — Pulsed Secondary Air Injection System TVV - Thermal Vacuum Valve
P/B — Power Brakes TWC -~ Three Way Catalytic Converter
PCM ~ Powertrain Control Module 3 A/T — Three Speed Automatic Transmission
PCV — Positive Crankcase Ventilation 2WD — Two Wheel Drive
PRESS ~— Pressure 4 x 2 ~ Two Wheel Drive
PROM — Programmable Read Only Memory U-joint - Universal Joint
PNP — Park/Neutral Position V ~ Volt (s)
P/S — Power Steering VAC ~ Vacuum
PSI — Pounds per Square Inch VDC — Volts DC
PSP — Power Steering Pressure VIN -- Vehicle Identification Number
Pt. — Pint = 1/8 gallon 0.473125! VRRRE -— Vehicle Refrigerant Recovery and
Pri — Primary Recycling Equipment
PWM — Pulse Width Modulate V-ref - ECM Reference Voitage
VSS ~ Variable Swirl System
Qt - Quart = 1/4 gallon 0.946252
0A-10 GENERAL INFORMATION

ABBREVIATIONS CHARTS (Continued)

VSS — Vehicle Speed Sensor w/b — Wheel Base

VSV — Vacuum Switching Valve W/L. — Warning Light
V-6 — Six Cylinder “V’ Engine w/o — Without
W — Watt (s) WOT — Wide Open Throttle
w/ — With WSS ~ Wheel Speed Sensor

ESSENTIAL SERVICE TOOLS

Essential service tools that are shown in this
service manual that have tool product numbers
beginning with “J” are available for worldwide
distribution from:
Kent-Moore
SPX Corporation
29784 Little Mack
ROSEVILLE,MI 48066-2298
1-800-328-6657
Mon.-Fri. 8:00 p.m. EST
Telex: 244040 KMTR UR
FAX-313-578-7375
 MAINTENANCE AND LUBRICATION OB-1

SECTION 0B

MAINTENANCE AND LUBRICATION

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE

Lubrication Detall Information .........::c.scsscssssecsssaressesseseessenteuroremenensensecesenneeneaseesseresataneenssereneneanauaeuaasamns aye OB- 1

Engine Oil and Viscosity Recommendation s. ..........ceseesersece raennenemnnererneerars ensemtensens cesecuauesenvoueaneceen OB- 1
Maintenance Schedulle ..........cccccsccsscssessressseonseeseeneonsnancnasuectususesogussressnensesnecsensnuenseeasnanszerecaetaenrnaunatensnnezenroes 0B- 3
Explanation of Complete Vehicle Maintenance Schedule .........0.-..scssssnesccerssansentensenssenanusninnecsatsaneneaniensenes OB- 6
Normal Vehicle US6 ..........cccscsseesctssseerescarsnescunsonsapeseseesnanecscaseneneunerseuceamennesseuraones savenanenenseesneneagaraenasanaazonns OB- 6
Owner Safety and Routine Maintenance ..........0:ssscssesseseressussnersssenscersonensnsnsersnarensinerenateentniorerarannvenens OB- 9
Noise Emission Control .......ccsccsssscnesnernsnrenieamactenemensenuens saovusnavusapeneutanenuaarsereesnauvoneqanvenersneveniertonatseedausenes OB-10
Noise Control SYSteIm.......cusecseeerscsnenencesciananesteanenuariersusnmasunanetanieninecaerneannenzeenss eieesesanensuasvosneuenaaoenss 0B-10
Tampering with Noise Control System Prohibited......... aetansersuansswsveseesdeususeueaeonnenuaarseunarsunenecousitengerssanenas 0B-10
Recommended Fluids and LUbriGant..........ccssscseseeusessssonecseurersccsueenensnessnanentenuiueauterssanstsnieaes caseusaeanansnneeae 0B-11
Lubrication Chart ......cccsc::ccccsssessescessensneteesserenceescsensersasnuancaauaianesunssaueasuanesnnedusanedacuecorsensusedmenvedauucauvansueesenasny 0B-12
Specifications .........ecscescerereceseneeesenscasentarscorsnssneesnnerssnansarsanesarecannnannsnenents saveddeanacdeaesuarsatenerseavenevaautsceseonseesson OB-13
Capacities ........ccsssecssseescssssssersnessnsertusetansennsinassarestisssssnrsensarsnenasranctmtanisenines saeveeuensueenansoestensusnenuneneens sennanes OB-13
Mintenace [tM .......ccccccrscscsssssssesesecsecsnenssseacedesesnansenonensausnuonaseandnenenenarsaresunsannaantatanesounaniiseageusscogsaencensaannanas 0B-13
Fastener TOrQues.....nccssccssssrseessnessecinansessensenseasaenencacsrausseauenennensesrcanenens eenencueentuorueasoneasansenmereniaceranseas euntenes 0B-13

LUBRICATION DETAIL INFORMATION

ENGINE OIL AND VISCOSITY quality. Be sure the oil you use has the API
RECOMMENDATIONS designation “CD”, either alone or shown with other
designations such as “SF/CD”. Oils which are not
The oil industry markets various types of engine labeled “CD” should not be used. For example, do
oil under certain service designation and not use oils labeled only SA, SB, SC, SD, SE,
specification numbers. CA, CB, CC, or oils with a combination of any of
The selection of a reliable supplier and close these letters—-such as SE/CC, as this may cause
attention to the oil and filter element change engine damage.
recommendations can provide satisfactory DO NOT USE SYNTHETIC OILS.
. . —— _
lubrication and longer life for the engine.
Using the proper engine oil and following the Diesel Engine Oil Viscosities
recommended oil change intervals is your best Viscosity numbers make up a classification of
assurance of continued reliability and performance lubricants in terms of fluidity or viscosity, but with
from your vehicle’s engine. no reference to any other characteristics or
Engine oil containers are labeled with various properties.
AP\(American Petroleum institute) designations of
 0B-2 MAINTENANCE AND LUBRICATION

ENGINE Ol. VISCOSITY GAADE — AMBIENT TEMPERATURE

[Singie grade)

[ferment ke 30°C ~ 1S
Temparature ly - 20°F) {OF}
(Miu grace:

Ee SAE 15W—40 1SW-SO 20W_—a0 2o0r— a

DO NOT USE SYNTHETIC OILS

Figure 1. Oi! Viscosity Chart

Where cold weather starting is a problem,oil and Diesel Break-In Oils And Additives
coolant system heaters,as well as proper fuel
The use of proprietary blends of supplementary
selection, will be helpful. However, if these are not
additives or concentrates such as engine oil
available, lighter viscosity oils may be used only to
supplements, break-in oils, tune-up compounds,
facilitate starting. Do not use starting aids in the air
friction reducing compounds, etc., is not
intake system. Such “aids” can cause immediate
recommended in lubricating oils of the diesel
engine damage.
engine in these vehicles.
The engine oil viscosity specification depends on
the temperature of the engine oil at the time of
Change Intervals
starting the engine. Viscosity recommendations for
various starting temperatures are shown in the The oil and oil filter change intervals for the
‘Viscosity Chart”. engine are based on the use of CD-quality oil and
When choosing an oil, consider the range of high quality filters. Using oil other than CD-
temperature your vehicle will operate in before the quality, or not changing the oil and filter often
next oil change. Then, select the recommended oil enough could reduce engine life. Darnage to
viscosity from the chart (figure 1). engines due to improper maintenance or use of
incorrect oil quality and/or viscosity is not covered
by the warranty.
 MAINTENANCE SCHEDULE FOR NPR, NQR/W-Series

Service Intervals

166 400

145 600
156 000

31200
124 800
135 200

114 400

83 200
93 600
104 000

62 400
72 800

20 800
41 600
52 000

10 400
Interval (kilometers)
Months or Miles
(kilometers)
whichever
comes first

104,000

91,000

78,000
84,500
97,500

71,500

45,500
52,000
58,500
65,000

39,000

26,000
32,500

19,500
13,000
6,500
interval (Miles)
No. item

Engine Noise Check

idle Speed

Valve Lash

NN]
Oo | +
injection Timing

Ww
injector

|
©
Engine Oil & Oil Filter or every 12 months

cir
or every 12 months

I~
Fuel Filter
ciele

a
MAINTENANCE SCHEDULE

Air Cleaner Filter or avery 12 months

Air intake system (Duct, Hose & Clamps)

Drive Belt or every 12 months

Engine Bolt Torque

Rotate Tires R R R R R R R R R R R R R R

(I): inspect, replace or adjust if necessary (A): Adjust (FR): Replace (7): Tighten to specified torque (L): Lubricate
* Initial Torque check at 650 miles is required. {C): Clean
MAINTENANCE AND LUBRICATION 0B-3
 MAINTENANCE SCHEDULE FOR NPR, NQR/W-Series (CONT.)

Service Intervals

31200

10 400
20 800
41 600
52 900
62 400
72 800
83 200
93 600
114 400
104 000
124 800
135 200
145 600
156 000
166 400
Months or Miles
(kilometers)
whichever
comes first
interval (Miles)

13,000
19,500

6,500
26,000
32,500
39,000
45,500
52,000
58,500
65,000
71,500
78,000
84,500
91,000
104,000
97,500
No. Item
4
i Engine Cooling System or every 12 months
Engine Coolant

oc
0B-4 MAINTENANCE AND LUBRICATION

or every 24 months
Exhaust System

Fuel Line System or every 12 months

Brake Lining and Pad for Wear
Brake Drum and Rotor for Wear and Damage or every 12 months
Brake Fluid or every 12 months
Hydraulic Brake Booster Fluid or every 24 months
Brake Line LSV and Hoses or every 12 months
MAINTENANCE SCHEDULE (CONT.)

Clutch Pedal Free Travel!

| | or every 12 months
Manual Transmission Oil R Riiiiik®R Ri | or every 12 months
Automatic Transmission Fluid R Pr iyiarR or every 12 months
| 1 | R
(1): Inspect, replace or adjust if necessary {A): Adjust (R): Replace (T): Tighten to specified torque (L): Lubricate
 MAINTENANCE SCHEDULE FOR NPR, NQR/W-Series (CONT)

Service Intervals

166 400

124 800
135 200
145 600
156 000

114 400
104 000

83 200
93 600

62 400
72 800

52 000

31 200
41 600

10 400
20 800
intervai (kilometers)
Months or Miles
(kilometers)
whichever
comes first
104,000

84,500
91,000
97,500

65,000
71,500
78,000

52,000
58,500

45,500

26,000
32,500
39,000

19,500
interval (Miles)

13,000
6,500
No. | Item
a

x
tc

or
25 | Automatic Transmission Filter or every 24 months

7
=
26 | Differential Gear Oil Pi iad or every 24 months

27 | Power Steering Fluid R R R or every 12 months

28 | Steering Gear Box Torque T T T T |) or every 12 months
i

F
ke
k

fo
oO
C
&
&
id)

6
>

[en

be
oO

cA)

vt

29 | Propeller Shaft Flange Torque

30 | Leaf Spring U-Bolt Torque” 7 i

-
~

-
b

-
kK

e
fron

re
be

be
I
31. | Wheel Nut Torque* T

| fe
be | ed

| amd

sd
com
med

nol
sod

nl

|1
J

aul

32 | King Pin
=f
von

ad
oad

ed

and
|

vend
33 | Propeller shaft or every 12 months
MAINTENANCE SCHEDULE (CONT.)

34 | Wheel Bearing Grease R R R or every 12 months

oad

wow
woud

35 | Rear Spring Pins LiL yLibae L

(1): Inspect, replace or adjust if necessary (A): Adjust (R): Replace {7}: Tighten to specified torque (L): Lubricate
* Initial Torque check at 650 miles is required.
MAINTENANCE AND LUBRICATION OB-5
0B-6 MAINTENANCE AND LUBRICATION

EXPLANATION OF COMPLETE VEHICLE

MAINTENANCE SCHEDULE
The following is a brief explanation of the service for at least several miles/kilometers.
listed in the preceding Complete Vehicle « to be driven on proper fuel (See Owner’s Manual:
Maintenance Schedule. Diesel Fuel Requirement.).
Unusual operating conditions will require more
NORMAL VEHICLE USE frequent vehicle maintenance, as specified in the
following section.
The vehicle maintenance instructions in the
Maintenance Schedule are based on the 1. ENGINE NOISE—These components have an
assumption that the vehicle will be used as effect on the control of noise emissions.
designed: 2. IDLE SPEED — Check and adjust the engine
* to carry passengers and cargo within the idie speed at first 6,500 miles (10,400 km) and
limitations specified on the tire placard. every 52,000 miles (83,200 km). Adjustments
* to be driver: on reasonable road surfaces within must be made with test equipment known to be
legal operating limits. accurate.
* to be driven on a daily basis, as a general rule,

Engine (Every 6,500 miles or 10,400 km) inspection sound absorption materials for tears, broken out
sections or attachment. Repair or replace as necessary.

Cooling system (Every 13,000 miles or Inspection fan, shroud and radiator for attachment, tears or
20,800 km) cleanliness. Repair or replace as necessary.

Air intake system (Every 26,000 miles or Inspect all ducts, hoses and intake silencers for leaks or
41,600 km) | chafing.Repair or replace as necessary.

Exhaust system (Every 6,500 miles or inspect silencer, pipes, gaskets, clamps and mounting for
10,400 km) exhaust gas leaks or looseness. Repair or replace as
necessary.

Cab (Every 6,500 miles or 10,400 km) Inspect sound absorption materials for tears, broken out
sections or attachment. Repair or replace as necessary.

3. VALVE LASH —~ Incorrect valve clearance will occurs first.

result in increased engine noise and lower * SEVERE SERVICE — Change every 3,600
engine output, thereby adversely affecting miles (5,760 km) or 3 months if the vehicle is
engine performance. Retorque rocker shaft often driven under one or more of these
bracket nuts before checking and adjusting conditions (a) driving in dusty areas, (b)
valve clearance. Check and adjust valve frequent idling or idling for lang periods, (c)
clearance at every 52,000 miles (83,200 km). driving four miles (6 km) or less in freezing
4. INJECTION TIMING — Incorrect injection weather, or other short trips in cold weather,
timing could result in increased exhaust where engine dose not thoroughly warm up.
emission or smoke emission, or lower engine Change oil and filter soon after driving ina
output. dust storm.
Check anc adjust injection timing every 52,000 7. FUEL FILTER — Replace filter at every 13,000
miles (83,200 km). miles (20,800 km) or 12 months whichever
5. INJECTOR -— Check spray condition at every occurs first, or more frequently if clogged. Drain
52,000 miles (83,200 km). water from the water separator every 6,500
6. ENGINE OIL AND OIL FILTER —- Change at miles (10,400 km).
interval noted below depending upon driving 8. AIR CLEANER FILTER — Replace the engine
conditions. air cleaner filter under normal operations every
*» NORMAL SERVICE — Change every 6,500 26,000 miles (41,600 km). Operation of vehicle
miles (10,400 km) or 12 months whichever in dusty areas will necessitate more frequent
 MAINTENANCE AND LUBRICATION 0OB-7

filter replacement. cooling system with a new engine coolant

9, AIR INTAKE SYSTEM — Check if air cleaner solution as described in the Owner’s Manual.
hoses and ducts are connected and correctly 14. ENGINE COOLING — Every 24 months or
installed every 26,000 miles (41,600 km). 26,000 miles (41,600 km), drain the engine
10. DRIVE BELT — Check belt driving the fan, coolant by opening the drain cock at the bottom
generator at every 52,000 miles (83,200 km). of the radiator core, flush and refill the engine
Look for cracks, fraying, wear, and proper cooling system with a new engine coolant
tension. solution.
Replace at every 104,000 miles (166,400 km). 15. EXHAUST SYSTEM — Check the complete
11. ENGINE BOLT TORQUE -—~ Loosened bolts exhaust system at every 6,500 miles (10,400
result in lower engine output. Check and adjust km). Check body areas near the exhaust
manifold mounting, and injection nozzle to system.
correct torque every 52,000 miles (83,200 km). Look for broken, damaged, missing, or out-of
Specified tightening torque position parts. Also inspect for open seams,
INTAKE/EXHAUST, MANIFOLDS 18/34 N-m holes, loose connections, or other conditions
(13/25 lb-ft) which could cause a heat build-up in the floor
INJECTOR 19N-m pan, or could let exhaust fumes seep into the
(14 lb-ft) passenger compartment. Dust or water in the
12. ROTATE TIRES — To equalize wear, rotate cabin may indicate a leak in the area. Needed
tires and adjust tire pressures at every 6,500 repairs should be made at once.
miles (10,400 km). 16. FUEL LINE SYSTEM — Inspect the fuel tank,
cap and lines for damage which coulc cause
leakage at every 13,000 miles (20,800 km).
Example: Inspect fuel cap for correct sealing ability and
indications of physical damage. Replace any
damaged or malfunctioning parts.
17. BRAKE LINING AND PAD FOR WEAR —
Check drum brake lining and disc brake pad for
wear or cracks at every 6,500 miles (10,400
km). Check brakes {including parking brake)
more often if conditions and habits result in
frequent braking.
Front Rear Front disc brake have built-in wear indicators
which are designed to make a high pitched
squeal or cricket-like warning sound when the
When tire tread pattern differs brake pads are worn to the point where new
between front and rear tires: pads are needed.
When the vehicte is in motion, the sound may

il
be constant or it may come and go. Pressing
the brake pedal firmly may cause the sound to
stop.
Have the brake linings or the brake pads
a)
replaced, if these conditions exist.
Front Rear Failure to do so can result in expensive damage
to the brake system or a serious accident.
Figure 2. Rotate Tires 18. BRAKE DRUM AND ROTOR FOR WEAR AND
DAMAGE ~~ Check brake drums (rear and
13. ENGINE COOLING SYSTEM — At 12 months parking) and rotor (front) for wear or damage at
or 6,500 miles (10,400 km) intervals, wash every 26,000 mile (41,600 km) or 12 months
radiator cap and filler neck with clean water, whichever occurs first.
pressure test system and radiator cap for proper 19. BRAKE FLUID — Check the fluid in brake fluid
pressure holding capacity, tighten hose clamps reservoir at every 6,500 miles (10,400 km).
and inspect condition of all cooling and heater 20. HYDRAULIC BRAKE BOOSTER FLUID --
hoses. Replace hoses if cracked, swollen or Replace power steering fluid every 24 months
otherwise deteriorated. or 32,500 miles (52,000 km), whichever occurs
Also each 12 months or 6,500 miles (10,400 first.
km), clean exterior of radiator core and if a1. BRAKE LINE, LSV AND HOSES — Check
necessary, drain, flush and refill the engine lines and hoses for proper hook-up, binding,
0B-8 MAINTENANCE AND LUBRICATION

leaks, cracks, chafing, etc. every 26,000 miles > If it felt warm, about normal operating
(41,600 km). Any questionable parts should be temperature of 158° to 176° F(70° to 80°C),
replaced or repaired at once. When rubbing or the level should be in the “H” range.
wear is noted on lines or hoses, the cause must 25. AUTOMATIC TRANSMISSION FLUID FILTER
be corrected at once. — Replace filter at every 26,000miles
22. CLUTCH PEDAL CONTROL — Check lines (41,600Km)
and hoses for proper hook-up, binding, leaks, 26. DIFFERENTIAL GEAR OIL — Replace
cracks, chafing, etc. at every 13,000 miles lubricant at every 26,000 miles (41,600 km).
(20,800 km). Any questionable parts should be Check lubricant level at every 6,500 miles
replaced or repaired. {10,400 km) or every 12 months, and add
23. MANUAL TRANSMISSION OIL —- Replace lubricant to within 0 to 10 mm (0 to 0.4 in) of
lubricant at every 19,500 miles (31,200 km). bottom edge of the filler hole if necessary.
Check lubricant level at every 6,500 miles
(10,400 km}, and add lubricant to levei of filler
hole if necessary.
24. AUTOMATIC TRANSMISSION FLUID (ATF) —
Check the ATF at each engine oil change and
replace fluid every 26,000 miles (41,600 km).
To check the fluid level, first set the parking
brake, then start the engine in “P” position.
With the regular brakes applied, move the
selector through all the gear position, ending
with “P”. You must check the ATF level with the
engine running at slow idle and the truck must
be on a level surface.

NOTICE: if you have driven for a prolonged

period of time or in city traffic in hot weather,
wait until the fluid cools down (Approx. 30 Figure 4. Differential Gear Oi! Level
minutes) before checking ATF level.
27. POWER STEERING FLUID — Replace power
steering fluid every 24 months or 32,500 miles
Remove the dipstick located at the rear right
(52,000 km), whichever occurs first.
side of the engine. Carefully touch the wet end
28. STEERING GEAR BOX TORQUE —- Retighten
of the dipstick to find out if the ATF is cool,
the fixing bolts of the steering gear box to the
warm or hot. Wipe it clean and push it back in
specified torque at every 26,000 miles (41,600
until the cap seats. Pull out the dipstick and
km).
read the ATF level.
Specified tightening torque
STEERING GEAR BOX 102 N-m
(75 |b-ft)
29. PROPELLER SHAFT FLANGE TORQUE —
Check the fixing bolts of propeller shaft flange
for looseness or damage at first 6,500 miles
° C S

(10,400 km). Retighten the fixing bolts to the

Pa if hot O.K.
a specified torque at every 13,000 miles (20,800
if hot add. km}.
Specified tightening torque
PROPELLER SHAFT FLANGE 102 N-m

LS
if cold add.
Cx y

If cold O.K.
30. LEAF SPRING U-BOLT TORQUE -—
the U-Bolt nuts to the specified torque
miles (1,050 km), 6,500 miles (10,400
(75 Ib-ft)
Tighten
at 650
km) and
thereafter each 13,000 miles (20,800 km}.
Figure 3. ATF Level Check Specified tightening torque
LEAF SPRING U-BOLT Front 127 N-m
* If it felt cool, about room temperature, the (94 Ib-ft)
level should be in the “OC” range. Rear 177 N-m
(130 lb-ft)
 MAINTENANCE AND LUBRICATION O0B-9

31. WHEEL NUT TORQUE — Check tire for 33. PROPELLER SHAFT — Lubricate the grease
excessive or abnormal wear, or damage. Also fitting on each universal joint and spline
check tire inflation pressures and adjust. Be coupling at 12 months or 13,000 miles (20,800
sure wheels are not bent or cracked and that km) whichever occurs first.
wheel nuts have been tightened to the specified 34. WHEEL BEARING GREASE — Ciean and
torque at 650 miles (1,050 km) and then every repack front wheel bearings at every brake
6,500 mile (10,400 km). Refer to Section 3 for relining or 32,500 miles (62,000 km) whichever
the specified torque. comes first.
Specified tightening torque 35. REAR SPRING PINS — Lubricate the grease
Front and Rear wheel 440 Nm fitting on the rear spring pins every 6,500 miles
(325 lb-ft) (10,400 km}.
32. KING PIN — Lubricate the grease fitting on the
king pins at 12 months or 6,500 miles (10,400
km) whichever occurs first.

OWNER SAFETY AND ROUTINE MAINTENANCE

Listed below are vehicle checks which should be E WHEEL ALIGNMENT, BALANCE, AND TIRES
made periodically by either the owner or a qualified — Check tires for abnormal wear or damage.
technician to ensure proper performance and safety Also, check for damaged wheels. A pull to the
of the vehicle. right or left on a straight and level road may
For your safety and that of others, any of the show the need for a wheel alignment. A
safety-related components that may have been vibration of the steering wheel or seat at normal
damaged in an accident should be checked and highway speeds may mean a wheel balancing is
necessary repairs performed before operating needed. Check tire pressure when the tires are
the vehicle. “cold”, at least monthly, and whenever the
At the minimum, these routine checks should be vehicle is serviced. (include the spare, if
made every 6 months or 6,000 miles (10,000 km), equipped.)
whichever comes first. Whenever repairs are Check the pressure more often if daily check
necessary, have them completed before operating shows it’s needed. Change tire pressure as
the vehicle. needed when changing loads.
A PARKING BRAKE — Park on a fairly steep hill F BRAKES —- Be alert to illumination of the jow
and hold the vehicle with the parking brake vacuum warning light or for the tone alarm, or
only. This checks holding ability. changes in braking action, such as repeated
Before checking item (B), be sure to have enough pulling to one side, unusual sounds when
room around the vehicle. Then firmly apply both the braking or increased brake pedal travel. Gneck
parking brake and the regular brake. regularly that the brake fluid reservoir is
Do not use the accelerator pedai. If the engine properly filled and check for fluid leaks. Any of
starts, be ready to turn off the ignition/engine these conditions could indicate the need for
control switch at once. Take these precautions brake system inspection and/or service.
because the vehicle could move without warning G EXHAUST SYSTEM — Be alert for any
and possibly cause personal injury or property changes in the sound of the exhaust system or
damage. any smell of fumes. These are signs the system
B STARTER SAFETY SWITCH (AUTOMATIC may be leaking. Have it checked and/or
TRANSMISSION) — Check by trying to start repaired at once.
the engine in each gear. The starter should H WINDSHIELD WIPERS AND WASHERS —
crank only with selector in position “P” or “N.” Check operation and condition of the wiper
C TRANSMISSION SHIFT INDICATOR blades. Check the flow and aim of the washer
(AUTOMATIC TRANSMISSION) —- Check that spray.
the indicator points to the gear chosen. | DEFROSTER — Turn the control lever to
D STEERING — Be alert for any changes in “Defrost” and the fan lever to “4”. Then check
steering action. An inspection or service is the airflow from the ducts at the inside base of
needed when the steering wheel is harder to the windshield. Engine running.
turn or has too much free play, or when there J REARVIEW MIRRORS AND SUN VISORS —
are strange sounds when turning or parking. Gheck that friction joints hold mirrors and sun
0B-10 MAINTENANCE AND LUBRICATION

visors in place. P DOOR LATCHES — Check that doors close,

K HORN —- Sound the horn periodically to be sure latch, and lock tightly. Check for broken,
it works. damaged or missing parts that might prevent
L LAP-SHOULDER BELTS —- Check seat belt tight latching.
system (including webbing, buckles, latch Q@ TILT CAB — Be sure the tilt lever is raised and
plates, and anchors) for proper operation, and the lock pin is inserted in the lever bracket.
for damage. R FLUID LEAKS — Check for fuel, water, oil, or
M SEAT ADJUSTERS — When adjusting a other fluid teaks by looking at the surface
manual seat, be sure seat adjusters latch by beneath the vehicle after it has been parked for
pushing the seat forward and backward. a while. If you notice diesel fumes or fluid at any
Do not attempt to adjust the seat when the time, have the cause found and corrected at
vehicle is in motion. once.
N LAMPS — Check panel lighting, warning lamps, S SPARE AND JACK — Check that spare tire
indicator lamps, and interior lamps. On the assembly and jack equipment (if equipped) are
outside, check: license plate lamps, side marker securely stowed at all times.
lamps, reflectors on outside mirrors, headlamps, T UNDERBODY — Corrosive materials used for
parking lamps, identification and clearance ice removal, snow removal, and dust contro!
lamps, taillights, brake lamps, turn signals, can collect on the underbody. If these materials
backup lamps, and hazard warning flashers. are not removed, accelerated corrosion (rust)
Have headlamp aim checked at once if beams can occur on underbody parts such as fuel
seem improperly aimed. lines, frame, floor pan, and exhaust system. At
O GLASS, MIRRORS, LIGHTS AND/OR least every spring, flush these materials from
REFLECTORS CONDITION --- Look for broken, the underbody with plain water. Take care to
scratched, dirty or damaged glass, mirrors, clean well any areas where mud and other
lamps or reflectors that could reduce the view or debris can collect. Sediment packed in closed
visibility, or cause injury. Replace, clean or areas of the frame should be loosened before
repair promptly. being flushed.

NOISE EMISSION CONTROL

NOISE CONTROL SYSTEM 2. The use of the vehicle after such device or
element of design has been removed or
The following information relates to compliance rendered inoperative by any person.
with Federal noise emission standards for vehicles Among those acts presumed to constitute
with a Gross Vehicie Weight Rating (GVWR) of tampering are acts listed below.
more than 10,000 Ib (4,536 kg). The Maintenance
Schedule provides information on maintaining the Insulation
noise control system to minimize wear of the naise * Removal of noise shields or underhood insulation.
emission control system during the life of the
vehicle. The noise control system warranty is given Engine
in the vehicle Warranty Folder. * Removal of engine speed governor, if so
These standards apply only to vehicles sold in the equipped,or rendering inoperative so as to allow
United States. engine speed to exceed manufacturer
specifications.
TAMPERING WITH NOISE CONTROL
SYSTEM PROHIBITED Fan and Drive
* Removal of fan clutch, if so equipped, or
Federal law prohibits the following acts or the rendering clutch inoperative.
causing thereof: * Removal of fan shroud, if so equipped.
1. The removal or rendering inoperative by any
person other than for purposes of maintenance, Air Intake
repair or replacement of any device or element * Removai of air cleaner silencer.
of design incorporated in any new vehicle for « Reversing air cleaner cover.
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser or while it is Exhaust
in use. « Removal of muffler and/or resonator.
« Removal of exhaust pipes and exhaust pipe
clamps.
 MAINTENANCE AND LUBRICATION OB-11

RECOMMENDED FLUIDS AND LUBRICANTS

USAGE FLUIDS/LUBRICANTS
Engine Oil SG/CE, SF/CD, SE/CD, CD Engine Oil
Manual Transmission Oil SAE 5W-30 SF below 32 °C (90 °F) or
SAE 40 engine oil above 32 °C (90 °F)
Automatic Transmission Fluid ATF Dexron®-III
Power Steering Fluid
Hydro Boost Brake Fluid
Rear Axle Multi-purpose gear oil SAE9O GL-5
Chassis Lubricant Multi-purpose grease with high temperature, good quality, lithium soap,
extreme pressure grease
Battery Terminals Petroleum Jelly
Clutch and Brake Fluid Brake fluid DOT 3 or equivalent
Cab-Door Hinges and A semi-fluid grease having extreme pressure properties and
Latches Lubricant containing zinc oxide (Lubricant or equivalent)
Engine Coolant Mixture of water and high quality ethylene glycol base type antifreeze
conforming to GM Spec. 6038-M or equivalent.
Windshield Washer Solvent Washer Solvent
Propeller Shaft, Universal NLGI #1 or #2 multi-purpose type grease
Joints and Sliding Sleeve
Lubricant
Propeller Shaft Center Bearing, NLGI #2 or #3
Wheel Hub Bearing Lubricant
0B-12 MAINTENANCE AND LUBRICATION

LUBRICATION CHART

GREASE POINTS REMARKS

2. King Pins — 4 fittings

3. Propeller Shaft Universal Joints, ~~ 5 fittings
Sliding Sleeve and Center
Bearing
4. Rear Spring Pins — 2 fittings

Get ney, .
5. F => 3

VA
i es — §

GREASE POINTS CHART

Figure 5. Grease Points Chart

 MAINTENANCE AND LUBRICATION OB-13

SPECIFICATIONS
CAPACITIES
Engine Crankcase
This capacity is for a normal refill and it is an approximate amount. Keep the level as close as possible to
the full mark without overfilling. Do not operate with the level below the low mark.
AHE1-TO ioc cccecccccncceccseccececeeeeesecceeeeeeeesasens
tees ee cfsesecneaedeneticagecsenedsereneesetentenenmeereessrenneseeneesueeuen 132 (3.4 gal)
This figure includes the full-flow oil filter, which should be changed at each oil change.

Engine Cooling System

CAPACITY... cece cc eeee cee eee ree ceneceseeeenuenenenenseneneecessneeeessescneesneeciressonesieesoneseneeernemeaeeceaesneemmiresnanernnees 142 (3.7 gal)
THEIMOStat .....cccccccecceeeesceeceeececeeeeeueneee ered seitaauasereeseconeasatanneseneeeeensen len teeeueaueeescnseeweseenas 82, 85 °C (180, 185 °F)
Radiator PreSSure Cap .....ccccccccccsecsncseneeeneseesceneeeeesssaususessauecesseesassaueeenesensnesnaetueeneeesonnaeanes 103 kPa (15.46 psi)

Fuel Tank
The fuel tank capacity is stated on a metal plate attached to the fuel tank body. Only fill the tank to 95
percent of its capacity. This allows room for expansion of the fuel.

Transmission
Manual Transmission Oil. ........ ccc. ccccecsccueceneneesresensesweneanaseasensseceeeceetoeessusseeseaeteneeseesneeeed NPR; 3.22 ( 6.8 pints)
NQR; 5.32 (11.2 pints)
Automatic Transmission FIUIG....0.........ccccccssecccnssseceeseceeereesanneeetumenreeeeeeneceeenannedsunuaauessaeeeaeees 13.52 (28.5 pints)

Rear Axle
CADACILY .0... eee eeeeteeteeereeeeseneerareneeees det eedcusevecadeececeeeeeeeedewedeaseeceniecerssaeseeciuassaueesaasaeaenseees 9.72 (20.5 pints)

MAINTENANCE ITEM

Air Cleaner (DONALDSON EGB10-8107) Filter............ ISUZU Part No. 8-94430-250-0 GM Part No. 94430250
Engine Oil Filter Cartridge ............scccccseserseerenersentseneeees ISUZU Part No. 8-97148-270-0 GM Part No. 97148270
Fuel Filter Cartridge ............ccsecceeeseseneecsneeeees ISUZU Part No. 1-13240-074-1 or -079-1 GM Part No. 94414796

FASTENER TORQUES

Intake Manifold Nut and Bolts .............2.006 cesenenetuenensanaeeedaceeetsesueaesneeescousesauneueebeneseeeeeeaenee 18N-m ( 13 ft-lbs)

Exhaust Manifold Nut and Bolts ...........ccc:cseececeeeereeeeeuaeeseveeseeteaseageeaneeteeeesenames se peneteneeaenane 34 N-m ( 265 ft-lbs)
INJ@CTON oo... eee cece seccetneeeeetneessnreeeetteeiceasenteneeetes peesenuawaseesssseeteees ist 10 N-m (7 ft-lbs), 2nd 19N-m( 14 ft-lbs)
Steering Gear Box Fixing Nuts and Bolts ..........:ccccceseeeteeeererecesseoteaecnaueneestrentacuseessassees 102 N-m ( 75 ft-lbs)
Propeller Shaft Flange Nuts 20.0.0... ccccscseeeeeenesneeeseeseeeeneersssneesseessasaseaeenensaeeneecnenstenerans 102 N-m ( 76 ft-lbs)
Leaf Spring U-Bolt Nuts... :ceceeeeeeeerieneenteeees dea edecendeeaseeedeeeaventensaeeeenneensaeeea Front 127 N-m ( 94 ft-lbs)
Rear 177 N-m (130 ft-lbs)
Wheel NUts ....cccccccccsssssecseceesceccaccsucesesseeveneeusneresaceessnencetseeneesseeeeevesussseuneuenesaeeeerseceesuneaseaeqens 440 N-m (326 ft-lbs)
MEMO
 HEATING AND VENTILATION 1A-1

SECTION 1

HEATING AND AIR CONDITIONING

CONTENTS
SUBJECT PAGE

Heating and Ventilation ........ccscssseessersssesssseensesscenmeseeestemensencasassarsaesssscneauecsensscensenanssnsssesnensesuaueseuasansneenstseasaentanas 1A

Ait Conditioning ............:ccssssensnensesorsesnssssersestsurseesensueneorsnssenssnsenneenescaasereacertnmaennsancnoetassugesensausieeuneateniugueaeanenas 1B

SECTION 1A
HEATING AND VENTILATION
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT
General DeSCription .......::.cscscsssssccsensensensseresensecnsrsnecsnsssssanienesouinionueuieaterecsusteeusnasassnaranouasacazseneannnnanaeanacaeasens
HEAle\r ....cccesccecesscctsesssscesnsonerseseeeseroesuuunuanercesuenussrseretsonnensannecnsanenen vauaedecenenseseneaeaeasunadaaueneneoseensentaedunensausaczumeuas
Control Lever ASSOMDIY..........-.:ccussesseensseensorssacenssenensessnnesscnsencensnunenesaneteseeaneesersousesoranseaseserasnssaaenenentas
Ventilation............00 ceconsauusearedduedauneeuoussnaseunessqouseaoeraneenenssenisenitasuneesuuasqocnssecssauvaazenacsenssensescuaeteonssenssauanaaouns
Air Select LeVer .....s.csscssssssserenneansersenseaneensees
Air Source Select Lever.......cscnscse ”
Fan SWItCH .......cccccsstcsessssseroaterosnesnees
Temperature Control Lever.
Circuit DiaQramm.......ecossesesseesosssereeienne
DiagGnOSis .......:sccecseressenesceensonseensanenasen
Heating Cycle .....ccccscnrseneisesnieess ona
Fann SWItCH .....c..sccrsnsssnesenceveneessensarnnsnanraeetennedsennene
Electrical Parts ........sccsccssssescssenseesssnsensenesesaecneneaniuenneeneescceuerneesanacnsessenoniemnsssaecenisasestenssaneunteuneasanuaneuseans
On-Vehicle Service....... seus nesurseaversuuessuuuvssuneusuasauavonasssssseauegeduenseusenacearsssonues saneesouconsenatsereerseyanennanenenrasoussuaeananuens
Heater Unit/ Heater Core
Heater Temperature Control Link Unit/ Air Mix Door...
Heater Mode Control Link Unit / Mode Door
Blower Assembly ... ersneutausnavauenvonees
Blower Link Unit / Mode Door...
Blower Motor .........0.c000 Lauuaevasenaausoneanneoene pesussenacesenbeesansaneneuneoceuss
Ventilation Grilie a
Defroster Nozzle / Ventilation Duct
Control Lever ASSEMDLy .......cscsessesseesescceaneennenens caus ana cuencanessdaaetentaneveseedentuaecaevaaqeesunycnuneueuaanensneacsonsaneens
Control Panel Humination Bulb. ........ccccssesesnenensercensssnsestaseesensvensausenseseaeseesavsansoussannorsceeserenearaneananans
PROSISCOF cccccccscocesseccenstccscsecseeuessunsonvecsustonnouuaonsssseenuansounenseetenesonseanenenadnsgeesumesnusesaneneannaerutageerssanendnennys peeteueuens
Heater, Air Conditioning, Condenser Fan and Ceramic Heater (M/T Vehicle only) ..........c.0ccsssecnssennenns 1A-26
Ceramic Heater and/or Full Hot Switch ........ccccsssssssesennssnerseeneeseeensosemerenseunersneenssasseresgescentaneesneuaneanyens 1A-27
1A-2 HEATING AND VENTILATION

GENERAL DESCRIPTION
HEATER
When the engine is warming up, the warmed The air select lever, with its different modes, also
engine coolant is sent out into the heater core. The allows you to select and maintain the most
heater system supplies warm air into the passenger comfortable passenger compartment temperature.
compartment to warm it up. The air source select lever is used to select either
Outside air is circulated through the heater core “FRESH” for the introduction of the outside air,or
of the heater unit and then back into the passenger “CIRC” for the circulation of the inside air. When
compartment. By controlling the mixture of outside the lever is set to “FRESH”, the outside air is
air and heater core air, the most comfortable always taken into the passenger compartment.
passenger compartment temperature can be When setting the lever to “CIRC” position, the
selected and maintained. circulation of air is restricted only to the inside air
The temperature of warm air sent to the with no introduction of the outside air and the air
passenger compartment is controlled by the in the passenger compartment gets warm
temperature control lever. This lever acts to open quickly. However, the lever is normally set to
and close the air mix door, thus controlling the “FRESH” to prevent the windshield from fogging.
amount of air passed through the heater core.

Side defroster nozzle (LH)

Defroster nozzle
Ventilation duct (LH}
/
/ Side defroster nozzle (RH)

AIC switch

“
Heater unit

Figure 1.Heater Assembly

 HEATING AND VENTILATION 1A-3

CONTROL LEVER ASSEMBLY

The vehicle has cable-control-type to control by The fan control is used to control the amount of
cable the mode and temperature of the heater unit air sent out at four levels from “LOW”’to‘HIGH” ,by a
and the mode door for the air source of the blower resistor
assembly.

Air select lever Air source select lever

| C ] (eS
eee 6)
CODLO C00 cons eo
@ @HOT A/C SPOFF1 2 3 4 |
(f=
| ) | {=}
C fe"|
d

i
A/C switch \ .
Temperature control lever (W/A/C} Fan switch

Figure 2. Control Lever Assembly

VENTILATION
Set “AIR SOURCE SELECT LEVER?” to“FRESH” The blower fan also serves to deliver fresh outside
position and turn on the blower fan.Heating can be air to the vehicle interior to assure adequate
done in this lever pasition, sending in fresh air ventilation.
from outside.

Figure 3. Ventilation
 1A-4 HEATING AND VENTILATION

AIR SELECT LEVER change by closing off outside air. In this position,
The air selector iever allows you to direct heated outside air is not delivered to the passenger
air into the passenger compartment through different compartment.
outlets.
1. Vent - In this position, air is discharged from FAN SWITCH
the upper air outlet. Air quantity is controled This lever controls the blower motor speed to
by the fan control knob. regulate the amount of air delivered to the defrost,
2. Bi- Level- In this position,air flow is divided pot, ang ventilation ducts:
between the upper air outlets and the foot air 1. Low
outlets, with warmer air delivered to the floor 2. Medium Low
outlets than the air delivered to the upper air 3. Medium High
outlets. 4. High
3. the floor only flow is directed to TEMPERATURE CONTROL LEVER

4. Def / Foot - In this position,air flow is divided “cole ne remperature contro leveris inthe ,
to the foot air outlet, while sending approx. 30% the flow air through heater core S to bloc
of total amount of air to the windshield. When the tem erature control lever is in the
5. Defrost - In this position,the most of air is “HOT” ositi Ch it mix d to al .
delivered to the side windshield. position, the alr mix door opens to allow air
to pass through the heater core and heat the
AIR SOURCE SELECT LEVER passenger compartment.
The intake of outside air and the circulation of inside , lacing the ever ‘ean intermediate Position nh
air are controlled by sliding this lever left or right. Cause SSer Or greater amount OF ai to reacn tne
Moving the air source select iever to the neat core in ins moce ine slated. compart:
“CIRC”position provides the quickest temperature P ~ "9 .

Heater unit

TO TO VENT OUTLET

Heater core
TO FOOT TO FOOT OUTLET
VENT MODE Bl LEVEL MODE FOOT MODE

TO DEF OUTLET TO DEF OUTLET

<__} : COLD AIR

> HOT AIR
UM: TEMP.CONTROLLED AIR

TO FOOT OUTLET
DEF/FOOT MODE DEF MODE

Figure 4.
 HEATING AND VENTILATION 1A-5

CIRCUIT DIAGRAM

RELAY; BLOWER
80A HEATER & A/C 25A
MAIN 53k HEATER at. 2. pa
[[e-14 1)
CMAN 8-14]
ie _
BW 2 SW. 3W 1 sie es~ OS A

S5W/R 2L/8
OBR FT
2 B.21-8-21]
2
fer]

RELAY; CHARGE (5) 8

Ss
2U/R 4
& B-13 3 3 B42--—-———_©
n
Cd .
®wo

b ofa!
1.251/0
eal 3

g fo~e
r
a 0.85 iabo \
=9

esL
<=
oto fea o.SLW
feat —o B| |,
BLOWER RESISTOR FAN SWITCH
FRAME
HEADLIGHT 38 ,
6
3 8
BRACKET (LH) E-{ 27 }
[p-29] JOINT
CONNECTOR

f=] fe) Gales) ba]

Via H-@ 2iia

112/53 |if4aié
alla 5) ats
Orr leliis

S$ fontpana is TOS

spenrns

7-7"

Figure 5.
1A-6 HEATING AND VENTILATION

DIAGNOSIS
HEATING CYCLE

TROUBLE POSSIBLE CAUSE CORRECTION

No heating or 1. Blower motor does not run, or Refer to “Fan switch Diagnosis”.
Insufficient heating runs improperly. Check the engine coolant temperature
2. Engine coolant temperature is after warming up the engine and check
iow. the thermostat. Replace as necessary.
Add engine coolant as required.
3. Blower motor does not work. Check if the water hose to the heater
4. Circulation volume of engine core is clogged, collapsed or twisted.
coolant is insufficient. Repair or replace as necessary.
Check water pump function.Repair or
replace as necessary.
Clean or replace as necessary.
5. Heater core clogged or Repair the temperature control link unit
collapsed. or mode doors.
6. The heater core is not provided Repair or adjust the control cables.
with air sent from the blower Repair or replace as necessary.
motor.
7. Duct connections defective or
unsealing.

Control knob moves | 1. Cable attaching clip is not “Repair.

but mode door does correct.
not operate. 2. Link unit of heater unit or *Repair.
blower assembly defective.

The mode door 1. Link unit of heater unit or *Repair.

cannot be set to the blower assembly defective.
mode selected. 2. Control cabie is not adjusted. *Adjust.
 HEATING AND VENTILATION 1A-7

FAN SWITCH
Current flows to the blower motor through the Blower motor speed is controlled in stages by the
Heater & A/C relay to activate the rotation of the blower resistor, by operating the switch from “LOW”
blower motor by turning “ON” the fan control lever. to “HIGH”.

[8-21
TSAnanc tm [Ba]
{F=4| oo OND Ne ~
| — sca
! 7
CHARGE 1 {r Ho 2 OF
@ aes

ee FAN Sw.
ps So }

a oO 30 O30 $

| oho «. o soft § | Radi

| ‘ O O 8 & O4c s

| | 3 Ct O4c — O10
. / =

CoE) = SN
a! __

[87]

B-a2

Figure 2. Control Lever Assembly

 1A-8 HEATING AND VENTILATION

CHART“A”

BLOWER MOTOR DOES NOT RUN

* IS BLOWER RELAY OK? |

[ YES| co
| » IS NO,[F-1] (254) FUSE OK?

[YES|
IS RESISTOR OK?
e

[YES|
- IS FAN SWITCH OK?

[ves]
» IS BLOWER MOTOR OK? REPLACE CONTROL LEVER ASSEMBLY

L
[YES| [ No |
* TURN THE IGNITION SWITCH "ON" (ENGINE IS RUNNING)
+ FUN SWITCH IS "ON"
[ REPLACE|
* CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT AT

LYES| (iS
POOR GROUND OR OPEN GIRCUIT EITHER BETWEEN OPEN CIRCUIT BETWEEN NO.[F-1]
(25A) FUSE AND NO.2 [B-14
 HEATING AND VENTILATION 1A-9

CHART“B”

BLOWER MOTOR DOES NOT RUN IN CERTAIN POSITION

® 1:(LOW)
BLOWER MOTOR DOES @® 2: (MEDIUM LOW)
NOT RUN AT © 3: (MEDIUM Hi) POSITION
® 4: (HIGH)
“ CHECKING iS PERFORMED ONLY
WHEN IN THE MULFUNCTION MODE.

* IS RESISTOR OK?

YES | NO |

| + 1S FAN SWITCH OK? REPLACE |

YES [RO]
@® CONDITION: REPLACE CONTROL LEVER
» OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR ASSEMBLY
TERMINAL NO. 1 [B-13] AND NO. 4 [B-42!
@ CONDITION:
* OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR
TERMINAL NO. 4 [B-13] AND NO. 5 [B-42]
© CONDITION:
+ OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR
TERMINAL NO. 6 [B-13] AND NO. 6 [B-42!
@ CONDITION:
» OPEN CIRCUIT BETWEEN CHASSIS SIDE CONNECTOR

CHART“C”

BLOWER MOTOR DOES NOT STOP AT “OFF” POSITION

[ - iS FAN SWITCH OK? |

|
YES [ne |
SHORT CIRCUIT BETWEEN CHASSIS SIDE REPLACE CONTROL LEVER
CONNECTOR TERMINAL | ASSEMBLY

* NO.3 AND NO.3 [B-42|

- NO.6 [B-13] AND NO.6 [B-42|
» NO.4 [B-13] AND NO.5 [B-42)
+ NO.1 [B-13) AND NO.4 [B-42]
1A-10 HEATING AND VENTILATION

ELECTRICAL PARTS Fan Switch (Figure 12)

1. Check for continuity between the terminals of
Inspect the fan switch.
Blower Motor (Figure 10) Terminal No.
1. Disconnect the blower motor connector from the SW position
blower motor.
1
2. Connect the battery positive terminal to the
No.1 terminal of the blower motor and negative 2
to the No.2. 3
3. Be sure to check to see if the blower motor 4
operates correctly.

Terminal No.
456321
(Le 99999 |
(SW Position) B42
OFF it ia
° oNa

ANE
Yo

NT ~~ {Switch side)

Figure 10. Blower Motor Check Figure 12. Fan Switch Check

Resistor (Figure 11)

1. Disconnect the resistor connector.
2. Check for continuity and resistance between the
terminals of the resistor.

Terminal No. , > 3 4 5 Resistance

SW position value (Q)}

1 O-+-O 2.3
2 Oo O 1.0
3 © © 0.3
4 O+Od —

itt vw. ODO

Motor
i

4 4
®
2 1
{SW Position)

Figure 11. Resistor Check

 HEATING AND VENTILATION 1A-11

ON-VEHICLE SERVICE
HEATER UNIT/ HEATER CORE
eee ee ee
ae a
oe
Fe

1. Instrument panel assembly

Defroster nozzle and
Nn

ventilation duct
Heater control cable
=~OOOMrNaAnhwW

. Foot duct
Duct
. Front grille
Water hose
. Bolt(Panel-heater unit)
. Bolt(Heater unit-reinforce)
. Heater unit
eh

. Heater core
ec

Figure 13. Heater Unit/Heater core Removal or Installation

 1A-12 HEATING AND VENTILATION

[+s] Remove or Disconnect (Figure 13)

Preparation: Pin
Disconnect the battery ground cable.
Drain engine coolant.
Discharge and recover refrigerant. (W/Air
conditioning)
(Refer to Section 1B “REFRIGERANT RE-
COVERY”)
Reintorce “——-—
1. Instrument panel assembly Ce
* Refer to Section 10 “STEEL TILT CAB” for Fixing bolt
INSTRUMENT PANEL ASSEMBLY removal (Heater unit — Reinforce)
procedure.
2. Defroster nozzle and ventilation duct
* Refer to “DEFROSTER NOZZLE
/ VENTILATION DUCT” removal procedure in Figure 15. Heater unit removal
this section. 11. Heater core
. Heater control cable
o

« Disconnect the cables from the heater unit. [os] Instali or Connect (Figure 13)
. Foot duct
oO &

. Duct To install, follow the removal steps in the reverse

NO

. Front grille order, noting the following points:

. Water hose (Figure 14) 1. Adjust the contro! lever assembly cables.
(Ay Rec to “CONTROL LEVER ASSEMBLY”
installation steps in this section .
2. When installing the heater unit, defroster
Water hose clip nozzles and ventilation ducts, be sure that
proper seal is made, without any gap between
them.
Check the engine coolant level. When the level
ao

is below the specified amount, replenish engine

coolant to the proper level.

Figure 14, Water hose removal

8. Bolt(Panel-heater unit)
9. Bolt(Heater unit-reinforce)
10. Heater unit (Figure 15)
- Drop the heater unit positioning pins from the
reinforce, and remove the heater unit while
sliding the engaged section between the
evaporator and the heater unit.
 HEATING AND VENTILATION 1A-13

HEATER TEMPERATURE CONTROL LINK UNIT / AIR MIX DOOR

j “7

\ Heater core

N
X
\ Mode door
\

. Heater unit
=

. Rod
OD

. Door lever
. Foot duct
. Upper case
SOP

. Air mix door

. Mix sub lever

Figure 16. Heater Temperature Control Link Unit/Air Mix Door Removal or Installation

| Remove or Disconnect (Figure 16) . Upper case

Preparation: . Separate two halves of the upper case.

Disconnect the battery ground cable. 6. Air mix door
7. Mix sub lever
Drain engine coolant.
1. Heater unit » Press the tab of the sub lever inward, and
« Refer to “HEATER UNIT” removal procedure take out the sub lever.
;
in this section.
2. Rod [oe] Install or Connect (Figure 16)

.
3. Door leverthe door lever while ws To install, follow the removal steps in the reverse
* Pull out raising up the order.
catch of the door lever.
 1A-14 HEATING AND VENTILATION

HEATER MODE CONTROL LINK UNIT / MODE DOOR

Heater core

. Heater unit
—

. Screw
OM

. Washer and mode main lever

. Rod
. Door lever
AA

. Foot duct
. Upper case
OOnN

. Door fever
. Mode sub lever

Figure 17. Heater Mode Control Link Unit/Mode Door Removal or Installation

| Remove or Disconnect (Figure 17) * Pull out the door lever while raising up the
catch of the door lever.
Preparation: §. Foot duct
Disconnect the battery ground cable. 7. Upper case
Drain engine coolant. 8. Door lever
. Heater unit 9. Mode sub lever
« Refer to “HEATER UNIT” removal procedure « Press the tab of the sub lever inward, and
in this section. take out the sub lever.
. Screw
® ND

. Washer and mode main lever | install or Connect (Figure 17)

anh

. Rod
To install, follow the removal steps in the reverse
. Door lever order.
 HEATING AND VENTILATION 1A-15

BLOWER ASSEMBLY

oe cee ot
Se
New ae oe oe ee ee ne
7

. Evaporator assembly
+

. Under cover (Without Air conditioner)

AOS
OAM

. Glove box (Without Air conditioner)

. Duct (Without Air conditioner)
. Washer tank(Without Air conditioner)
. Washer tank bracket
. Blower control cable
Dn

. Head light assembly(RH)

. Bolt (Panel-Blower assembly)
=—$OoO

. Bolt(Blower assembly-Reinforce)
cml

. Blower assembly
co

Figure 18. Blower assembly Removal or Installation

| Remove or Disconnect (Figure 18)

Preparation:
Disconnect the battery ground cable.
Discharge and recover refrigerant. (W/Air
conditioning)
(Refer to Section 1B “REFRIGERANT RE-
COVERY”)
1. Evaporator assembly
* Refer to Section 1B “AIR CONDITIONING”
for EVAPORATOR ASSEMBLY removal
Clip * ohip
procedure.
2. Under cover (Without Air conditioner)
(Figure 19)
- While pulling the under cover with care, "
remove the clips on the back side of the Figure 19. Under Cover Removal
cover.
1A-16 HEATING AND VENTILATION

3. Glove box (Without Air conditioner) 10. Bolt(Blower assembly-Reinforce) (Figure 22)
+ Open the glove box and remove the fixing
screws.
4. Duct (Without Air conditioner)
Bolt (Blower assembly — Reinforce)
5. Washer tank(Without Air conditioner}
* Remove the washer tank fixing three
bolts(Upper: two,Lower: one) and disconnect
the connector.
6. Washer tank bracket
* Disconnect the harness connection connector
and remove the fixing bolts.
7. Blower controi cable
+ Disconnect the blower contro! cable from the
Fuse box
blower assembly.
8. Head light assembly(RH)
* Refer to Section 8 “CAB AND CHASSIS
ELECTRICAL” for HEADLIGHT removal Figure 22.
procedure.
11. Blower assembly
* Remove the grommet provided at the lower
* Remove the blower fixing bolts.
right side of the blower assembly, and pull in
+ Drop the biower positioning pins from the
the harness to the room through the blower reinforce to remove them.
hole.(Figure 20)
[oe] Install or Connect (Figure 18)

To install, follow the removal steps in the reverse

order, noting the following points:
1. Adjust the control lever assembly cables.
[Ay Rete to “CONTROL LEVER ASSEMBLY”
installation steps in this section .

Figure 20.
9. Bolt (Panel-Blower assembly) (Figure 21)

\
Headlight bracket (RH)

Figure 21.
 HEATING AND VENTILATION 1A-17

BLOWER LINK UNIT / MODE DOOR

1. Blower assembly
2. Blower filter
(Equipped with Air Conditioner)
3. Door lever
4. Lower case
5. Upper case
6. Mode door
7. Mode sub lever

Figure 23. Blower Link Unit/Mode Door Removal or Installation

4, Lower case
[ea] Remove or Disconnect (Figure 23) 5. Upper case
» Separate two halves of the upper case.
Preparation:
6. Mode door
Disconnect the battery ground cable.
7. Mode sub lever
1. Blower assembly
.
: Refer to “BLOWER ASSEMBLY” removal | install or Connect (Figure 23)
procedure in this section.

2. Blower filter (Equipped with Air Conditioner) To install, follow the removal steps in the reverse
3. Door lever order.
+» Pull out the door lever while raising up the
catch of the door lever.
 1A-18 HEATING AND VENTILATION

BLOWER MOTOR

1. Under cover
2. Washer tank
3. Washer tank bracket
4. Blower motor assembly
5. Clip
6. Fan
7. Blower motor.

[,
Blower motor
ony CONNECLOL

Figure 24. Blower Motor Removal or Installation

2. Washer tank
[4] Remove or Disconnect (Figure 24) » Remove the washer tank fixing three
Preparation: bolts(Upper: two,Lower: one) and disconnect
Disconnect the battery ground cable. the connector.
1. Under cover (Figure 25) 3. Washer tank bracket .
* While pulling the under cover with care, * Disconnect the harness connection connector
remove the clips on the back side of the and remove the fixing bolts.
cover. 4. Blower motor assembly
« Disconnect the motor connector.
§, Clip
6. Fan
7. Blower motor.

[oe] install or Connect (Figure 24)

To install, follow the removal steps in the reverse

order,

Figure 25. Under cover removal

 HEATING AND VENTILATION 1A-19

VENTILATION GRILLE

[Driver side]
1. Meter cluster
2. Ventilation grille
[Passenger side]
1. Instrument panei assembly
2. Ventilation duct
3. Ventilation grille

Figure 26. Ventilation Grille Removal or installation

[es] Remove or Disconnect (Figure 26)

Preparation:
Disconnect the battery ground cable.
[Driver side]
1. Meter cluster
* Refer to Section 8 “CAB AND CHASSIS
ELECTRICAL” for METER CLUSTER removal
procedure.
2. Ventilation grille
* Push the catches of the grille on the back side
of the cluster to the inside, and remove the
ventilation grille.
[Passenger side]
1. Instrument panel assembly
Figure 27. Ventilation Grille Removal or installation
* Refer to Section 10D “STEEL TILT CAB” for
INSTRUMENT PANEL COMPONENTS
removal procedure. fe] install or Connect (Figure 26)
2. Ventilation duct
3. Ventilation grille (Figure 27) To install, follow the removal steps in the reverse
order.
 1A-20 HEATING AND VENTILATION

DEFROSTER NOZZLE / VENTILATION DUCT

. Instrument panel assembly

. Ventilation: duct (RH)
. Ventilation duct (CTR)
. Ventilation duct (LH)
. Reinforcement stay
. Defroster nozzle
. Side defroster nozzle

Figure 28. Defroster Nozzle/Ventilation duct Removal or Installation

[es] Remove or Disconnect (Figure 28) | Instail or Connect (Figure 28)

Preparation: To install, follow the removal steps in the reverse

Disconnect the battery ground cable. order.
1. Instrument panel assembly
* Refer to Section 10D “STEEL TILT CAB” for
INSTRUMENT PANEL COMPONENTS
removal procedure.
. Ventilation duct (RH)
PO

. Ventilation duct (CTR)

“NO GW

. Ventilation duct (LH)

. Reinforcement stay
Or

. Defroster nozzle
. Side defroster nozzle
 HEATING AND VENTILATION 1A-21

CONTROL LEVER ASSEMBLY

. Glove box A/C switch connector

=

. Genter cluster
OM

Knob Fan switch connector

. Control panel bezel
ODob

. Control cable
. Air conditioner switch
. Control lever assembly
SN

Figure 29. Control Lever assembly Removal or Installation

[+9] Remove or Disconnect (Figure 29)

Preparation:
Disconnect the battery ground cable.
1. Glove box
* Open the glove box and remove the fixing
screws.
2. Center cluster(Figure 30)
* While pulling the cluster with care, remove the
upper and the back side clips of the cluster.
« Disconnect the cigar lighter and illumination
connectors.
3. Knob

Figure 30. Center Cluster Removal

1A-22 HEATING AND VENTILATION

4. Control panel bezel (Figure 31) 7. Control lever assembly

* Push the four catches at both sides of the » Remove the lever fixing bolts and pull the
bezel to the inside, and remove the lever assembly out.
illumination buib from the bezel. * Disconnect the air conditioner switch
connector clip and fan switch connector from
the lever assembly.
* Remove the control cable fixing clip.

Figure 32. Control Panei Bezel Removal

5. Control cable
* Push the four catches at both sides of the
bezel to the inside, and remove the
illumination bulb from the bezel.
6. Air conditioner switch(Figure 32)
* Push the two catches at both sides of the
bezel to the inside, and remove the
itumination bulb from the bezel.

Press
AIC switch

Control lever

view@)

Figure 32. Control Panel Bezel Removal

 HEATING AND VENTILATION 1A-23

2) Connect the control cable at the “COLD”/

| Install or Connect (Figure 29 and 33}
“HOT” position of temperature control link of
To install, follow the removal steps in the reverse the heater unit and fix with the clip.
order, noting the following points: and fix it with the clip.
1. Adjust the control cables. «Air select control cable
*Air source control cable 1) Slide the control lever to the right
1) Slide the control lever to the left “CIRC” (“DEFROST” position).
position). 2) Connect the control cable at the
2) Connect the control cable at the “CIRC” “DEFROST” position of the mode control
position of the link unit of blower assembly link of the heater unit and fix it with the clip.
and fix it with the clip. 2. Check control cable opration.
*Temperature control cable
1) Slide the control lever to the left.
(“MAX COOL’ position).

AIR SOURCE SELECT LEVER TEMPERATURE CONTROL LEVER AIR SELECT LEVER

[C000 000 ce+e ee@@HOT |

Coo

(ast GS w

Figure 33. Control Cable Adjusting

 1A-24 HEATING AND VENTILATION

CONTROL PANEL ILLUMINATION BULB

1. Control panel bezel

2. Control panel illumination bulb

Figure 35. Control Pane! Removal or Installation

[eo] Remove or Disconnect [oe] install or Connect

Preparation: To install, follow the removal steps in the reverse

Disconnect the battery ground cable. order.
1. Control panel bezel
« Refer to “CONTROL LEVER ASSEMBLY”
removal procedure.
2. Controi panel illumination bulb
+ Pull the bulb from the bulb socket.
 HEATING AND VENTILATION 1A-25

RESISTOR

Washer tank RB
1. Under cover
2. Resistor connector
3. Resistor

Figure 36. Resistor Removal or installation

| Remove or Disconnect P+ Install or Connect

Preparation: To install, follow the removal steps in the reverse

Disconnect the battery ground cable. order.
1. Under cover
* While pulling the under cover with care,
remove the clips on the back side of the
cover.
2. Resistor connector
3. Resistor
1A-26 HEATING AND VENTILATION

HEATER, AIR CONDITIONING,

CONDENSER FAN AND CERAMIC
HEATER (M/T VEHICLE ONLY)
GENERAL DESCRIPTION
The air conditioning circuit consists of A/C When Fan Control Knob (Fan Switch) is put on with
compressor, condenser fan, A/C switch, fan switch, Temp.Control Lever being in the “FULL HOT”
blower motor, pressure switch, electronic position (FULL HOT Switch on) Ceramic Heater
thermostat and blower resistor. When the engine is within Heater Unit generates heat, raising a heater
running, the A/C starts to work with both the A/C blow-off temperature to enhance heating
and fan switches "ON", followed by the engagement performance.
of the magnetic clutch of the A/G compressor. It
stops to work when either the fan switch or the A/C
FULL HOT Switch
OFF
switch turns "OFF". In addition, the A/C system has
the function of temporary stop of its operation by
, ON
function of the pressure switch when sensing
abnormal rise of the refrigerant pressure in the Fan Switch
OFF
system.
, ON
Thermoswitch (Engine)
(‘ON” with engine OFF |
coolant temp. being
80°C or lower)

ON r
Ceramic Heater “ON” Ceramic Heater “OFF”
 HEATING AND VENTILATION 1A-27

CERAMIC HEATER AND/OR FULL HOT SWITCH

1. Under cover
2. Ceramic heater
2a. Full hot switch |

A fonts
iT WW Heater jeer
f) ot. =
a5 rd Full hot switch
YP wh
REND =e
Switch cover ~~ \ fo iw 9 fi Ne

La O19 7 ay)
€ 4S ¢ % ”

Figure 37. Blower Motor Removal or Installation

2. Ceramic heater
[+ Remove or Disconnect (Figure 37 and 38) * Remove the connector and clip for harness
1. Under cover fixing, then remove the ceramic heater fixing
- Pull the under cover to forward then remove screw and pull the ceramic heater to forward.
the clip. (Whitch is located behind of the 2a. Full hot switch
under cover.) « Remove the connector and clip for harness
fixing, then remove the full hot switch fixing
screw.

foe] Install or Connect (Figure 37)

To instali,follow the removal steps in the reverse

order, noting the following points:
1. When install the full hot switch, temp control
rink location should be “FULL HOT” and also
confirm to be cantact of connector terminal of
switch side.
Under cover

Figure 38. Under Cover Removal

MEMO
 AIR CONDITIONING 1B-1

SECTION 1B

AIR CONDITIONING
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

De@SCIiIPtiOn.........:c:csscecesecrsoeesereessessussusnssunsusnsenvacsnareseeausousuenerensuesesneonsaseneneeaesaneasesensnanssusnspenesansanensasssenionannerseney 1B- 2
Refrigerant Cycle ..........ccscessssesssesscesenieeesesssseusersenssonsensersusnsnenenaceausansnansaescansesnanensneecanssareaaentananauenenseunes 1B- 3
System Components and Location ........ccscsssneseasesanemestersnneseneaenansenesanunnsascsninnsernntareneneauiseneanertens 1B- 3
Air Conditioning parts ..........cscccccsserssseensussscsstensssnseesseosensnesenssassnensreaeenanesnansnsessanenensnensennevansaazsnenasnusaes 1B- 7
Circuit Diagrain..........cccccsserecsssesssesrcerseesusssesesnsteresssoetcensestarenaas snaeenseoeseaeauoesedensenesensiesananentenstaetearnaeureaaeness 1B- 8
Connector list ........:..ccscsesesscesesseenenennensonsnuecsnosuaneessueseueuurauuseuaussanceousnorsuaeaoneesiseatenssssusssecaeesnenenensdeesnanasonness 1B- 9
Diagnosis ........cceesesessssssserecrsenestenscerseenneonsnssnsnonenarsneauansearacseseaessuentonsemunanuasneontan caneecesssavnaueteceracouvonsapeseaneaes 1B-11
Air Conditioning Cycle .........cscsscnssenoseescncrsessessssesanseonterseusessieensevsneneuonseanassesneusnuaasensoanenenensesenseatnenaan snes 1B-11
Checking Refrigerant System with Manifold Gage .......ccsscccsesrensssessensessesoonsensansecessneasinesnasenssuscivonave 1B-12
Magnetic Clutch .......cccsssscsesnsenesencesenesenenarsanienssssenneees sunevesaesnenseunsusanvenaeaaceneateanesnadseaeansaesseatantaveuavsnenses
Ceramic Heater........ eeeaneneousceusetasenssenatinstussneuaaenoesaaey ssteneennesteenseenseneoean seseesenecersraeseueesnenueentuonsasensnensecausessueete
Condenser fan Motor ......sssccsseorscsnsestcontensunseuensuscaesmiuassuasuaseedsneedueauuusesusenanmeseeuaauseudensnaranesarersneanaeneenaaene
Electrical parts .........ccccscsscscesssesmrsseneessesnsenes caneuaeeceeuesusneesenuseansaeensensaueseudsnanaeunavasaanacanuseanvannenvesvaventuaaveaess
On-Vehicle Service.........scscccccsssescnsssssneesntsaessoessuaenemsusasenraraensnaseusnneesusueasenrscansusseesesessasatencsensoasessnenenesuantsaene
General Repair procedure ............csesnscssrsessmeessnnsassenonssensereeonseecensennvenenenanearsecoritennsenseneduetonteusneauaaeas
COMPSESSOL .........ccsccsenesssessssennenenennees caueesduanaeacuesssuecevecsuenseunesesonen
New Compressor Installation
Compressor Overhaul ........cccsncesreceesertsensctscastnonecssersanincensesneneuunnnas caeeeneaessueevuseusanssunseuuecoinedeaesn
COMPFeSSOF Ol ......cecccsseseseserseessceneensssenersonsnnansanneassauanennsnssiansneraveatineuegtsscanseasmnanuaenavensaneentaes senvanveneoeune
CONGONSER ......ccccccsessessstesnscnseeensusensseeetonsansteaeeseusniesenesasniesuersrauacenseanesstonneesoogesneunacentennanaestonaesereersunntienionees
Receiver-Drier.......sccccsescesserscecssecsscessssnsnnsnsessesnesnanecunsuaseaqeusamnasesauecnenseaessesuoniegnapnedeuseenueaaeseannansageneassseaeeenens
Triple Pressure SWItGH.......cccssscssscsessessssrsessessensaeeestreetsenensesiannesannsnsaaneniennscnnsnenucanseestsusceaneonnenesnentsensneetes
Evaporator ASSOMDIy ..........seceseeeseceenesees saneaenaeunuusuauseasoueauseuensnenssessoasusucusceasenneesusersrsatenassssunseenasenaanenayas
Evaporator Core and/or Expansion Vale .........cccccsecerersnsecssaccansenrsasonsecuneensneenssssssnsssseasensecannnneanieaens 1B-44
Air Conditioner (A/C) Switch ..........ccsssssssecsesssnseesenennonentarcennaanseananenniaees casecansananeanscseeseneanenamensedsouensensanes 1B-46
Blower Filter .........cccsssussonssssennenseneerinns suneensesusocsnesnasounvasinsoouenaensonnansstuauaneeuane ceesaaeeaees ceveseantuonvennaneeseaaney 1B-48
Refrigerant Lime..........ssccssscsesecessecsssesesmneneessesersnennersianessensneseniaunsvensennensauisaneaeatantacantsnnustonnerneensensnoneens 1B-49
Specifications ..........cssesessesrseseenscsssnesscessereneenereasarsneseaaeesaensgeenusnascursueneesennpennenesserssenssensauanseceneansananatensets 1B-50
Fastener TOrques ..........ccscssssssssrosnneensssorensennenneennessnasionsiansesecsnenoteanivensaunasnuansanusnersensatas sovestenaeenseesatesuseners 1B-51
cannes 1B-51
Special TOMS ........cecccssosecssecsssseseeccsersessstenesetnarsessseneersersmussaveatsornscaneeuenssenssassesnsscatansnsassenesaanseaeaeneanesanan
1B-2 AIR CONDITIONING

DESCRIPTION
The air conditioning system consists of a Heat is required to change the liquid refrigerant to
compressor, a condenser, an evaporator, a a gas or vapor.
receiver/dryer and the necessary contrals and Cooling of the vehicle cab occurs when the HFC-
safety devices to ensure its safe and reliable 134a refrigerant changes from a liquid to a gas in
operation. the evaporator. Air passing through the evaporator
A gas/liquid refrigerant (depending on gives up heat to the HFC-134a refrigerant, which
temperature and pressure) is contained in the absorbs heat while changing to a gas. The cooled
system as a heat exchange medium. air is circulated in the cab by a blower.

29
Side vent Center vent Side vent Side defrost Side defrost

{}
|
Outside air

v
Ws
-

10

———
| Engine
reotmsncnanenctcat!

Compressor
CONRAN =

Magnetic clutch
Receiver-drier
Triple pressure switch
Condenser
Evaporator assembly
Expansion vaive
Cooling air Temperature sensor

Oo
Evaporator core
‘ Taoeceeeee High pressure, high temperature gas Blower motor
- High pressure, high temperature . Heater unit
. Heater core
* mixture of gas and liquid
. Temp. control door
WZZLieLe, High pressure, medium temperature liquid (Air mix door)
Low pressure, low temperature Mode centrol door
mixture of liquid and gas (DEF)
SESS Low pressure, low temperature gas Mode control door
(VENT)
. Mode control door
(HEAT)
Electronic thermostat

Figure 1. Basic Refrigeration Gycie

 AIR CONDITIONING 1B-3

REFRIGERANT CYCLE refrigerant is sent to the evaporator is called

expansion. in addition, the expansion valve controls
The refrigeration cycle includes the following four the flow rate of the refrigerant liquid while
processes: decreasing the pressure. That is, the quantity of
refrigerant liquid vaporized inside the evaporator is
Evaporation determined by the quantity of heat which must be
removed at a prescribed vaporization temperature.
The refrigerant is changed from a liquid to a gas
it is important that the quantity of refrigerant be
inside the evaporator. The refrigerant mist that
controlled at exactly the right value.
enters the evaporator vaporizes readily. The liquid
refrigerant removes the required quantity of heat
from the air around the evaporator core cooling fins
SYSTEM COMPONENTS AND
and rapidly vaporizes. Removing the heat cools the
LOCATION
air, which is then radiated from the fins and lowers
the temperature of the air inside the vehicle.
Compressor (Figure 2)
The refrigerant liquid sent from the expansion A belt-driven, six-cylinder swash plate type
valve and the vaporized refrigerant gas are both compressor (DKS-15CH) is used. Three double end
present inside the evaporator and the liquid is pistons form the six pumping chambers.
converted to gas. Refrigerant flow is controlled by reed vaives and
With this change from liquid to gas, the pressure internal passages.
inside the evaporator must be kept low enough for Front and rear cylinder heads hold the valves and
vaporization to occur at a iower temperature. plates to the main body and are secured by six
The vaporized refrigerant is then returned to the through bolts.
compressor. The compressor is bolted to the left lower side of
the engine.
Compression The compressor is lubricated by compressor oil
The refrigerant is compressed by the compressor mixed with the refrigerant. An electrically actuated
until it is easily liquefied at normal temperature. clutch and other controls determine compressor
The vaporized refrigerant in the evaporator is cycling. The rear head of the compressor is
sucked into the compressor. This action maintains provided with pressure relief valve to prevent the
the refrigerant inside the evaporator at a low malfunction of the compressor due to the
pressure so that it can easily vaporize, even at low abnormally high pressure of refrigerant.
temperatures ciose to 0°C (32°F).
Also, the refrigerant which is returned to the Magnetic Clutch (Figure 2)
compressor is compressed inside the cylinder to The clutch consists of a magnetic coil, the drive
increase the pressure and temperature. The pulley, the armature and attaching parts. When
refrigerant can now easily be liquefied at normal current is supplied to the magnetic coil, the flexible
ambient temperatures. armature is pulled against the pulley. Since the
armature is attached to the compressor shaft and
Condensation the pulley rolls on a bearing mounted on the front
The refrigerant inside the condenser is cooled by cylinder head, the armature, pulley belt and engine
the outside air and changes from gas to liquid. crankshaft pulley then drive the compressor shaft.
The high temperature, high pressure gas coming
from the compressor is cooled and liquefied by the Compressor ;
condenser with outside air and accumulated in the N\ Magnetic clutch
receiver/drier. The heat radiated to the outside air
by the high temperature, high pressure gas in the
compressor is called heat of condensation. This is
the total quantity of heat (heat of vaporization) the
refrigerant removes from the vehicle interior via the
evaporator and the work (calculated as the quantity
of heat) performed for compression.

Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize.
The process of lowering the pressure to
encourage vaporization before the liquefied Figure 2. Compressor with Magnetic clutch
1B-4 AIR CONDITIONING

Condenser (Figure 3) Triple Pressure Switch (Figure 4)

The condenser assembly mounted on the right The triple pressure switch is installed atop the
side of the frame is made up of tubes and cooling receiver/drier/. This swich is constructed with a
fins, which carry the refrigerant and provide a rapid unitized type of two switches. One of them is a low
transfer of heat. The air passing through the and high pressure switch (Dual pressure switch) to
condenser cools the high pressure refrigerant switch “ON” or “OFF” the magnetic clutch as a
vapor, causing it to condense into a liquid. result of irregularly high-pressure or low-pressure of
the refrigerant. The order one is a medium pressure
switch (Cycling switch) to switch “ON” or “OFF” the
condenser fan by sensing the condenser high side
pressure.
* Low-pressure contro! (kpa/PSI)
Compressor
ON 1186 + 30 (27 + 4)
OFF :176 + 20 (26 + 3)
« Medium-pressure control
Compressor
ON 11471 + 98 (213 + 14)
OFF :1079 +118 (156 + 17)
« High-pressure control
Compressor
ON 12345 + 196 (341 + 28)
OFF :29042 + 196 (427 + 28)

Figure 3. Condenser

Receiver/Drier (Figure 4)
The receiver/drier performs four functions;
* As the quantity of refrigerant circurated varies
depending on the refrigeration cycie conditions,
sufficient refrigerant is stored for the
refrigeration cycle to operate smoothly in
accordance with fluctuations in the quantity Receiver/Drier
_

circurated.
* The liquified refrigerant from the condenser is
mixed with refrigerant gas containing air
bubbles. If refrigerant containig air bubbles is
sent to the expansion valve, the cooling Figure 4. Receiver/Drier and Triple pressure
capacity will decrease considerably. Therefore, switch
the liquid and air bubbles are separated and
only the liquid is sent to the expansion valve. Evaporator (Figure 5)
« The receiver/drier utilizes a filter and dryer to The evaporator cools anc dehumidifies the air
remove the dirt and water mixed in the cycling before the air enters the vehicle. High-pressure
refrigerant. liquid refrigerant flows through the expansion valve
A receiver/drier may fail due to a restriction inside into the low-pressure area of the evaporator. The
the body of the unit. A restriction at the inlet to the heat in the air passing through the evaporator core
receiver/drier will cause high pressures. is lost to the cooler surface of the core, thereby
Outlet restrictions will be indicated by low pressure cooling the air.
and little or no cooling. An excessively cold
As heat is lost between the air and the evaporator
receiver/drier outlet may indicate a restriction.
core surface, moisture in the vehicle condenses on
The receiver/drier of this vehicie is made of
the outside surface of the evaporator core and is
aluminum with a smaller tank. It has 300cc
drained off as water.
(8.5Imp fl oz) refrigerant capacity.
When the evaporator malfunctions, the trouble
will show up as inadequate supply of cool air. The
cause is typically a partially plugged core due to
 AIR CONDITIONING 1B-5

dirt, a malfunctionig blower motor, or low refrigerant

aL
Insulator a
level.
The evaporator core with a laminate louver fin is a or core :
single-sided tank type where only one tank is
provided under the core.

Evaporator

Figure 6. Expansion Valve

Electronic Thermostat (Figure 7)

The thermostat consists of the thermosensor
and thermostat unit which functions electrically to
reduce the noises being generated while the system
Figure 5. Evaporator is in operation.
Expansion Valve (Figure 6) The electronic thermosensor is mounted at the
evaporator core outlet and senses the temperature
This expansion valve is an external pressure type
of the cool air from the evaporator. Temperature
and it is installed at the evaporator intake port.
signais are input to the thermostat unit. This
The expansion valve converts the high pressure information is compared by the thermo unit and the
liquid refrigerant sent from the receiver/drier to a results in output to operate the A/C thermo relay
low pressure liquid refrigerant by forcing it through and turn the magnetic clutch “ON” or “OFF” to
a tiny port before sending it to the evaporator. prevent evaporator freeze-up.
This type of expansion valve consists of a A characteristic of the sensor is that the resistance
temperature sensor, diaphragm, ball valve, ball decreases as the temperature increases and the
seat, spring adjustment screw, etc. resistance increases as the temperature decreases.
The temperature sensor contacts the evaporator
outlet pipe, and converts changes in temperature to
Thermo
pressure. It then transmits these to the top chamber
of the diaphragm.
The refrigerant pressure is transmitted to the
diaphragm's bottom chamber through the external
equalizing pressure tube.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined
by the force acting on the diaphragm and the spring
pressure.
The expansion valve regulates the flow rate of the Electronic
tharmostat
refrigerant. Accordingly, when a malfunction occurs
to the expansion valve, both discharge and suction
pressures are low, resulting in insufficient cooling
capacity of the evaporator.
Figure 7. Electronic Thermostat
1B-6 AIR CONDITIONING

Refrigerant Line (Figure 8)

Restrictions in the refrigerant line will be indicated
by:
1. Suction line; A restricted suction line will cause
low suction pressure at the compressor, low
discharge pressure and little or no cooling.
2. Discharge line; A restriction in the discharge
line generally will cause the discharge line to
leak.
3. Liquid line; A liquid line restriction will be
evidenced by low discharge and suction
pressure and insufficient cooling.
Refrigerant flexible hoses that have a iow
permeability to refrigerant and moisture are used.
These low permeability hoses have a special nylon
layer on the inside.

Resin layer (Nylon)

. Reinforcement layer (Polyester)

internal rubber layer /

Eaternal rubber layer

Figure 8.Refrigerant Line

Service Charge Vaive (Figure 9)

The Service Charge Vaives are located behind
the front grille.

Low pressure side

High pressure side

Figure 9. Service Charge Valve location

 AIR CONDITIONING 1B-7

AIR CONDITIONING PARTS

Blower filter
f
/

_-— Evaporator

Refrigerant
suction line Compressor
* . S “

Refrigerant
liquid line
/
“

Receiver
_~ Grier
we

. / Ri iT " oS

Condenser on “Xb

Compressor ~
bracket

se
y “7 _ “5
Tension pull

Figure 10.
 t
i
RELAY;
| [Rca] 60a RELAY;ENGWARMCUT [J-15]
(1) M/T VEHICLE ONLY CERAMIC HEATER
i awa.
1 CERAMIC HEATER re
t
aia FO
woe eee enna ccc eeenneeee wena een weet nnn ene i
j THERMO SWITCH
[FL-3] 60. fE-22] 16a
GLOW SB/L 1.25B/L CONDENSOR FAN

RELAY; RELAY;
RELAY; Af THERMO nese CONDENSOR FAN
FL-1] 80A HEATER & A/C F-2| 104 . [hs ;
AIRCON gspR Paw ll . W
2 MAIN
ew.

i,§
o

(F-1] 204 a-37|4 io

a
ATT OIE
CHARGE (5) HEATER
1B-8 AIR CONDITIONING

a
GS
=ao

0.5BR

rd
2k
0.8GY

eo
Ho-6-
ma

PRESSURE SWITCH
:
t
t
'

0.58
ea 2]
3G/R

0.5LG
0.851,

2b

GENERATOR ({B)
Sct elt z
01
IE
fl
ia

FRAME B-14: 1n-39 B38] H.

BLOWER Le 648
MOTOR
ae
aWiG

“fe | osGw_

B14]
AC SWITCH LE
alk
CONDENSOR FAN
th

Bic
MAGNETIC CLUTCH
ELECTRONIC THERMOSTAT
[fe]
ig

(COMPRESSOR)

Figure 11. Gircuit Diagram

0.58
CIRCUIT DIAGRAM

3W/G

0.5G/W

a
ot
oT

0.58
t
CERAMIC HEATER

sin
lew

i
'
'
S\
0.858

t
r
t
s2}-———-O
i

4 OFF N '
O.5G/Y lele

B-29| JOINT i
FAN SWITCH i
CONNECTOR t
&
4
HEADLIGHT 3B al T le 28 i
BRACKET (LH) lL27 } 1
O.5G/V

t
3B

i
1
!
FRAME-LH (CENTER) HE--[
2 | i

REIN FOR CEMENT tt-E194

 AIR CONDITIONING 1B-9

CONNECTOR LIST

FES
i
=
7
i
7:

Figure 12. Connector List

1B-10 AIR CONDITIONING

CONNECTOR LIST

rT|
Lo
2

(MBP T/M) (MAX T/M)

c—
I |
Sj. Jes SS].
ee SS

J-24

Figure 12a. Connector List

 AIR CONDITIONING 1B-11

DIAGNOSIS

AIR CONDITIONING CYCLE

PROBLEM CHECK POINT TROUBLE CAUSE CORRECTION

No Cooling or 1. Magnet clutch function. 1. Clutch does not run. 1. Refer to MAGNETIC
Insufficient CLUTGH DIAGNOSIS in
Cooling this section.
2. Compressor drive belt. 2. Drive belt loose or 2. Adjust the drive belt
broken. specified tension or
replace the drive belt.
3. Magnetic clutch friction 3. Clutch face 3. Clean the magnetic
face. discoloration and slip. clutch face or replace.
4. Magnetic drive plate 4. Incorrect clearance 4. Adjust the clearance
and pulley. between magnetic drive refer to ON-VEHICLE
plate and pulley. SERVICE in this section.
5. Compressor. 5. Seized. 5. Replace the compressor.
6. Refrigerant. 6. Insufficient or excessive 6. Check sight glass (Refer
charge of refrigerant. to "Reading Sight
Glass").
Discharge and recover
refrigerant. Recharge to
specified amount.
7. Refrigerant ieakage. 7. Leaks in the refrigerant 7. Check refrigerant
system. system for leaks and
refrigerant line
connection or repair as
necessary.
Discharge and recover
refrigerant.
Recharge to specified
amount.
8. Condenser. 8. Condenser clogged or 8. Clean the condenser or
insufficient radiation. replace as necessary.
9. Heater temperature 9. Hot water circuit does 9. Repair the control link
control fink. not completely shut due unit.
to control link unit
defective.
10. Expansion valve. 10. Unsteady operation due | 10. Replace the expansion
to foreign substance. valve.

Insufficient 1. Evaporator. 1. Clogged or frosted. 1. Check evaporator core

Velocity of and clean or replace the
Cooling Air core.
2. Air leakage. 2. Air leaking from cooling 2. Check evaporator and
unit or air duct. duct connection then
repair as necessary.
3. Blower motor. 3. Blower motor does not 3. Refer to "DIAGNOSIS
rotate properly. OF HEATING SYSTEM"
in SECTION 1A.

For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,
EVACUATION AND CHARGING?” in this section.
 1B-12 AIR CONDITIONING

DIAGNOSIS (CONT.)
CHECKING REFRIGERANT SYSTEM HEC-134a Pr r ture Relationehi
WITH MANIFOLD GAGE > a Pressure-Temperature Relationship

Pressure Temperature
Since Refrigerant-134a (HFC-134a) is used in
the air conditioning system in this vehicie, be (kPa) (psi) (°C) (°F)
sure to use manifold gages, charging hoses and
other air conditioning service tools for HFC-134a 36 5.3 ~20) ~4,4
when checking the refrigerant system. (Refer to 67 9.7 15 5
“ON-VEHICLE SERVICE” for Precautions for 104 15 ~10 14
HFC-134a Air Conditioning System in this 147 4 5 23
section.) 196 28 0 32
255 37 5 At
Conditions; 314 45 10 50
« Run the engine at idling 399 57 15 59
* Air conditioning switch is “ON” 471 68 20 68
« Run the blower motor at “4” (high) position 569 82 25 77
* Temperature control knob set at “COLD” 677 98 30 86
« Close the ali doors 785 114 35 95
» Air source selector lever at “RECIRC” Q12 499 40 104
1059 154 45 113
Normal pressure guideline; 1216 176 50 429
At ambient temperature:
Approx. 25~30°C (77-86°F) Connect the manifold gage (Figure 13)
Low-pressure side: Low-pressure hose (LOW) - Suction side
Approx. 127-265 kPa (18.5-38.4 psi) High-pressure hose (Hl) - Discharge side
High-pressure side:
Approx. 1,373-1,765 kPa (199~255.9 psi)
Refer to the table on refrigerant pressure-tempera-
ture relationship.

\
5‘ o
" 7
he
—— = \
ty
ohm 5

\ ih.
BF aa
a
SA
iN yee
<a

LOW SIDE
NN Ny,

aN
"~ HIGH SIDE

Figure 13. Checking Refrigerant System with Manifold Gage

 AIR CONDITIONING 1B-13

DIAGNOSIS (CONT.)

RESULT CHECK POINT / SYMPTOM TROUBLE CAUSE CORRECTION

Discharge (High 1. Condenser or cooling 1. Condenser clogged or . Clean the condenser

Gage) Pressure fan. dirty. fins.
Abnormally Cooling fan does not Check cooling fan
High operate properly. operation.
2. Insufficient cooling. 2. Excessive refrigerant .* Discharge and
in system. recover refrigerant.
Recharge to
specified amount.
3. High pressure gage 3. Air in system. . Evacuate and charge
drop (After stopping refrigerant system.
A/C, pressure drops
approx. 196 kPa/28 psi
quickly).

Discharge (High | _ 1. Insufficient cooling. 1. Insufficient refrigerant .* Check for leaks.

Gage) Pressure in system. * Discharge and
Abnormally recover refrigerant.
Low Recharge to
specified amount.
2. Low pressure gage . Clogged or defective . Replace expansion
indicates vacuum. expansion valve. valve.
3. Frost or dew on . Restriction caused by . Check system for
refrigerant line before debris or moisture in restriction and replace
and after receiver/drier receiver/drier. receiver/drier.
or expansion vaive,
and low pressure gage
indicates vacuum.
4. High and low pressure
gage balanced quickly .* Gompressor seal . Repair or replace the
(After turned off A/C). defective. compressor.
+ Poor compression
due to defective
compressor gasket.
1B-14 AIR CONDITIONING

DIAGNOSIS (CONT.)
RESULT CHECK POINT / SYMPTOM TROUBLE CAUSE CORRECTION

Suction (Low 1. Low pressure gage . Excessive refrigerant . Discharge and recover
Gage) Pressure (Low pressure gage is in system. refrigerant. Recharge
Abnormally lowered after to specified amount.
High condenser is cooled by
water).
. Low pressure hose 2.° Unsatisfactory valve . Replace the expansion
temperature (Low operation due to valve.
pressure hose defective
temperature around temperature sensor
the compressor of expansion valve.
refrigerant line « Expansion valve
connector is lower than opens too long.
around evaporator).
. High and low pressure 3. Gompressor gasket is . Repair or repiace the
gage balanced quickly detective. compressor.
(After turned off A/C).

Suction (Low . Insufficient cooling. 1. insufficient refrigerant .* Check for leaks.

Gage) Pressure in system. « Discharge and
Abnormally recover refrigerant.
Low Recharge to
specified amount.
. Frost on the expansion 2. Expansion valve . Replace the expansion
valve inlet line. clogged. valve.
. Receiver/drier inlet and 3. Receiver/Drier clogged . Replace the
outlet refrigerant line receiver/drier.
temperature (A distinct
difference in
temperature develops).
. Expansion valve outlet 4. Expansion valve . Replace the expansion
refrigerant line (Not temperature sensor valve.
cold and low pressure defective.
gage indicates
vacuum).
. When the refrigerant 5. Clogged or blocked . Replace refrigerant
line is clogged or refrigerant line. line.
blocked, the low
pressure gage reading
will decrease, ora
vacuum reading may
be shown.
. Evaporator core is 6. Thermo switch . Replace thermo
frozen. defective. switch.
 AIR CONDITIONING 1B-15

DIAGNOSIS (CONT.)

RESULT CHECK POINT / SYMPTOM TROUBLE CAUSE CORRECTION

Suction (Low 1. Insufficient cooling. 1. Excessive refrigerant 1. Discharge and recover

Gage) and in system. refrigerant,then
Discharge (High Recharge to specified
Gage) Pressure 2. Condenser. 2, Condenser clogged or amount.
Abnormally dirty. 2. Clean the condenser
High 3. Suction (Low) pressure 3. Air in system. fin.
hose (Not cold). 3. Evacuate and charge
refrigerant.

Suction (Low 1. Insufficient cooling. insufficient refrigerant in « Check for leaks.

Gage) and system. « Discharge and recover
Discharge (High refrigerant. Recharge to
Gage) Pressure specified amount.
Abnormaily Low
 1B-16 AIR CONDITIONING

DIAGNOSIS (CONT.)
MAGNETIC CLUTCH
MAGNETIC CLUTCH DOES NOT OPERATE

* IGNITION SW “ON” (ENGINE IS RUNNING)

A/C AND FAN SW “ON”.

|
* DOES A/C SW INDICATOR LIGHT TURN ON?

+ NO.[F-2| (10A) FUSE OK?

Tr
* IS A/C SWITCH OK?

vs
| + 1S FAN SWITCH OK?

[ Yes

* CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT [ REPLACE

BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO.1
AND GROUND?
|
YES ca
+ CHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE OPEN CIRCUIT
CONNECTOR TERMINAL NO.3 AND NO.2 |B-42!? BETWEEN NO|| F-2 | FUSE AND
NO.1

[YES|
POOR GROUND OR OPEN CIRKIT BETWEEN CHASSIS SIDE OPEN CIRCUIT
CONNECTOR TERMINAL NO.1 [B-42 AND BODY GROUND
(No.[B-7])
 AIR CONDITIONING 1B-17

(A)
[ - IS PRESSURE SWITCH OK?

es
| « IS A/C THERMO RELAY OK? + INSUFFICIENT REFRIGERANT OR
PRESSURE SWITCH DEFECTIVE

=* CHECK TO SEE IF BA. TTERY VOLTAGE IS PRESENT

BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO.1
AND GROUND?

NO

: CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT * MAGNETIC CLUTCH DEFECTIVE

BETWEEN CHASSIS SIDE CONNECTOR TERMINAL NO.1
AND GROUND?

[ne |
OPEN CIRCUIT
| * DISCONNECT THE A/G THERMO RELAY
(BETWEEN NO.2 [ J-6 | AND NO.1 [E-5])
|
- CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT
BETWEEN CHASSIS SIDE RELAY TERMINAL NO.1 [B-37]
AND GROUND?

YES

» CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT OPEN CIRCUIT

BETWEEN CHASSIS SIDE RELAY TERMINAL NO.2[B-37| (BETWEEN NO.| F-2 | FUSE AND NO.1 )
AND GROUND?

ca
OPEN CIRCUIT
» CHECK TO SEE IF CONTINUITY BETWEEN CHASSIS SIDE
(BETWEEN NO] F-1 | FUSE AND NO.2 B-37})
CONNECTOR TERMINAL NO.2 [B-39] AND NO.3 [B=15],
NO.2 AND NO.2

YES
[NO

[ OPEN CIRCUIT |
[ELECTRONIC THERMOSTAT DEFECTIVE
 1B-18 AIR CONDITIONING

CERAMIC HEATER
CERAMIC HEATER DOES NOT OPERATE

| - i$ FL-5 NORMAL? |

YES|
[no
* CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT
BETWEEN CHASSIS SIDE RELAY TERMINAL NO.3 | J-14
AND GROUND?

=
| ° IS CERAMIC HEATER RELAY NORMAL? OPEN CIRCUIT
(BETWEEN FL-5 AND NO.3
[v-14])

YES NO

* IS FULL HOT SWITCH NORMAL? REPLACE

YES

* CHECK CONTINUITY BETWEEN CHASSIS SIDE

CONNECTOR TERMINAL NO.2 |B-134| AND GROUND WITH
FAN SWITCH ON.

YES

+ CHECK CONTINUITY BETWEEN CHASSIS SIDE OPEN CIRCUIT

CONNECTOR TERMINAL NO.2 |B-136) AND GROUND. (BETWEEN NO.2 |B-134, AND
[B-7})

“=
| REPLACE CERAMIC HEATER
NO

OPEN CIRCUIT
(BETWEEN NO.2 B-136] AND
[B-136])
 AIR CONDITIONING 1B-19

CONDENSER FAN MOTOR

CONDENSER FAN DOES NOT OPERATE

- IGNITION SW “ON” (ENGINE IS RUNNING)

A/C AND FAN SW “ON”.

- DOES A/C COMPRESSOR OPERATES CORRECTLY? |

Ce
r- NO. (1996 model:10A, 1997 model:15A) FUSE OK? | REFER TO "MAGNETIC CLUTCH"

[ves]
- CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT [ REPLACE |
BETWEEN CHASSIS SIDE CONNECTOR TERMINAL
NO.1 AND GROUND?

es] co
CHECK TO SEE IF CONTINUITY BETWEEN NO.4 [J-17], OPEN CIRCUIT
BETWEEN NO,| F-22| FUSE AND
NO.3 [J-6|, NO.2 [J-17], GROUND?
NO.1

[res]
° CHECK TO SEE IF BATTERY VOLTAGE IS PRESENT [ POOR GROUND OR OPEN CIRCUIT
BETWEEN CHASSIS SIDE CONNECTOR TERMINAL
NO.1 AND GROUND?

[ves]
POOR GROUND ,OPEN CIRCUIT OR
CHECK TO SEE IF CONTINUITY BETWEEN NO.2 [J-51] CONDENSER FAN RELAY |S FAULT.
AND GROUND?

YES

OPEN CIRCUIT
[ * CONDENSER FAN MOTOR DEFECTIVE
 1B-20 AIR CONDITIONING

ELECTRICAL PARTS 2. Apply battery voltage to the clutch side connector

terminal, check to see if the magnetic clutch is
Inspect attracted to the pulley.
Heater &A/C, A/C Thermo, and Condenser Fan
Relay (Figure 14)
1. Check for continuity between relay side
connector terminal.

3)-) ess Continuity

)-(5) teases No continuity
(When battery voltage is applied between (2)-(4))
(3)-) senor No continuity
OLOne Continuity

Figure 16. Magnetic Clutch Check

Triple Pressure Switch (Figure 17)
1. Disconnect the connector and check for
continuity between pressure switch side
connector terminal.
2. Recennect the connector to activate the air
conditioning, and check to see if there is
continuty between the chassis side connectors
and the fan operates.
[AIC OFF]
Figure 14. Relay Check Terminal No. Control Continuity
AIC Switch (Figure 15)
1. Check for continuity between A/C switch side
G2) Magnetic clutch| Continuity
connector terminals.
@4) Condenser Fun | No Continuity
Terminal No.
— i 2 3
SW position ~~ _. [AC ON]
ON O+0-+0 Refrigerant pressure Terminal Continuity | Fan
OFF O--O
1079118kpa/155+17kpa Continuity OFF
@O@®
1474+98kpa/213414kpa Continuity | ON

gence

| \
oO ®
Figure 15. A/C switch Check
Magnetic Clutch (Figure 16)
1. Disconnect the magnetic clutch harness
connectors. Figure 17. Pressure switch Check
 AIR CONDITIONING 1B-21

Electronic Thermostat (Figure 18) Condenser Fan (Figure 19)

1. With the air select lever set to "VENT" and the 1. Disconnect the condenser fan connector from
air source select lever to “CIRC”, start the air the condenser.
conditioning. 2. Connect the battery positive terminal to the No.
2. While shifting the temperature control lever from 1 of the condenser fan connector and negative
"FULL COOL" through the "FULL HOT", check to to the No. 2.
see if the magnetic clutch turns on and off. 3. Be sure to check to see if the condenser fan
(* Note that the time required to reach the “OFF” operates correctly.
point depends on the warm or cold air at 3.5 +
0.5 2C at the electronic thermostat thermosensor.)
3. While the magnetic clutch is turning "ON" and

Terminal No| Magnetic clutch Voltage

@@® -— OFF
~
Battery voltage

|) / ee
______ Thermostat unit Terminal No.

,
aca Ty | I
Figure 19. Condenser Fan Check

| AC
| thermo
| ON Ww 1 ' relay

| {bore q 1 _.

| | 7
Magnetic
@) \
E- | : clutch
=)
Thermo| Or Fan sw
sensor
|
|
|
|
|
|

Figure 18. Thermostat Check

 1B-22 AIR CONDITIONING

ON-VEHICLE SERVICE

GENERAL REPAIR PROCEDURE Repair of Refrigerant Leaks

Refrigerant Line Connections
Precautions for Replacement or Repair of Install new O-rings, if required. When
Air Conditioning Parts disconnecting or connecting lines, use two
There are certain procedures, practices and wrenches to prevent the connecting portion from
precautions that should be followed when servicing twisting or becoming damaged (Figure 20).
air conditioning systems:
* Keep your work area clean.
* Always wear safety goggle and protective gloves
when working on refrigerant systems.
Beware of the danger of carbon monoxide fumes
caused by running the engine.
Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
« Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
* When discharging and recovering the refrigerant,
do not allow refrigerant to discharge too fast; it
will draw compressor gil out of the system.
« Keep moisture and contaminants out of the
system. When disconnecting or removing any
lines or parts, use plugs or caps to close the Figure 20. Refrigerant Line Connection
fittings immediately. Never remove the caps or
When connecting the refrigerant line at the block
plugs until the lines or parts are reconnected or
joint, securely insert the projecting portion of the
installed.
joint portion into the connecting hole on the unit
« When disconnecting or reconnecting the lines,
side and secure with a bolt.
use two wrenches to support the iine fitting, to
Apply specified compressor oil to the O-rings prior
prevent from twisting or other damage.
to connecting (Figure 21).
* Always install new O-rings whenever a CAUTION:
connection is disassembled.
Compressor (PAG) oil to be used varies
« Before connecting any hoses or lines, apply new
according to compressor model. Besure to
specified compressor oil to the O-rings.
apply oil specified for the model of compressor.
* When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
1. Use the J-39500 (ACR4: HFC-134a
Refrigerant Recovery / Recycling /
Recharging System) or equivalent to
discharge and recover the refrigerant.
2. Remove and replace the defective part.
3. After evacuation, charge the air conditioning
system and check for leaks.

Figure 21. Apply Compressor Oil to the O-rings

Prior to Connecting
 AIR CONDITIONING 1B-23

O-rings must be closely aligned with raised Leak at Refrigerant Line Connections
portion of refrigerant line (Figure22). 1. Check the torque on the refrigerant line fitting
and, if too loose, tighten to the specified torque.
» Use two wrenches to prevent twisting and
damage to the line.
* Do not over tighten
. Perform a leak test on the refrigerant line fitting.

MG
. If the leak is still present, discharge and recover

oo
the refrigerant from the system.
4, Replace the O-rings.
» O-rings cannot be reused. Always repalce
with new ones.
» Be sure to apply specified compressor oil to
the new O-rings.
§. Retighten the refrigerant line fitting to the
specified torque.
* Use two wrenches to prevent twisting and
damage to the line.
Figure 22. Position of O-ring
6. Evacuate, charge and check the system.
insert nut into union. First tighten nut by hand as
much as possible.(Figure 23). Leaks in the Hose
Then, tighten nut to specified torque .(Refer to if the compressor inlet or outlet hose is leaking,
“SPECIFICATIONS” for Fastener Torques in this the entire hose must be replaced. Refrigerant hose
section.) must not be cut or spliced for repair.
1. Locate the leak.
2. Discharge and recover the refrigerant.
3. Remove the hose assembly.
« Cap the open connections at once.
4, Connect the new hose assembly.
« Use two wrenches to prevent twisting or
damage to the hose fitting.
+ Tighten the hose fitting to the specified
torque.
5. Evacuate, charge and check the system.

Compressor Leaks
if leaks are located around the compressor shaft
seal or shell, replace or repair the compressor.

Figure 23. Connecting Refrigerant Line

1B-24 AIR CONDITIONING

Recovery, Recycling, Evacuation and Refrigerant Recovery

Charging The refrigerant must be discharged and
Handling Refrigerant-134a {HFC-134a): recovered by using the J-39500 (ACR4: HFC-134a
Air conditioning systems contain HFC-134a. Refrigerant Recovery / Recycling / Recharging
This is a chemical mixture which requires special System) or equivalent before removing or mounting
handling procedures to avoid personal injury. air conditioning parts.
+ Always wear safety goggles and protective 1. Connect the high and low charging hoses of the
gloves. ACR¢ set as shown below.(Figure 24)
* Always work in a weil-ventilated area. Do not
weld or steam clean on or near any vehicle-
installed air conditioning lines or components.
* If HFC-134a should come in contact with any part
of the body, flush the exposed area with cold
water and immediately seek medical help.
« If itis necessary fo transport or carry any
container of HFC-134a in a vehicle, do not carry it
in the passenger compartment.
* lf itis necessary to fill a small HFC-134a
container from a large one, never fill the container
completely. Space should always be allowed
above the liquid for expansion.
* HFC-134a and Refrigerant-12 (R-12) should
never be mixed as their compositions are not the
same.
* HFC-134a PAG oil tends to absorb moisture more
quickly than R-12 mineral oi! and, therefore,
should be handled more carefully.
« Keep HFC-134a containers stored below 40°C
(100°F).
Figure 24. Refrigerant Recovery
WARNING: 2. Recover the refrigerant by following the ACR4
« SHOULD REFRIGERANT-134a (HFC-134a} Manufacturer’s Instructions.
CONTACT YOUR EYE(S), CONSULT A 3. When a part is removed, put a cap or a plug on
DOCTOR IMMEDIATELY. the connecting portion so that dust, dirt or
* DO NOT RUB THE AFFECTED EYE(S). moisture cannot get into it.
INSTEAD, SPLASH QUANTITIES OF FRESH
COLD WATER OVER THE AFFECTED AREA Refrigerant Recycling
TO GRADUALLY RAISE THE TEMPERATURE
Recycle the refrigerant recovered by J-39500
OF THE REFRIGERANT ABOVE THE
(ACR4: HFC-134a Refrigerant Recovery/ Recycling
FREEZING POINT.
/ Recharging System) or equivalent.
* OBTAIN PROPER MEDICAL TREATMENT AS
For the details of the actual operation, follow the
SOON AS POSSIBLE. SHOULD THE HFC-134a
steps in the ACR4 Manufacturer’s Instructions.
TOUCH THE SKIN, THE INJURY MUST BE
TREATED THE SAME AS SKIN WHICH HAS
BEEN FROSTBITTEN OR FROZEN.
 AIR CONDITIONING 1B-25

that the gage manifold pressure is at 750 mmHg

Evacuation of the Refrigerant System
(30 inHg), close both hand valves.
(Figure 25) 9. Close positive shutoff valve. Stop the vacuum
*NOTE: pump and disconnect the center hose from the
Explained below is a method using a vacuum
vacuum pump.
pump. Refer to the ACR4 manufacturer's
instructions when evacuating the system with a Charging the Refrigerant System
ACR‘.
There are various methods of charging refrigerant
Air and moisture in the refrigerant will cause
problems in the air conditioning system. into the air conditioning system.
These include using J-39500 (ACR*: HFC-134a
Therefore, before charging the refrigerant, be
Refrigerant Recovery / Recycling / Recharging
sure to evacuate air and moisture thoroughly from
the system. System) or equivalent and direct charging with a
weight scale charging station.

Charging procedure
» ACR* method
For the charging of refrigerant recovered by
ACR%4, follow the manufacuturer's instruction
(Figure 26}.

(High side)

Figure 25.Evacuation of the Refrigerant System

~ J-39500
1. Connect the gage manifold.
- High-pressure valve (HI) - Discharge-side
- Low-pressure valve (LOW) - Suction-side
. Discharge and recover the refrigerant.
Go AO

. Connect the center hose of the gage manifold

set to the vacuum pump inlet. Figure 26. ACR‘ Method
4. Operate the vacuum pump, open shutoff valve
and then open both hand valves. * Direct charging with a weight scale charging
station method (Figure 27)
5. When the low-pressure gage indicates approx.
750 mmHg (30 inHg), continue the evacuation 1, Make sure the evacuation process is correctly
for 5 minutes or more. completed.
2. Connect the center hose of the manifold gage to
6. Close both hand valves and stop the vacuum
the weight scale.
pump.
3. Connect the low pressure charging hose of the
7. Check to ensure that the pressure does not
manifold gage to the low pressure side service
change after 10 minutes or more.
valve of the vehicle.
+ If the pressure changes, check the system for
leaks. 4, Connect the high pressure charging hose of the
manifold gage to the high pressure side service
- {f leaks occur, retighten the refrigerant line
valve of the vehicle.
connections and repeat the evacuation steps.
8. If no leaks are found, again operate the vacuum
pump for 20 minutes or more. After confirming
1B-26 AIR CONDITIONING

Refrigerant Container WARNING: BE ABSOLUTELY SURE NOT TO

OPEN THE HIGH PRESSURE VALVE OF THE
MANIFOLD GAGE. SHOULD THE HIGH
PRESSURE VALVE BE OPENED, THE HIGH
PRESSURE REFRIGERANT WOULD FLOW
BACKWARD, AND THIS MAY CAUSE THE
REFRIGERANT CONTAINER TO BURST.

9. When finished with the refrigerant charging,

close the low pressure valve of the manifold
gage and container valve.
10. Check for refrigerant leaks.

Checking the A/C system

1. Run the engine and open all the vehicle doors.
Weight Scale ~ (Low) (High) 2. Turn A/C switch “ON”, set the fan switch to its
highest position and set temperature lever to full
Figure 27.Direct Charging with a Weight Scale cool position.
3. Check the high and low pressure of the
5. Place the refrigerant container up right on a manifold gage.
weight scale. » Immediately after charging refrigerant, both
Note the total weight before charging the high and low pressure are slightly high, but
refrigerant. they settle down to the pressure guidelines
5a. Open refrigerant container valve. shown below:
5b. Open low side valve on the manifold gauge set. Ambient temperature: 30-35 °C (86-95 °F)
Refer to the manufacturer's instruction's for a Pressure Guidelines:
weight scale charging station. * High-pressure side;
. Perform system leak test. Approx. 1470-1667 kPa (213.3~241.7 psi)
« Charge the system with approx. 200g (0.44 « Low-pressure side:
ips) of HFC-134a. Approx. 127-196 kPa (18.5-28.4 psi)
« Make sure the high pressure valve of the * if an abnormal pressure is found, refer to
manifold gage is closed. “CHECKING REFRIGERANT SYSTEM WITH
* Check to ensure that the degree of pressure MANIFOLD GAGE?” in this section.
does not change. 4, Put your hand in front of the air outlet and move
« Check for refrigerant leaks by using a HFC- the temperature control lever of the control
134a leak detector. panel to different positions. Check if the outlet
* If a leak occurs, recover the refrigerant. temperature changes as selected by the control
Repair the leak, and start all over again from lever.
the first step of evacuation.
. If no leaks are found, continue charging
refrigerant to the air conditioning system.
« Charge the refrigerant until the scale reading
decreases by the amount of the charge
specified.

Specified amount — g (lbs) 600 (1.32)

« If charging the system becomes difficult:

(1) Run the engine at idling and close all the
vehicle doors.
(2) Turn A/C switch “ON”.
(3) Set the fan switch to its highest position.
(4) Set air source selector lever to “RECIRC”.
(5) Slowly open the low side valve on the
manifold gage set.
 AIR CONDITIONING 1B-27

COMPRESSOR

1. Magnetic Ciutch Harness

Connector
2. Refrigerant Line Connector
3. Drive Belt
4, Compressor
Bolt A: M10 L = 50 mm (2.0 in)

Figure 28. Compressor Removal or installation

| Remove or Disconnect (Figure 28)

Preparation:
+ Battery ground cable.
- Discharge and recover refrigerant (Refer to
“REFRIGERANT RECOVERY’ in this section).
1. Magnetic clutch harness connector (1).
2. Refrigerant line connector (2).
» When removing the line connector, connecting
part of the line connector and the compressor
should immediately be plugged or capped in
order to prevent foreign matter from being
mixed into the line.
3. Drive beit (3).
+ Loosen the tension pulley lock nut and then
Figure 29. Compressor Bracket Removal or
loosen the adjusting bolt.
Installation
4. Compressor (4).
» Remove the compressor from the engine
mounting bracket (figure 29).
1B-28 AIR CONDITIONING

[><] Install or Connect (Figure 28) NEW COMPRESSOR INSTALLATION

1. Compressor (6). After new compressor is filled with 180cc (6.08

* Attach the compressor to the engine mounting ~ FL.OZ) of oil, perform the following steps:
bracket using four boits. 1. Gently release nitrogen gas from the new
compressor by loosing the compressor service
[2] Tighten plug fixing bolt (figure 31).
« Take care not to let the compressor oil flow
* Compressor fixing bolts to 32 N-m (24 Ib-ft). out.
« Inspect O-rings and replace if necessary.
2. Drive belt (5).
2. Turn the compressor several time by hand to
» Push the drive belt with the force of 10 kg (22
prevent any liquid compression.
ib), and adjust the drive belt tension by
3. When installing on a new system, the
tightening idie pulley tension adjustment bolt,
compressor shouid be installed as it is. When
until the 10 mm (0.4 in) deflection of the belt is
installing on a used system, the compressor
obtained. Then tighten the pully center nut
should be installed after adjusting the amount of
(figure 30). compressor oil.
(Refer ta "COMPRESSOR OIL" in this section)
fQ] Tighten

« Tension pully center (lock) nut to 49 N-m (36

lb-ft).

3. Refrigerant line connector (4).

« O-rings are not reused. Always replace with
new ones.
* Be sure to apply new specified compressor oil
to the O-rings when connecting refrigerant
line.

[a] Tighten

* Refrigerant line connector fixing bolt to 27

N-m (20 Ib-ft).
Figure 31. New Compressor Installation
4. Generator brace (3).
CAUTION:
fa] Tighten The A/C-belt must be adjusted after Fan-belt
adjustment. If the required procedure is not
* Generator brace fixing bolt to 32 N-m (24 followed, the A/C-belt may experience excessive
ib-ft). tension, and possible premature fallure.

5. Magnetic clutch harness connector (2).

6. Air inlet pipe (1).

1. Pulley center nut

2. Adjustment bolt
“ 4 3. Crank pulley
22 Ibs 4+ Drive belt
(10kg)
. A/C Compressor
20,630.70 in . A/C-Belt
. Tension pulley
. Generator
. Fan-Belt
5. Fan-pulley
. Crank pulley

Figure 31a. Drive Belt Adjustment

Figure 30. Drive Belt Installation

 AIR CONDITIONING 1B-29

COMPRESSOR OVERHAUL

Armature bolt
OMBNAARWN=

Armature assembly
Shim (s)
Snap ring
Cover (If so equipped)
Pulley assembly
Lead wire connector
Field coil
Feit (If so equipped)
10. Shaft seal cover (If so equipped)
11. Snap ring
12. Shaft seal assembly
13. Through bolt with gasket
14. Front cylinder head
15. O-ring
16. Gasket
17. Front valve piate
18. Front suction vaive
19. Rear cylinder head
20. O-ring
21. Gasket
22. Rear vaive plate
23. Rear suction valve
24. Cylinder and shaft assembly

Figure 32. Compressor Overhaul

1B-30 AIR CONDITIONING

| Remove or Disconnect (Figure 32)

1. Armature Boit (1)

« Use clutch hub holder J-7624 to prevent the
armature from rotating, then remove the bolt.
(figure 33)

Figure 35. Snap Ring Removal

6. Pulley Assembly (6}

* Use pulley puller pilot J-33943-A and pulley
puller J-8433 to remove the pulley assembly.
(figure 36)
« Check the appearance of the pulley assembly.
Figure 33. Armature Bolt Removal If the frictional surface of the pulley shows
signs of excessive grooving due to slippage,
2. Armature assembly (2) both the pulley and drive plate should be
+ Use clutch plate remover J-33944-A and replaced. The frictional surfaces of the pulley
forcing screw J-33944-4 to remove the assembly shouid be cleaned with a suitable
armature assembly. (figure 34) solvent before reinstallation.
+ If the frictional surface shows signs of damage
due to excessive heat, the driver plate and
pulley should be replaced.

Figure 36. Pulley Assembly Removal

7. Lead Wire Connector (7)

Figure 34. Armature Assembly Removal « Remove the lead wire from lead wire fixing
bush.
3. Shim(s) (3)
4, Snap Ring (4) 8. Field Coil (8)
5. Cover (5) (if so equipped) * Loosen three screws and remove the field coil
+ Use snap ring pliers to remove the snap ring. with lead wire. (figure 37)
(figure 35) « Check coil for loose connector or cracked
insulation.
 AIR CONDITIONING 1B-31

Figure 37. Field Coil Removai Figure 39. Snap Ring Removal

9. Felt (9) (if so equipped) 12. Shaft Seal Assembly (12)

10. Shaft Seal Cover (10) (If so equipped) » Use shaft seal remover J-33942-B to remove
- Use shaft seal remover J-33942-B to remove the shaft seal assembly.
the shaft seal cover. (figure 38) » Engage the remover hook with the shaft seal
« Engage the remover hook with the shaft seal assembly groove and slowly draw the shaft
cover groove and slowly draw the shaft seal seal assembly out. (figure 40)
cover out. * The shaft seal is precision-machined and its
critical parts are finished to extremely close
tolerances. The assembly must be handled
with great care, its slip face demanding
particularly careful handling.
« The shaft seal can not be reused. Install a
new shaft seal at reassembly.
« Take care not to scratch or otherwise damage
the shaft seal face.
« Keep the shaft seal free from lint and dirt.

J-33942-B

es
d Sanam
Shaft seal

Figure 40. Shaft Seal Removal

Figure 38. Shaft Seal Cover Removai
13. Through Bolt with Gasket (13)
11. Snap Ring (11) 14. Front Cylinder Head (14)
- Use snap ring pliers to remove the snap ring. 15. O-ring (15)
(figure 39) « Alternately tap the projections on the
circumference of the front cylinder head with a
1B-32 AIR CONDITIONING

screwdriver and a plastic hammer to remove

the front cylinder head. (figure 41)

Figure 42. Rear Cylinder Head Removal

21. Gasket (21)

Figure 41. Front Cylinder Head Removal 22. Rear Valve Plate (22)
23. Rear Suction Vaive (23)
16. Gasket (16) 24. Cylinder and shaft assembly (24)
17. Front Valve Plate (17) » Check the rear valve plate for scratching and
18. Front Suction Vaive (18) bending.
Check the front valve plate for scratching and * Gheck the rear valve plate and the rear
bending. cylinder head for nicks and burrs on the
Check the front valve plate and the front sealing surface.
cylinder head for nicks and burrs on the * Buff or replace the valve plate and cylinder
sealing surface. head if nicks and burrs are present.
Buff or replace the valve plate and cylinder * Check that the rear valve plate passage is
head if nicks and burrs are present. free from obstructions.
Check that the front valve plate passage is « Check the rear valve plate and the cylinder
free from obstructions. head for cracks.
Check the front valve plate and the cylinder * Replace the valve plate and cylinder head if
head for cracks. cracks are present.
Replace the valve plate and cylinder head if
cracks are present. [oe] Install or Connect (Figure 32)

19. Rear Cylinder Head (19) 1. Cylinder and Shaft Assembly (24)
20. O-ring (20) * Clamp the cylinder shaft assembly in a vise.
Alternately tap the projections on the The rear side of the cylinder shaft assembly
circumference of the rear cylinder head with a must be facing up.
screwdriver and a plastic hammer to remove
the rear cylinder head. (figure 42) 2. Rear Suction Valve (23)
» Apply a coat of new compressor oil to the new
suction valve.
* Install the suction valve by aligning it with the
spring pin and the cylinder valve relief
grooves. (figure 43)
 AIR CONDITIONING 1B-33

7. Front Suction Valve (18)

* Set the cylinder shaft assembly with the front
, Escape groove
side facing up.
« Apply a coat of new compressor oil to the new
Suction valve suction valve.
« Install the suction valve by aligning it with the
spring pin and the cylinder valve relief
grooves. (figure 45)

Escape groove

Piston - Suction valve

a
%

Figure 43. Rear Suction Vaive

3. Rear Valve Plate (22)

« Apply a coat of new compressor oil to the new
valve piate.
a “” ”
- Install the valve plate to the suction valve by a
~
ne ne

aligning it with the spring pin. Piston

NOTICE: Do not mix up the front and rear vaive

plates. Figure 45. Front Suction Vaive

8. Front Valve Plate (17)

4, Gasket (21)
* Apply a coat of new compressor oil to the new
« Apply a coat of new compressor oil to the new
valve plate.
gasket. Install the gasket to the valve plate. « install the valve plate to the suction valve by
aligning it with the spring pin. (figure 46)
5. O-ring (20)
6. Rear Cylinder Head (19)
NOTICE: Do not mix up the front and rear vaive
- Apply a coat of new compressor oil to the new plates.
O-ring. Install the O-ring to the rear cylinder
head.
+ Install the rear cylinder head.
* Tap the rear cylinder head into place with a
plastic hammer. (figure 44)

Valve plate

Suction valve
Figure 46. Front Valve Plate Instaliation

9. Gasket (16)
+ Apply new compressor oil to the new gasket.
» Install the gasket to the valve plate by aligning
Figure 44. Rear Cylinder Head Installation it with the spring pin.
1B-34 AIR CONDITIONING

10. O-ring (15)

11. Front Cylinder Head (14) J-34614
+ Apply a coat of new compressor oil to the new ~
O-ring. Install the O-ring to the front cylinder
head.
* Install the front cylinder head.
* Tap the front cylinder head into place with a
plastic hammer.

NOTICE: When installing the cylinder head, be

careful that the end of the drive shaft does not
damage the shaft seal assembly surface in the
cylinder head.

12. Through Bolt with Gasket (13)

» Gaskets cannot reused. Always replace with
new ones. Tighten the bolts to the specified
torque a little at a time in the sequence shown
in the illustration. (figure 47)

Tighten

* Through bolt to 22 N-m (16 Ib-ft)

* Rotate the compressor drive shaft two or

three times to make sure that it moves
smoothly.
Figure 48. Shaft Seal Installation

14. Snap Ring (11)

* Use snap ring pliers to install the snap ring.

15. Shaft Seal Cover (10) (If so equipped)

16. Felt (9) (If so equipped)
* Clean the sealing portion of the compressor
and shaft seal cover.
* Install the shaft seal guide J-34614 onto the
end of the drive shaft. (figure 49)
* Apply new compressor oil to the shaft seal
guide.
* Install the shaft seal cover onto the drive shaft
by using shaft seal installer J-33942-B.
. ; « The installation position of the shaft seal
Figure 47. Through Bolt Installation cover is shown in the illustration. (figure 49)
13. Shaft Seal Assembly (42)
* Clean the sealing portion of the compressor
and shaft seal.
* Install the shaft seal guide J-34614 onto the
end of the drive shaft. (figure 48)
* Apply new compressor oil to the shaft seal
guide.
* Install the shaft seal onto the compressor
drive shaft head by using shaft seal installer
J-33942-B. (figure 48)
 AIR CONDITIONING 1B-35

19. Pulley Assembly (6)

* Use pulley installer J-33940-A and drive
handie J-8092 to install the pulley assembly.
(figure 51)

Top

4 y.33942.8 ¢
18° 18°

Shaft seat
cover

Figure 51. Pulley Assembly Installation

Fett
20. Cover (5) (If so equipped)
21. Snap Ring (4)
Wy Bottom 4 « Install the snap ring with the inside indented
portion facing out. (figure 52)

Figure 49. Shaft Seal Cover installation

17. Field Coil (8) (Figure 50)

18. Lead Wire Connector (7)
+ install the field coil to the compressor.
» Lead wire must be facing up.

fA] Tighten
« Field coil screw to 5 N-m (44 Ib-in)

Figure 52. Snap Ring Installation

22. Shims(s) (3)

23. Armature assembly (2)
« Install the drive plate to the compressor drive
shaft together with the original shim(s). (figure
53)
Press the drive plate by hand.

Figure 50. Field Coil Installation

1B-36 AIR CONDITIONING

Figure 53. Armature and Shim Installation Figure 55. Clutch Hub Clearance

24. Armature Bolt (1)

* Use clutch hub holder J-33939 to prevent the COMPRESSOR OIL
drive plate from rotating. (figure 54)
Oil Specification
fR] Tighten
Always use R-134a Swash Plate Compressor Oil
+ Armature bolt to 13 N-m (113 Ib-in) (AIPDN Part No. 2-901 88-300-0).
- After tightening the bolt, check to be sure the
pulley rotates smoothly. Handling of Oil
* The oil should be free from moisture, dust, metal
powder, étc.
« Do not mix with other oil.
* The water content in the oil increases when
exposed to the air. After use, seal oil from air
immediately.
(R-134a Swash Plate Compressor Oil absorbs
moisture very easily.)
« The compressor oil must be stored in steel
containers, not in plastic containers.

Compressor Oil Check

The oil used to lubricate the compressor
circulates with the refrigerant.
Whenever replacing any component of the system
Figure 54. Armature Bolt installation or a large amount of gas leakage occurs, add oil to
maintain the original amount of oil.
« Check to be sure that the clutch clearance is
between 0.3-0.6 mm (0.01—0.02 in). Oil Capacity.
* If necessary, install adjusting shim(s).
« Adjusting shims are available in the following
thickness. (figure 55) Capacity total in system 180cc (6.08 FL.OZ.)

Compressor (Service
0.1 mm (0.0039 in)
parts) charging amount 180cc (6.08 FL.OZ.)
Thickness 0.3 mm (0.0118 in)
0.5 mm (0.0197 in) Checking and Adjusting for Used Compressor
1. Perform oil return operation.
(Refer to “OIL RETURN OPERATION? in this
section.)
2. Discharge and recover refrigerant and remove the
 AIR CONDITIONING 1B-37

compressor. compressor and install it onto the vehicle.

3. Drain the compressor oil and measure the 6. Perform oil return operation.
extracted oil with a measuring cylinder. (figure 7. Remove the compressor and recheck the
56) amount of oil.
8. Adjust the compressor oil.

Collected Amount Charging Amount

more than 120cc same as collected
{4.05 FL.OZ.) amount

below 120cc
(4.05 FL.OZ) {20cc (4.05 FL.OZ.)

Ghecking and Adjusting for Compressor

Replacement
180cc (6.08 FL.OZ.) of oil is charged in
compressor (service parts). So it is necessary to
drain the proper amount of oil from new
compressor.
Figure 56. 1. Perform oil return operation.
2, Discharge and recover refrigerant and remove
4. lf the amount of oil drained is much less than the compressor.
120cc (4.05 FL.OZ.), some refrigerant may have 3. Drain the compressor oil and measure the
leaked out. Conduct leak tests on connections extracted oil with a measuring cylinder.
of each system, and if necessary, repair or 4, Check the compressor oil for contamination.
replace faulty parts. 5. Adjust oil tevel following the procedure below.
5. Check the compressor oil for contamination.
(Refer to “CONTAMINATION OF Arnount of oil drained Draining amount of oil
COMPRESSOR OIL’ in this section.) from used compressor from new compressor
6. Adjust oil level following the procedure below.
more than 120cc _same as collected
(4.05 FL.OZ.) amount
Collected Amount Charging Amount
below 120cc
more than 120cc same as collected 120cc (4.05 FL.OZ.)
(4.05 FL.OZ.)

/ 6. Evacuate, charge and perform oil return

below 120cc
(4.05 FL.OZ.) 120cc (4.05 FL.OZ.) operation.
7. Gheck system operation.
7. Install the compressor, then evacuate, charge
and perform oil return operation. Contamination of Compressor Oil
8. Check system operation. Unlike engine oil, no cleaning agent is added to
the compressor oil. Even if the compressor runs for
When it is impossible to perform oii return a long period of time (approximately 1 season), the
operation, the compressor oil should be oll never becomes contaminated as long as there is
checked in the following order: nothing wrong with the compresssor or its method
1. Discharge and recover refrigerant and remove of use.
the compressor.
2. Drain the compressor oil and measure the inspect the extracted oil for any of the following
extracted oil with a measuring cylinder. conditions:
3. Check the oil for contamination. « The capacity of the oil has increased.
4. If more than 120cc (4.05 FL.OZ.) of oil is » The oil has changed color to red.
extracted from the compressor, supply same » Foreign substances, metal powder, etc., are
amount of oil to the compressor to be installed. oresent in the oil.
if the amount of oil extracted is less than 120cc
(4.05 FL.OZ.), recheck the compressor oil in the if any of these conditions exists, compressor oil
following order: is contaminated.
5. Supply 120cc (4.05 FL.OZ.) of oil to the Whenever contaminated compressor oil is
1B-38 AIR CONDITIONING

discovered, the receiver/drier must be replaced.

Oil Return Operation

There is close affinity between the oil and the
refrigerant. During normal operation, part of the oil
recirculates with the refrigerant in the system.
When checking the amount of oil in the system, or
replacing any component of the system, the
compressor must be run in advance for oi! return
operation. The procedure is as follows:
1. Open the all doors and engine hood.
2. Air conditioning switch is “ON” and run the
blower motor at “4” (High) position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate
the system.

Replacement of Component Parts

When replacing system component parts, supply
the following amount of oil to the component parts
to be installed.

Component parts to be installed Amount of ail

Evaporator 50cc (1.7 FL.OZ.)
Condenser 30cc¢ (1.0 FL.OZ.)
Receiver/drier 30cc (1.0 FL.O2Z.)
Refrigerant line (one piece) 10cc (0.33 FL.OZ.)

Refrigeration oil must be replenished if more than

two parts are removed at the same time. After
installing these components, check compressor oil.

Figure 57.
 AIR CONDITIONING 1B-39

CONDENSER
1. Condenser fan motor connector
2. Refrigerant line connector
3. Condenser assembly fixing bolts and nuts
4. Condenser assembly
5. Condenser bracket assembly UNION NUT

3{(C)
3A) BOLT;M6, L=12
BOLT;M10, L=30 (B)
BOLT;M8, L=20
1 Naw ;
NUT:M10 \ /} K| | / ERONT
TAPPING SCREW
—

SA BOLT;M8, L=20
“S SO BRACKET (B)
BOLT;MB8, L=20
a D4 oO “gtA)
oe? ~~ BOLT;M10, L=30
(B) BRACKET

Figure 58. Condenser Removal or installation

[es] Remove or disconnect (Figure 58) [+4] install or connect (Figure 58)
Preparation: 1. Gondenser bracket assembly
« Disconnect the battery ground cable. 2. Gondenser assembly
« Discharge and recover refrigerant (Refer to « If installing a new condenser, be sure to add
“REFRIGERANT RECOVERY’ in this section). 30 cc (4.0 FL.OZ) of new specified
1. Condenser fan motor connector compressor oil to a new one.
2. Refrigerant line connector 3. Condenser assembly fixing nuts and bolts
« Using a backup wrench when disconnecting
and reconnecting the refrigerant line. [2] Tighten
« When disconnecting the line, the line should
» Condenser assembly fixing bolts and nuts (A)
immediately be plugged or capped to prevent
foreign matter from being mixed into the line. to 36 N-m (27 ib-ft).
« Condenser bracket fixing bolt (B} to 18 N-m
3. Condenser assembly fixing bolts and nuts
(13 lb-ft).
(A) » Candenser brace fixing bolt (C} to 8 N-m (69
4. Condenser assembly
5. Condenser bracket assembly lp FE).
« Remove three bolts (B)
1B-40 AIR CONDITIONING

4. Refrigerant line connector + O-rings cannot be reused. Always replace

with new ones.
[RX] Tighten « Be sure to apply new specified compressor oil
to the O-rings when connecting refrigerant
* Refrigerant line connector fixing nut:
line.
Condenser and compressor side to 19 N-m
(14 lb-ft). 5. Condenser fan motor connector
Condenser and receiver-drier side to 15 N-m
(11 Ib-ft).

RECEIVER-DRIER

1. Pressure switch connector

2. Refrigerant tine
3. Receiver-Drier

Figure 59. Reciever-Drier Removal or Installation

| Remove or disconnect (Figure 59) [oe] Install or connect (Figure 59)

Preparation: To install, follow the removal steps in the reverse

* Disconnect the battery ground cable. order, noting the following points:
* Discharge and recover refrigerant (Refer to 1. If installing a new receiver-drier, be sure to add
“REFRIGERANT RECOVERY’ in this section). 30 ce (1.0 FL.OZ) of new compressor oil to a
1. Pressure switch connector (4) new one.
2. Refrigerant line (2) 2. Put the receiver-drier in the bracket, and
+ Using a backup wrench when disconnecting connect with the refrigerant line. Check that no
and reconnecting the refrigerant line. excessive force is imposed on the line. Fasten
¢ When disconnecting the line, the line should the bracket bolt to the receiver-drier.
immediately be plugged or capped to prevent 3. O-ring cannot be reused. Always replace with
foreign matter from being mixed into the line. new ones.
3. Receiver-Drier (3) 4. Be sure to apply new specified compressor oil
« Loosen the bracket bolt (A) , remove the bolts to the O-rings when connecting refrigerant line.
) and carefully pull out the receiver-drier.
fa] Tighten

* Refrigerant line connector fixing nut receiver-

drier side to 15 N-m (11 [b-ft).
 AIR CONDITIONING 1B-41

TRIPLE PRESSURE SWITCH

1. Triple pressure switch connector

2. Triple pressure switch

Figure 60. Pressure Switch Removal or Installation

Remove or disconnect (Figure 60) [oe] install or connect (Figure 60)

Preparation:
To install, follow the removal steps in the reverse
¢ Disconnect the battery ground cable.
order, noting the following points:
* Discharge and recovery refrigerant (Refer to
1. O-ring cannot be reused. always replace with
“REFRIGERANT RECOVERY’ in this section).
1. Triple pressure switch connector (1) new one.
2. Be sure to apply new compressor oil to the O-
2. Triple pressure switch (2)
ring when connecting pressure switch.
¢ Turn the pressure switch counterclockwise to
remove it. Tighten
» When removing the switch connected part, the
capped to prevent foreign matter from being * Pressure switch to 13 N-m (113 Ib-in)
mixed into the line.
1B-42 AIR CONDITIONING

EVAPORATOR ASSEMBLY

Electronic thermostat connector

fo

ae. eon \ |
S Herrronaecest
ern |

Drain hose

. Glove box
. Under cover
OONOOhwr—

. Washer tank
. Center cluster
. Temperature control cable
Duct
. Front grille
. Refrigerant line
. Evaporator assembly

Figure 61. Evaporator Assembly Removal or Installation

 AIR CONDITIONING 1B-43

5. Temperature control cable

[es] Remove or disconnect (Figure 61)
« Disconnect the temperature control cable of
Preparation: the control lever assembly from the heater
+ Disconnect the battery ground cable. unit.
* Discharge and recover refrigerant (Refer to 6. Duct
“REFRIGERANT RECOVERY?’ in this section). 7. Front griile
1. Glove box + After removing the grille, remove the grille
+ Open the glove box and remove the fixing fixing clip (RH) (Figure 64)
screws.
2. Under cover
* While pulling the under cover with care,
remove the clips on the back side of the
cover.(Figure 62)

Clip

Figure 64. Front grille removal

8. Refrigerant line
¢ Using a backup wrench when disconnecting
and reconnecting the refrigerant line.
* When removing the line connected part, the
Figure 62. Under cover removal connecting part should immediately be
3. Washer tank plugged or capped to prevent foreign matter
+ Remove the washer tank fixing three from bbeing mixed into the line.
bolts(Upper: two,Lower: one) and disconnect 9. Evaporator assembly (Figure 65)
the connector.
* Disconnect the resistor and thermostat
+ Do not disconnect the washer tank tube. connectors.
4, Center cluster « Disconnect the drain hose.
* While pulling the cluster with care, remove the
upper and the back side clips of the cluster.
- Disconnect the ciger righter and illumination

=>
; Evaporator
connectors.(Figure 63)

SS
~) Drain hose
Grommet

Figure 65. Evaporator Removal or Installation

Figure 63. Center cluster removal

 1B-44 AIR CONDITIONING

3. Be sure to apply new specified compressor oil

Install or conn i
be] connect (Figure 61) to the O-rings when connecting refrigerant lines.
To install, follow the removal steps in the reverse ;
order, noting the following points: Q Tighten
1. To installing a new evaporator assembly, , be . Refri gerant outlet line
: to 25 N-m (18 ib-ft).
sure to add 50 cc (1.7 FL.OZ) of new + Refrigerant inlet line to 15 N-m (11 lb-ft).
compressor oil to a new one.
2. O-ring cannot be reused. Always replace with
new ones.

EVAPORATOR CORE and/or EXPANSION VALVE

Insulator

1. Evaporator assembly
2. Electronic thermostat
3. Upper case
4. Insulator and under cover
5. Evaporator core
6. Expansion valve

Figure 66. Evaporator core Removal or Installation

; : 1. Evaporator assembly
[es] Remove or disconnect (Figure 66) - Refer to “EVAPORATOR ASSEMBLY”
Preparation: removal procedure in this section.
- Disconnect the battery ground cable. 2. Electronic thermostat =
- Discharge and recover refrigerant (Refer to - Remove the sensor fixing Clip.
“REFRIGERANT RECOVERY’ in this section). « Pull out the grommet from the upper case to
remove the thermostat.
 AIR CONDITIONING 1B-45

. Upper case
FR] Tighten
+ Separate the upper and lower case.
+ Slit the case parting face with a knife since * Refrigerant line position A to 10 N-m (7 lb-ft)
the lining is separated. * Refrigerant line position B to 15 N-m (11 Ib-ft)
. Insulator and under cover * Refrigerant line position C to 20 N-m (14 Ib-ft)
. Evaporator core
* Pull up the core from the lower case.
. Expansion valve (Figure 67)
* Tear off the insulator carefully.
+ Remove the sensor fixing clip.
« Use back-up wrench when disconnecting all
refrigerant pipes and remove the expansion
valve.
tall iteh
aut
Wut
TT

as
Expansion valve =, XK
a
((

l
Figure 68.
6. Apply an adhesive to parting face of lining when
assembling evaporator assembly.
finality

7. The thermostat sensor is installed on the core

§
iH

with the clip and it must not interfere with the

A

core.(Figure 69)

Figure 67. Expansion valve Removal

| Install or connect (Figure 66)

To install, follow the removal steps in the reverse
order, noting the following points:
1. O-rings cannot be reused. Always replace with
new ones.
2. Be sure to apply new specified compressor oil
to the O-rings when connecting lines.
3. Be sure to install the expansion valve sensor
and the insulator on the place where they were
before.
. To install a new evaporator core, add 50cc (1.7 Figure 69.
FL.OZ) of new specified compressor oil to a
new core and install the thermostat sensor to
the evaporator core specified position with the
clip where it was before.
 1B-46 AIR CONDITIONING

AIR CONDITIONER (A/C) SWITCH

1. Center cluster
2. Knob
3. Control panel bezel
4. AIG (Air conditioning) switch

Figure 70. A/C Switch Removai or Installation

[es] Remove or disconnect (Figure 70) 3.2. Control

Knob panel bezel (Figure 72)
Preparation: * Push the four catches at both sides of the bezel
- Disconnect the battery ground cable. to the inside, and remove the ilNumination bulb
1. Center cluster (Figure 71) from the bezel.
« While pulling the cluster with care, remove the
upper and the back side clips of the cluster.
* Disconnect the cigarette lighter and
illumination connectors.

IHiumination bulb

Back side of the bezel

Figure 72. Control Panei Bezel Removal |

Figure 71. Center Cluster Removal

 AiR CONDITIONING 1B-47

4. AIC (Air conditioning) switch (Figure 73)

- Push the catches at both sides of the A/C
switch to the inside, and remove the switch by
pulling out.

Press
AIC switch

2 (2

Control lever

view (A)

Figure 73. Air Conditioning Switch Installation

[oe] Install or connect (Figure 70)

To install, follow the removal steps in the reverse

order.
 1B-48 AIR CONDITIONING

BLOWER FILTER

1. Glove box
2. Blower filter

Figure 74. Blower Filter Removal or installation

[+9] Remove or Disconnect (Figure 74) fd Install or Connect (Figure 74)

Preparation: To install, follow the removal steps in the reverse
Disconnect the battery ground cable. order.
1. Glove box
+ Open the glove box and remove the fixing
screws.
2. Blower filter
* Pull out the blower filter from the blower upper
slit.
 AIR CONDITIONING 1B-49

REFRIGERANT LINE

1. Front grille
2. Clip and bracket
3. Liquid line (High-pressure hose)
4. Suction line (Low-pressure hose)
5. Discharge line
(High-pressure hose)
6. Liquid line (High-pressure pipe)

Figure 75. Refrigerant Line Removal or Installation

fo] Remove or disconnect (Figure 75) = Install or connect (Figure 75)

Preparation: To Install, follow the removal steps in the reverse

» Disconnect the battery ground cable. order, noting the following points:
- Discharge and recover refrigerant (Refer to 1. O-rings cannot be reused. Always replace with
“REFRIGERANT RECOVERY’ in this section). new ones.
1. Front grille 2. Be sure to apply new specified compressor oil
+ After removing the grille, remove the grille to the O-rings when connecting refrigerant lines.
fixing clip (RH) 3. To install a new refrigerant line (one piece), add
. Clip and bracket 10 cc (0.33 FL.OZ) of new specified compressor
oil to a new one.
Ooahanh

. Liquid line (High-pressure hose)

. Suction line (Low-pressure hose)
FQ] Tighten
. Discharge line (High-pressure hose)
. Liquid line (High-pressure pipe) « Refrigerant line to the specified torque. (Refer
+ Use a back-up wrench when disconnecting to “TORQUE SPECIFICATIONS?” in this
and reconnecting the refrigerant lines. section.)
» When removing the refrigerant line connecting
part, the connecting part should immediately
be plugged or capped to prevent foreign
matter from being mixed into the line.
1B-50 AIR CONDITIONING

SPECIFICATIONS
BLOWER MOTOR
TYPO cee ccseeeeccseeetsesseecesscesscessecssssnecsusasesavacsesesuesessessutetuvessertseessee Sirocco Fan Diameter 140 mm (5.5 in)
Current Consumption... veeeeananeaecsunasenmenesuasadeanensanoeaaeunseseutenenensuceuavasenaeas 18 amp or less at 13.5 V

HEATER UNIT
TeMperature CONtOL ......eccecsseceeeseecaeesesssessnecsavecsesatscssesacsesasstcarsesaareseasssvarscesescessstseeseecsees Reheat air mix
CAPACILY «2... cee cesceeeceseeceressecseessecsuusseesaesssseavsussascueesesssessuauatessassassasevsutsieveteccceseess 3700Kcal./hr (4.3 kW)
Ait POW... .ceceecesceeeeescseecceucseeersssessensessesussesssssuessuenscaacsassssessessussvencasanvavsasusatessesssssacesteseeceieeececseceses 280m*/hr

HEATER CORE
TYPO... .eeceeeccesensesseseescesesssesecacssessesussausessatvaerassessessuseessapsussssssavasuessacsaesaesaasaessensecssesevseseasereces Fin &tube type

EVAPORATOR
TYPO oo ececesscesececseesessessesssascauesuesaesaesssseeessssususnaesseceusesesssssssssauseassausetesateaecuseseses Al-laminate louver fin type
CAP ACIY «oe. eee eceeseeeesecssseeseeeneeesssecstessuesusecsnecassenenersuasetnerunes beedeneseeeeeeeneensteeneeas 3850Kcal./nr (4.4 kW)
Ait OW... .ceesescecenseeesesnenssecaseseusesanssersesesseensesaasessaesuesaesssvensssssiusussasesevasa satasaussasseessetesssceseusecseseeee 420m*/hr
THERMOSTAT SWITCH
Type ........ eedeeneeeeeeanmeasaenessseeeveuteuseuaseccaacussensatesenaaeonnaeusseatsensececacesssesssacancnecguessaseetsarvenes Electronic thermostat
wean ee epeesnuaeueeeeadcasneaeeesensenanetecerssesensnenereeeenwes eaneeansecnnansseseestenessaretsseeesssesereees OFFI3.5£0.5°C (38.340.9 °F)
seeeneceeeecnneeseesenseesesensaeaeassesanenessueasseseaaereteeetescasaeseaeesesusdeuenssusduseesersesnewssersenens ON: 5.040.5°C (41.0+0.9 °F)
CONDENSER
TYPO oo eeeceececesesceassecesscesssvecsuesaeeesenessssseausussesseasecuuscesuaueasssveaseeeseeeusaeevantescanecaresesess Aluminum louvered fins
CAPACIY oo... eecceessceesecseeesceseesseersvacecsnassecsastecsuesesesssacanscsessuseusvaueuansesusesisesnsrausseaceens 6,750 kcal/hr (7.8 kW)

RECEIVER/DRIER............ deseuncouaesaceagaeceaeesusseeceenuennsaneaues beeeeeenneeeenes Assembly includes duai pressure switch

Low pressure control
ON:186 + 30 kPa (27 + 4 psi)
OFF:176 + 20kPa(26 + 3 psi)
Medium pressure control
ON:1471 + 98 kPa (213 + 14 psi)
OFF:1079 + 118 kPa (156 + 17 psi)
High pressure control
ON:2354 + 196 kPa (341 + 28 psi)
OFF:2942 + 196 kPa (427 + 28 psi)
REFRIGERANT
TYPO ..ecccccccsceceeeseeeessesesteeseseseesaeseseseeeseascessesacessuessssescssueasensoesecsuesssscsusseseecereeaaesusstaneserseseesessesenes HFC-134a
Capacity ............ one eeeesaceaascunnensansenensseneueueedeeseeacasesdesoesestretuentennestecsseceessaesssepesssucsusesseasseenenaea 600g (1.32 Ibs)
Oil Type «oo. ceeecsecreceeeeenenes HFC-134a Swash Plate Compressor Oil (AIPDN PARTS NO.2-90188-300-0)
Oil Capacity o.oo... ee cccecneeessoeectsnsenseneessseecsuceseeesassueesesssuuseaeuscssauacesenseassensasenenareeaseens 180 cc (6.08 FL.OZ.)

FUSES
Heater (Blower MOtor) 0.0... eee scssccecssesensssnsecesseneeesesesusvensavssussenssecseseaseesecassedsuacssscsnasseveserstaseeesereeccene 25 A
AIC wee ccececcencceesesseneeeussseccassnesuesesaeesaneecasavsesaeeusasessnsecesnseecnsesssseseusutecsussesatesparesetuedsasseeaesseecstasegusnsceessaess 10A
CONDENSES FAN ooo... eee ces cccseeessneecsnesenenrecseetensesecaeseseseenenssenesesenaeecsueneceusesueusenssssucarevanasesseusueesaneseessseanan 15A

COMPRESSOR
MOE] 00. cece ccecssseeescacessesaceesenseesonseseaesensaueeuscsaesesesseessseenesusececesuassuseaaessusvasesensuseeeneensaeesensuaecs DKS-15CH
TYPO oo. ceeecceeeceeeeesecesennseeasserseesessauscasecsuusnessacneectaaaeseeuessusseuscsuseeesuseseeessneaesnseuseatseass 6 Cylinder Swash Plate
DiSPIACEMEN .....ceeeececcescecensenaeneesseeeeesneeeeeeessaeevescnseneteseaeseesesauseceusenansesuseersees 147 cc/rev (8.97 cu-in/rev)
PROLALION o.oo eee ccc cceeeeectuseeesaaseessonnensenauaeesenaseeeecseetseeessausecessnneseusenatuseaesantessns Clockwise (Front side view)
Shaft SOL... ec ccc css ecseecosseesssnenccsaspeceeaesseeeesetetssaenesensersasuscsssedestesseaceneassussuasssseestcessenavecaners Lip type
WIQNL ..........secccccceceescesesuesseneeeccsuseusesaseeeseacanesareneeseescuaeueteceatessnesssaucesusensesutensucesecsusneareeeres 4.4 kg (9.7 Ibs)

CLUTCH COIL
Magnetic Clutch Type... sees beceusgaeeesenneanetaeeaeeescessneesenneceseussannes Dry Single Disc 110 mm (4.33 in)
Coil RESISTANCE... eect eereeeeereseneceneeeeenessecaearereretcateessesuncenseasauneesesneneas 3.5 ohms £5 % at 25 °C (77 °F)
COMPHIANCE.......cescccsteecascsstnceecreesseneuncetsecesssanaaeesersesessusasnenecassscesunsueeseuseteatasuastseassessuseesseensetnsausaraseverss 44wW
Minimum Working Voltage ................ ee ceccscsnsencomeansensuecussasssuasececsaeesecueeseeseessscesseeceea® 10.5 V at 90 °C (194 °F)
Starting TOrQue.......ccccceccccescusecsssesecsecesesenaeaeesssaeseeseaaecenessuvesscesseseseeeseccssetsecestenesesneuss 49 N-m (36 Ib-ft)
WIGNK 0... ccccceceseesseeuseearseeeenseerseueaecensenscanuemeseoneaupsauaaaesaeesecensuaaecesteusnasesoeaeusenseuaaautaneusseseess 2.5 kg (5.5 Ibs)
 AIR CONDITIONING 1B-51

FASTENER TORQUES
N-m (24 ib-ft)
Compressor Fixing BOIts ........cccsscsseeeeeeeeteeessssersnanssnnnesscansessnencraeecenianenerssenstaseanscssnenaneneaesaes 32
N-m (20 Ib-ft)
Refrigerant Line Connector (Compressor Side) ........:ecsesesecenecteseeetaneesertneereranneneesscaeas 27
N-m (36 lb-ft)
Drive Belt Tension Pulley Center Nut ..........cccesecesceeeeeereesrseessnenarssenneesnerersenesnreneesenensneaness 49
N-m (24 Ib-ft)
Generator Brace Fixing Bolt ..........csecesceceeseneeteereentersneriecsecnessesnesnenseesesteusnenetaeraesesanertnetass 32
Field Coil Mounting SCreW...........2::ccccseseestesecnreeeereeteeseeneusaetiasraseesusnstesnsrerscasraneereatsenenenats 5 N-m (43 Ib-in)
Magnetic Clutch Armature Bolt .........-::ccsseesssereesnerensnensnenensseeneiacensasseecananesenseeeensenateeneaens 13 N-m (113 Ib-in)
(56 Ib-ft)
Condenser Bracket Fixing Bolt .............ccscssesssseesereecrererensneeesraseeneeceeanecentaecerenansaraneecaseseaas 76 N-m
Condenser Fixing NUt........:seeececceeneseesrsseseresseeceneccansaneaeenecsersassusraeareanencenennecteatenesgessasenecnes 32 N-m (24 lb-ft)
Condenser Brace Fixing Bolt............ccccccecesecsnesseesseerenenneneenssseneesnensteesanecenenersaneaseeseneranseenensyes 18 N-m (13 lb-ft)
N-m (14 lb-ft)
Refrigerant Line Connector (Condenser and Compressor SId@) ....cccccceccceceseeeteeeaenseestneeeseeeneaes 19
cece eeeeeeeseeneteeneeeneneees 15 N-m (11 Ib-ft)
Refrigerant Line Connector (Condenser and Receiver-Drier Sid@) .........c
N-m (11 Ib-ft)
Refrigerant Line Connector (Receiver-Drier SiG) ooo. ..ecccccseeeeseeseseeeereeeeretneessneeesaeesnearensuaertrass 15
N-m (87 lb-in)
PresSure SWItCH ......cccccceccseesseessecceseecsereeseeenneseseneanesnaeenseeeeesnieessnnaccnsnensaeseneesensaeerernaeornantenaess 10
N-m (17 tb-ft)
Refrigerant Outlet Line Connector (Evaporator Sid@)...........-.-sesecreesseesesneeenseeseeenneneenneaennas 24
test cseecreeneenenenensnanenetentcgs 15 N-m (11 lb-ft)
Refrigerant inlet Line Connector (Evaporator Side) .........:..seecri
Side) ......0ceccccesesereeceeeereeseeenseeeeenes 24 N-m (17 lb-ft)
Refrigerant Line Connector (Evaporator and Compressor

SPECIAL TOOLS

TOOL NO. TOOL NO.

ILLUSTRATION TOOL NAME ILLUSTRATION TOOL NAME

Gy J-33943
Pulley puller pilot
J-39500-A
ACR *
(HFC-134a Refrigerant J-8433
Recovery / Recycling / Pulley puller
Recharging / System)
J-33942
Shaft seal remover and
installer

J-7624 J-34614
Clutch hub holder — Shaft seal guide
}

J-33939-A J-33940
Drive plate puller ip Pulley installer

J-33944-4 J-8092

— Forcing screw Drive handle

MEMO
 FRAME AND BODY MOUNTS 2A-1

SECTION 2

FRAME AND CAB

CONTENTS

SUBJECT PAGE

Frame and Body MOUnts ..........scssssccssssecssssereeceeneneesnsssssmsnsssinassatsncnersrenceneecusatnacarsassaeentianeaueneoresuenecntoseaesansnanates 2A

2B
Cab Maintenance........c::.-ccccssssssssssecscsssseeenerseansenssenssersnesstsssscsnecesensensausausceesonsoecessanecansnarconasassaunacnasuanecersenseusseanes
2C
Sheet Metal .......ccccsccesccccsccsssecssesesecseneenessersasseneuensusversocanersueassennncasersenussesnseseestananrsnanenssseenssaeseneuouseoceananenusnnersentrass

SECTION 2A

FRAME AND BODY MOUNTS

from which they were
NOTICE: When fasteners are removed, always reinstall them at the same location
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE
2A- 2
FLAME cecsecscssecssssscecesesssecssssnssenssrenssosssnenesaraseaseseeansneacunasssusaensuusnsausarsesscanesecensuneatesagauazsnsanenonecenanreasaanaacaanonsanats
renee 2A- 2
DeSCription .......c::-ssscssssssesseesnsesssessesensoressersonsnnnnneanacecorsnsceassnansteneanesssecnanssesnanensuranecaeaareastensesssuneeeaneaneesene
2A- 3
Diagnosis Of Frame......ssssssssseccsssessstnssssssessnsesesnecensnsceeranseennsatsannanennaceneesnnsnnnssarsuasenennszroaananonmantannansensensansneeens 2A- 5
On-Vehicle Service ....cscccscsessscscsssescnercsnetsssecasecsuncseserenteassencazansuseasonssesusssenusensassusenansazorenunauocounnansnnnacasenseeates
2A- 5
Checking Frame Alignment .........-s::-sscsssssssssencsstssnseenecnserennensessnssnusnnensnanasucauenunssecaarcnnasanuaneuesangcaanensensstens
sacecanssuranseuenavsanseanseaeenecensenennenenanens 2A- 6
Straightening Frames............s0sse0 ssennenevesaaensenesnesuenoenousencensmeentansiesaesnes
2A- 6
Reinforcement........-:s:cccsscsssensccssssesessseruressnsnnssrsentussansnessesuseersuauoassanaesassonranseaensasenssanseazonsenesevansnnanenanacaneanees
gases 2A- 9
Repairing Cracks ......ssssscscssssccsesssssssstecensenecsessnnsescrssnaersesnssensnnnaaeonennansceanansrecanarannaqavaneuqanenseanessrsensssens 9 2A-
WENGIING ...ssessccssescssssssuseesssssnsncesnsessonsensetnanstesnesnrsnersnsnecaseenasunecanaravectanensonenenasegussanaesanansseesssnanneneeneaeeeenegeneee
2A-10
Crossmember Replacement ........-.:ssscsesssessssseeresssstnscensssserentaneansensencesuuascereansnnsenseneranennananensssunaangengsenseneas
2A-10
Body MOUnt .....:-s:sosscssssssssessssseersrssnsrsssanscnscensssersanaracereanennsensnssananansctecsensnansanasinennascauaunasansannaseeenasseeeanssegeasens 2A-10
Description .......cscescssssrcersenssnrsnernssnssstsecsmaneanseanensarenseanecsates jevsenuevosenaneecentaseousessucussouseansuatenannensuesanseuntensens 2A-10
Longitudinal Sill Mounting.............ssc-sesesnseees enaesussussucnenseugessesansuusesecenseaatonscansuroensseaucanennaesaaneceusneneaseneatass 2A-13
Other Types of MOUntingS .....---ssscssssescssnesssnsenssnsescenanensuesesnsssonsaceonsensatanensonsssaconssnconsvaneauasneneettgsseegegseteags 2A-13
eee eae eee eeet
Specifications....-..csosssceeessssnseececenssmensnnsseensceesnnsnensrconnnacsstanananasencrsnennsssseesseasseeannnaeseeeneeneeseeeeneeees 2A-13
Widths Between the Web of Frame Rails ..........--.:scssssessssserssnenseerssnecentnsensennennsanersseaceassqnnenenaeannatsunneenenes 2A-13
Yield Strength of Different Metal .........--..ssssscssssssssersssnsensenasssssnessenssnssnnernascnnecnnnasnencnsannnecasnnnstesennaneresteas 2A-14
Welding Chart......ccsesssscsssssssssessesssssaveesersunensennssenssnuasersccaneresnusussuuacunsssnngnsssangeansascenuecssconassansannsansennsaneeensseeeas 2A-14
Electrode Chart ....c.ccsssesscccsesssscsssssssssensscscsansnsesunsesensusnenssernnssnncseneesaneacansanauansaessenronsennsacacananenannstacenensssensanss
nnaazenerqussnanennnnassnneeenastenseeaaseeanegsets 2A-15
Plug Weld Chart .......csssssscssssssnssstesserssstercensansssenscensnustsessnunnsascansersnssonarse
 2A-2 FRAME AND BODY MOUNTS

FRAME

DESCRIPTION entire frame has been twisted. One rail will

basically slope up while the other rail will
The main parts of a frame are the side rails and basically slape down.
crossmembers. The rails carry the load and the 8. SIDESWAY—This refers to a side rail that is
crossmembers stabilize the rails. The entire frame bent to the side of where it should be.
must be stiff enough to support the load it carries. It 9. TRACKING—This refers to the alignment of the
must also be flexible enough to absorb and vehicle axles with each other. A misaligned
distribute the stress placed on it. frame can cause improper tracking. If the
These vehicles have straight, full-channel, side vehicle is tracking correctly, all axles will be
rails. The rails should be parallel! at all points along parallel to each other and perpendicular to the
their length. center line of frame.
To prevent corrosion, a batten compound must be 10. WEB—The vertical part of a channel-type frame
applied to the mating surface of dissimilar metals. rail.
Example: An aluminum battery box mounted on a
steel frame rail. Minimizing Frame Failures
Proper frame alignment is important to ensure
Generally, frame failures can be minimized or
normal life and functioning of many other parts of
eliminated by minimizing the concentration of stress
the vehicle. If the vehicle has been involved in a
in small areas of the frame:
fire, collision, or has been overloaded, there is
1. Vehicles should be used only for those
cause to check the frame alignment. If, for any
purposes for which they were designed.
other reason poor alignment is suspected, it should
a. They should not be overloaded.
be checked. A procedure for this is described later
b. They should be loaded evenly;localized
in this section under “Checking Frame Alignment.”
overloads should be avoided.
It is possible that certain conditions may make the
c. Dump trucks should not be used to spread
frame appear to be out of alignment when, in fact, it
loads.
is not. These conditions are also described under
d. Use baffles in tank trucks.
“Checking Frame Alignment.”
@. Avoid excessive fifth-wheel settings.
Terms used later in this section are briefly defined
f. Do not operate the vehicie on extremely
as follows:
rough terrain.
1. SECTION MODULUS—This is a measure of the
g.Take into account the forces that will be
strength of a frame, based on height, width,
placed on a frame from the operation of
thickness and shape of the side rails. it does
equipment, such as snow plows, when
not account for the strength of the material used
picking a frame for a new vehicle or
in the frame.
reinforcing a frame.
2. YIELD STRENGTH—This is a measure of the
. Follow recommended practices when repairing
Ro

strength of the material from which the frame is

a frame or when mounting a body or equipment
made. lt is the maximum load (kPal[psi]) that
on a frame.
can be placed on a material and still have it
a. Avoid sudden changes in the section
return to its original shape.
modulus.
3. RESISTANCE TO BENDING MOMENT
d. Do not drill holes in the frame rail flanges.
(RBM)—This is a single measure of frame
c. Space holes in the web section of a rail at
strength that accounts for both the section
least 13 mm (1/2 in) from one another.
modulus and the strength of the material used.
d. Use existing holes whenever possible.
(It is the product of section modulus and yield
e. Do not cut holes with a torch.
strength.)
i. Do not cut notches in the rails
4. SAG—This refers to a frame or side rail that is
g. Do not overheat the frame rails
bent down from where it should be. h Avoid welding on the flanges.
§. BUCKLE—This refers to a frame or side rail i Bo not allow more than three holes to exist
that is bent up from where it should be.
on the same vertical line of the web.
6. DIAMOND—This refers to the condition where
j. Holes made in a reinforcement should be
one entire frame rail is moved forward from, or
placed at least two times the material
to the rear of, its correct alignment with the thickness from the edge of the
other rail.
reinforcement.
7. TWIST—This refers ta the condition where the
 FRAME AND BODY MOUNTS 2A-3

DIAGNOSIS OF FRAME

PROBLEM POSSIBLE CAUSE CORRECTION

Sag . Loads greater than the frame is 1-8. Straighten and reinforce the
designed to carry. frame as described later in this
. Uneven load distribution. section. See “Straightening
hm

. Abrupt changes in section modulus. Frames” and “Reinforcements”.

oO

(For a brief definition of section modulus,

see the “Description” at the beginning of
this section.)
. Excessive fifth-wheel settings.
ib

. lmproper body, or accessory, mounting:

— Holes drilled in the flange of the
frame rail.
— Too many holes in the web section of
the rail.
—- Holes in the web section that are too
close to each other.
— Four or more holes in the same
vertical line of the rail web.
— Welds on the flange, particularly
across the flange or along its edge.
— Not using filler blocks in the channel
of the rails when a body (or special
equipment) has been mounted with
the use of U-bolts.
— Cutting holes in the rail with a torch.
— Cutting notches anywhere on the
rails.
. A fire involving the vehicle.
. Acollision involving the vehicle.
oN

. The use of equipment for which the

frame has not been designed or
reinforced.

. Operating a dump truck with the box 1-6. Straighten and reinforce the
Buckle
raised to spread loads. frame as described later in this
. The use of equipment such as snow section. See “Straightening
~

Frames” and “Reinforcements”.

:

plows for which the frame was not

designed.
. The surging of liquids in a tank truck.
.Acollision involving the vehicle.
ombh

. A fire involving the vehicle.

. In addition to these causes, refer to the
possible causes 3 and 5 under “Sag”.
These may contribute to “Buckle”.
2A-4 FRAME AND BODY MOUNTS

DIAGNOSIS OF FRAME (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Sidesway 1. A collision involving the vehicle. 1-4. Straighten and reinforce the
2. A fire involving the vehicie. frame as described later in this
3. The use of equipment such as snow section. See “Straightening
piows for which the frame was neither Frames” and “Reinforcements”.
designed nor properly reinforced.
4. In addition to these causes, refer to
possible causes 3 and 5 under “Sag”.
These may be contributing factors.

Diamond 1. A collision involving the vehicle. 1-2. Straighten and reinforce the
2. Towing ancther vehicle with a chain frame as described later in this
attached to one corner of the frame. section. See “Straightening
Frames” and “Reinforcements”.

Twist 1. An accident or collision involving the 1-2. Straighten and reinforce the
vehicle. frame as described later in this
2. Operating the vehicle on very rough section. See “Straightening
terrain. Frames” and “Reinforcements”.

improper 1. Frame is out of alignment. 1. Straighten and reinforce the

Tracking frame as described later in this
section.
. Front or rear axle has shifted. . Realign and secure the axle.
. Incorrect wheel alignment may make the . Align the wheels. Refer to
vehicle appear to be tracking incorrectly. FRONT END ALIGNMENT (SEC.
3A) of this manual.

Cracks in the . Loose crossmember attaching bolts. . Straighten and reinforce the rail.
Web of the Rails Ream bolt holes and replace with
larger bolts if necessary.
Retighten bolts.
. Concentration of stress that may result Replace, or weld and reinforce
from many different factors. the rail. See the appropriate
(See “Sag” under Diagnosis previously heading, later in this section.
described in this chart. Also see
“Minimizing Frame Failures” and
“Reinforcements” later in this section.)
 FRAME AND BODY MOUNTS 2A-5

ON-VEHICLE SERVICE

CHECKING FRAME ALIGNMENT points representing each rail. If the rail is

straight and the points are carefully marked,
Types of frame misalignment can be divided into the line should be very close (within 3 mm
five groups. The five groups are sag, buckle, [1/8 in] to each point). A point or points
more than 3 mm (1/8 in) from the line
diamond, sidesway, and twist. For a brief definition
of these terms, refer to “Description” at the indicates “sidesway.”
beginning of this section. If the rear sections of the rails are straight and
there is 80 cm (31.5 in) between the web at the
A misaligned frame rail may have moved forward
end point of one rail and that of the other rail,
from, up or down from, or to the side of where it
consider the rails to be in alignment so far.
should be. These causes must all be checked.
. Check the length of each rail line. They should
The easiest way to check frame alignment is with
gages made for this purpose. Detailed instructions be the same length.
. Check the width at the front and rear of the
are normally supplied with gages at the time of
vehicle. The normal widths, by model, are given
purchase. Therefore, instructions for gage use are
not given in this manual. in the “Specifications” at the end of this section.
. Pick a point on one rail line, a given distance
it is possible to check frame alignment without the
from one end of the rail. Mark the point. Mark a
proper gages. The procedure is described later in
this section. point at the same spot on the other rail line.
. From the two points chosen, mark a diagonal to
Whether alignment is checked with or without
the opposite rail. Make the diagonals the same
gages, the vehicle must be parked on a level
section of floor. length.
. From the original two points, mark a second pair
Certain conditions call for preliminary checks
of diagonals to the opposite rails. These
before actually checking the frame. Suspension or
diagonals should be the same length as one
axle problems may make it appear that the vehicle
frame is out of alignment. another, but longer than the first pair (figure 1).
if an axle has shifted, “Diamond” or “Sidesway” may
appear to exist when, in fact, they do not. A weak
spring may make the vehicle appear to have a
twisted frame.
A visual inspection of the top and bottom flanges
of each rail may reveal the area where sag or
buckle exists. In the case of sag, wrinkles may
appear on the top of the upper flange; such
wrinkles are definite evidence of sag. Wrinkles on
the bottom of the lower flange are definite evidence
of buckle.
. Diagonals of Equal Length 2
Checking Alignment Without Gages from Corresponding Points
, Line Representing
(Figure 1)
Left-Hand Rail
1. Move the vehicle to a level, well-lighted section . Points on Floor Determined
of floor. by using a Plumb Bob.
2. Make a diagram of the frame on the floor . Centerline
beneath the vehicle. Do this as follows:
a. Pick several points on the bottom flange of Figure 1. Rail Layout and Alignment Check
each frame rail. There should be clear
access from these points to the floor. Mark . Mark a line between the points of intersection of
one point at the rear end of each rail. All the two pairs of diagonals. If no “diamond”
points should be the same distance from the exists, this line should be the same distance
vertical part (web) of the rail. from each frame rail at all points along its
b. Use a plumb bob to transfer the points on length.
the rail to the floor directly beneath them. . Use a bubble protractor to measure the slope of
c. Move the vehicle away from the points on each rail at different points along its length
the floor. (figure 2). The actual slope of the rails is not
d. Use a chalk line to mark a line through the
 2A-6 FRAME AND BODY MOUNTS

important but the slope of the two rails should the flow of the damaging forces. In many instances,
be the same. When using a bubble protractor to to reverse the flow of forces, pressure must be
measure the slope of a rail, keep the following applied from different directions at the same time.
points in mind: Careful use of controlled heat is important. Too
a. Tires must all be the same size to get a much or too little heat, or the improper application
meaningful reading. of heat, is a major source of trouble. Frame heating
b. Tires must all be equally inflated. should be done with a large-sized tip (multi-hole

eo
c. A weak spring will result in a false reading. heating tip) and a neutral flame should be used
(oxygen adjust opened just enough to remove the
feathers or stringers from the blue center at tip of

g
torch). Heat the area that will be stretched as frame
is straightened. Heat the area AFTER SUFFICIENT
PRESSURE HAS BEEN EXERTED to cause a
slight checking, or silvery cracks, to appear on the
surface of the metal. Gradually increase the
pressure while heating. Do not heat beyond
600°C(1200°F). A red glow indicates that the
material is overheated. Overheating will cause
distortion and stretching, and will change the
characteristics of the metal.

REINFORCEMENTS

Reinforcements are used to increase the frame

strength. They do this by increasing the section
modulus of the area reinforced. (For a brief
Figure 2. Checking Slope With a Bubble Protractor definition of section modulus, refer to the
“Description” at the beginning of this section.)
10. An alternative method of checking the vertical Besides increasing frame strength, reinforcements
alignment of a normally straight rail (step 9) is make the frame less flexible. This must be
as follows: considered when reinforcing a frame. Too stiff a
a. Measure the distance from the rail to the frame can fail. An effective reinforcement must
floor at different points along the rail. (The compensate for factors which caused the original
vehicle must be on level section of floor.) damage but not introduce new factors which
b. Transfer these distances, in order, toa produce concentrations of stress.
sheet of graph paper. On new vehicles, the strength needed in the
c. Connect the points on the graph paper that frame may be provided with reinforced rails rather
represent each distance. than with heavier, one-piece rails. If the wheelbase
d. Ifthe rail is straight (vertically) the points is long, the unsupported span between the axles
shouid all lie on a straight line. may be too great, and reinforcements should be
added.
STRAIGHTENING FRAMES It is not possible to specify the type or length of
reinforcements for every situation. Each case must
Frame straightening can be complicated, and be studied individually. However, several general
usually requires special equipment. It should be guidelines should be kept in mind. Care must be
attempted by competent personnel only. taken to avoid abrupt changes in section modulus.
A complete analysis of the condition of the frame This requires reinforcements to be tapered. It also
should be made before any steps are taken to requires certain practices when welding, drilling
straighten it. Analyzing the cause of failure will help holes, and using bolts. These are covered later in
determine the correct sequence of steps in the this section.
repair. (See “Possible Causes” under “Diagnosis” A further guideline is that of dissimilar metals.
and “Minimizing Frame Failure” previously outlined Metals may vary in type and strength. A
in this section.) it is essential that the frame reinforcement should have as high a strength as
material be identified before any work is done on it. the frame it is reinforcing. See the “Specifications”
Frame rails of vehicles covered in this manual are at the end of this section for yield strengths of
J-1392-050 steel. different materials.
Corrective procedures should be set up to reverse
 FRAME AND BODY MOUNTS 2A-7

Types inside of the rail channel. It is designed to

Seven types of reinforcements are shown in prevent flange buckling due to high torsional
figure 3. These reinforcements can be combined in inputs or shock loading during tractor hookup
different ways to meet especially heavy demands or operations.
the needs of special situations. Some reinforcement . Channel Reinforcement (figure 3, view 7)—- May
practices are shown in figure 4. Reinforcements be used on the inside or outside of the frame
labeled “wrong” would result in too abrupt a change rail.
in section modulus. lt reinforces both flanges and the rail web.
1. Upright “L” Reinforcement (figure 3, view 1)— . Strap Reinforcements (figure 3, view 3)— These
May be used on either the inside or outside of are used on the rail flange on the inside of
the frame rail. It should be used where channel.
maximum stress occurs on the bottom of the They should be plug-welded at 150 to 200 mm
lower flange. (6 to 8 in) intervals. Do not weld across the end
2. Inverted “L” Reinforcement (figure 3, view 9)— or along the edges of the reinforcement.
May be used on either the inside or the outside . Fich Plate Reinforcement (figure 3, view 4)—
of the frame rail. It should be used where These are used on the outside of the rail web.
maximum stress occurs on the upper flange. It They may extend above or below the rail. They
can also be used where the frame or stiffen the frame.
hangerbracket design does not allow the use of . Web reinforcement (figure 3, view 6)-— These
an upright “L” reinforcement. are used on the inside of the rail web. They are
3. Inverted “J” Reinforcement (figure 3, view 8)— plug welded at 150 to 200 mm (6 to 8 in)
This is attached to the web section only, on the intervals.

ee ,
7

1. Upright “L” Reinforcement 4, Fish Plate Reinforcement 7. Channel Reinforcement

2. 150 to 200 mm (6 to 8 in) 5. 200 to 250 mm (8 to 10 in) 8. Inverted “J” Reinforcement
3. Strap Reinforcement 6. Web Reinforcement 9. Inverted “L” Reinforcement

Figure 3. Types of Reinforcements

2A-8 FRAME AND BODY MOUNTS

Making Reinforcements of a cutting torch, all cracks, nicks, and burrs

In general, when making a reinforcement of any must also be removed from the edges of holes.
type, observe the following practices: 3. Avoid gaps caused by reinforcements that stop
1. Taper the reinforcement plates to avaid abrupt short of the ends of crossmembers, gussets,
changes in section modulus. Angles at the edge brackets, etc. (figure 4).
of a reinforcement plate should be less than 45 4. Cut reinforcements long enough so that they
degrees (figure 4}. can be tapered and still extend beyond the
2. When reinforcement plates are shaped by use critical area.

ORIGINAL
SECTION

REINFORCED
SECTION
X : x

WRONG
Lak) “8
Of 1X
REINFORCED
\
SECTION
SECTION ~~ fo “GAP"

PLATE
BEFORE BENDING

45° OR
pn
LESS ~. f
CORRECT

CORRECT

Figure 4. Reinforcement Practices

Attachment size at the bottom of the hole. (Remove the lip of a

Use bolts or rivets to attach reinforcements. hole with a reamer),
Bolting is preferred. Avoid attaching the In generai, when attaching reinforcements,
reinforcements by welding. (In some cases, welding observe the following:
may be acceptable. Such cases include the plug . Bolt reinforcements to the frame.
Poh —

weld used on strap or web reinforcements.) Bolt . Use existing holes if possible.
holes that are enlarged or irregularly worn may be . Avoid drilling holes in the frame flange.
reamed to accept the next larger bolt diameter and . Holes should be made as close to the neutral
then used to hold the reinforcement. For critical axis (halfway between the flanges) as possible.
areas, body-fit bolts with hardened washers can be . Bolt holes should be no larger than those
an

used. The use of body-fit bolts requires reaming the already existing in the frame such as for spring
hole to a nonstandard size to get an interference fit bracket bolts.
for the bolt. Whenever possible, use existing holes 6. No more than three holes should be on a
rather than drill new ones. vertical line of the web.
if new holes must be made, use cobalt high- 7. Holes should be at least 13 mm (1/2 in) apart.
speed drills. (Dritls should be sharpened to give 8. Holes in a reinforcement plate should be at
150 degrees included angie with 7 to 15 degrees lip least two times the material thickness from the
clearance.) If a pilot hole is made, avoid enlarging it edge of the plate.
in successive stages. Avoid breaking through to full
 FRAME AND BODY MOUNTS 2A-9

REPAIRING CRACKS starting point to the 6 mm (1/4 in) hole at the

extreme end. The angle of the “V” will depend
Two common types of cracks are shown in figure on the welding process used. See
5. The straight crack will normally start from the “Specifications” at the end of this section, for
edge of a flange. It will go across the flange and the correct angle.
through the web section of a rail. Finally, it will 4. The bottam of the crack should be opened up 2
continue through the other flange. This type of mm (1/16 in) to allow good penetration of the
stress, in small areas of the frame, can be caused weld. (A hacksaw biade may be used for this.)
by excessive bending movement, and torsional 5. Weld with the proper electrode and proper
loading. (See “Minimizing Frame Failures,” welding techniques. See “Welding” outlined
previously outlined in this section.) later in this section for tips on weiding. See the
“Specifications” at the end of this section for the
proper electrode.
6. Grind the weld smooth on both the inside and
the outside of the rail or crossmember. Be
extremely careful to eliminate weld buildup or
notches on the edge of the flange.

WELDING
improper welding techniques are the cause of
many weld and/or frame failures. The following
information points out potential areas of difficulty
and provides some general guidelines for
successful frame welding.
Sunburst Cracks Most weld failures occur at the end of the weld in
areas of the frame that are under high stress. By
properly finishing the ends of a weld, failures can
be reduced; this can be done by making a hole or
Figure 5. Common Types of Cracks slot in the part to be attached, and then using a
fillet weld around a slot or plug weld. Do not leave a
Sunburst crack(s) will radiate from a hole in the notch at the end of a weld. For a guide to the
web section of a rail or crossmember. They are diameter and depth of plug welds by thickness of
caused by high loads being applied at a mounting material welded, see the “Specifications” at the end
bracket or crossmember which is not securely or of this section. In most cases, less welding, lower
properly attached to the rail. cost, and a more successful weld will result.
if cracks occur to both the rail and reinforcement Over-welding can also be harmful, especially if it
at a particular area of the frame, they must be in an area of the frame that receives high
repaired separately. The flanges must react concentrations of stress.
independently to prevent localized stress
concentration. Use a copper spacer between When Welding:
cracked base rail flanges and reinforcement 1. Do not use oxyacetylene welding equipment.
flanges. 2. Be sure to use the correct electrode. See the
Crossmember mounting flange cracks may be “Specifications” at the end of this section for the
repaired in the same manner as side rail cracks. electrodes that can be used on frames.
However, the weld bead should be built up to 3. Whenever possible, use small diameter
provide a good, smooth radius. lf a crossmember is electrodes and make several passes; this is
greatly damaged, it should be replaced. preferred to using large diameter electrodes and
it may be necessary to align the frame and level making fewer passes.
the rails before repairing the frame. 4, Do not use more heat than is necessary to give
The following procedure should be used to repair good penetration.
cracks in a rail, reinforcement or crossmember: 5. Do not run more passes than necessary.
1. Remove any equipment that will interfere with 6. Be sure the weld is free from craters and
access to the crack. undercuts.
2. Locate the extreme end of the crack and drill a 7. Be sure slag is removed before each
6 mm (1/4 in} hole. successive pass.
3. Vee-grind the entire length of the crack from the 8. When repairing a crack, grind the surface of the
 2A-10 FRAME AND BODY MOUNTS

weld flush with the parent material. CROSSMEMBER REPLACEMENT

9. When mounting accessories, do not weld
across the flanges. ie] Remove or Disconnect
10. When mounting accessories,do not weld within
19 mm (3/4 in) of a flange. 1. Wires, cables, and/or lines near the
11. Do not weld up to the edge of a part being crossmember.
welded to a frame. Leave 6 mm (1/4 in) 2. Brackets, valves, or other components near the
between the end of the weld and the edge of crossmember.
the part. 3. Crossmember bolts or rivets.
12. Do not weld cast brackets to the frame. 4, Crossmember.
13. Do not weld the flanges of cracked
[oe] Install or Connect
reinforcements and base rails together.
14. Connect the welding machine ground cables as 1. Crossmember to the frame rails.
close to the working area as possible. 2. Bolts and rivets.
15. Avoid unnecessary contact between the welding 3. Brackets, valve, or other components.
cables and any part of the vehicle. 4, Wires, cables, and/or lines.
16. Do not attach the welding cables near the
vehicle wiring.

BODY MOUNTS

DESCRIPTION
Mounting a platform-type body on the vehicle
frame requires several considerations. Construction
of the piatform will affect the way it can be attached
to the frame. The intended use of the platform will
determine, in part, how it should be attached to the
frame. Concentrations of stress on the frame,
resulting from the mounting, must also be
considered. 1. Sill Channel
Mounting any structure on the vehicle frame will 2. Longitudinal Sill
cause concentrations of stress. Every attempt 3. Angle Iron
should be made to keep these concentrations to a 4. Chassis Frame Side Rail
minimum. A good way to do this, when mounting a
platform body, is to mount it on longitudinal sills as Figure 6. Longitudinal Sill Attachment
described later in this section. This avoids heating
LONGITUDINAL SILL MOUNTING
the frame, welding on it, or drilling additional holes
in it.
Longitudinal! sills are on the underside of a
Platform bodies without longitudinal sills should, if
platform body and extend from the front edge of the
possible, have them added to allow longitudinal sill
platform to the rear edge. Normally there are two.
mounting. Sills can be constructed of dry hardwood.
They are spaced at a distance equal to the width
They are then attached to either wood or metal
between the frame rails of the vehicle. One sill rests
cross sills by means of angle irons and bolts (figure
on top of each rail. Ideally, the entire edge of the sill
6).
is in contact with the top surface of the rail flange.
In some cases, longitudinal sill mounting may not
Clip plates and bolts hold the sill on top of the rail.
be possible. Other mounting methods are
The bolts are perpendicular to the sill and frame,
discussed briefly, later in this section. It must be
but are to the outside of—rather than through—
stressed, however, that if the recommended
them. A clip plate above the sill and one below the
procedure is not followed, the strains of load and
rail hold the boits in place (figure 7).
chassis movement may not be distributed correctly.
This could result in damage to the body and/or
Sill Considerations
frame. The only recormmended procedure is
longitudinal sill mounting. The following points concerning sills should be
kept in mind:
1. The height of the sill should be sufficient to
 FRAME AND BODY MOUNTS 2A-11

prevent the body from striking the tires or other 5. Sills may be as wide as the rail flange, but not
parts of the chassis, with maximum spring wider. If sills are narrower than the rail, spacer
deflection. (Take into consideration a full-load blocks should be attached to the sill at each
operation over extremely rough terrain.) point where the sill is held to the rail (figure 7).
. Sills should extend as close as possible to the These blocks should extend over the edge of
back of the cab without interfering with the the rail. Grooves should be cut in the side of the
mounting or movement of the cab. block to provide clearance for the mounting
. Sills should rest squarely on the top flange of bolts. The grooves help hold the bolts in place.
the side rails.(If rivet heads prevent a solid The blocks should be attached to the sill with
bearing of wood sills, countersink the sills just screw as shown in figure 7. The grain of the
enough to clear the rivet heads. DO NOT USE block should be perpendicular (up and down) to
SPACERS to raise the sills above the rivet the grain of the sill.
heads. If the longitudinal sills are metal, it will . Install a sheet metal channel on top of the sill at
be necessary to use a full-length hardwood strip each point where it will be held to the rail (figure
between the sill and rail. Countersink the 6 or 7). This is to prevent the clip plate from
hardwood strip to clear the rivet heads. becoming sunk in the sill. The channel should
. Wood sills should be chamfered 13 mm (1/2 in) be a minimum of 1.7mm (#14 gage) sheet
at the front end. The chamfer should be tapered metal. The sill should be cut away slightly to
to meet the frame 31 to 46 cm (12 to 18 in) from provide room for the channel and to allow it to
the end of the sill (figure 7.) sit flush with the side of the sill.

1. Frame Side Rail 5. Clip Plate 9. Prevailing Torque Nut

2. Longitudinal Sill 6. Metal Channel 10. Cross Sill
3. Spacer Block 7. Mounting Bolt 11. Chamfer Sil--13 mm (0.5 in)
4. Wood Filler Block 8. Nut

Figure 7. Longitudinal Sill Mounting

2A-12 FRAME AND BODY MOUNTS

Point of Attachment would then be used in place of the bolts.

The following rules, concerning each point where . U-bolts can be used in place of the bolts or
the sill is held to the frame, should be kept in mind: studs (figure 8), although bolts or studs are
1. Each sill should be held to the rail in at least preferred.
three places. The points of attachment should If U-bolts are used, they must be the “flatted”
be spaced, as nearly as possible, the same type. They should be positioned with the
distance apart. threaded ends of the bolts pointing down. A
. Two hex-head bolts should be used at each spreader must be used at the top to increase
point of attachment. the bearing surface and provide relief from the
. Use two nuts on the end of each boit. Tighten corner radii of the bolt.
the inner nut firmly; then tighten the outer nut . Use a wood block “filler” in the frame channel
firmly against the inner nut. Do not use a single between the two bolts, studs, or ends of each
nut and a helicai-spring washer. U-bolt (figure 8). The block should be long
. Bolts should be 13 mm (1/2 in) in diameter. enough to extend beyond the edges of the clip
. The clip plates above the frame should be of a plate and wide enough to overhang the rail
thickness equal to the diameter of the boits flange. Cut grooves on the inside edge of these
being used. blocks to provide clearance and a “seating” for
. If the design of the body does not permit the the mounting bolts.(it may be necessary to cut
use of bolts and clip plates, a tapped plate can the corners off these blocks to avoid interfering
be used instead of a clip plate (figure 8). Studs with wires, etc., on the rail.)

N
TAPPED PLATE TYPE MOUNTING U-BOLT TYPE MOUNTING

1. Jamnut 6. Spacer Block 11. Mounting Bolt

2. Nut 7. Frame Side Rail 12. Helical Spring Washer
3. Clip Plate (not tapped) 8. Wood Filler Block 13. U-Bolt Clip
4. Metal Channei 9. Mounting Stud 14. U-Bolt
5. Longitudinal Sill 10. Clip Plate (Tapped)

Figure 8. Three Types of Mounting

 FRAME AND BODY MOUNTS 2A-13

OTHER TYPES OF MOUNTINGS in a relatively small area (the points of

intersection of the sills), and frame plates and
The recommended mounting for platform bodies nuts protrude above the floor of the body. If this
on these vehicles is the longitudinal sill mounting type of mounting is still selected, follow the
described previously in this section. Other types of suggestions under “Points of Attachment,”
mountings are possible. However, care must be previously outlined in this section. Note that the
taken to avoid concentrations of stress that will clip plates will be on a diagonal through the
damage the body and/or frame. A few other intersection of sill and frame rail rather than
methods are described below: perpendicular to them.
1. FISH PLATE ATTACHMENT—A fish plate is
welded to the subframe of the body and bolted Guidelines
to the vehicle frame. This is durable and 1. Avoid welding the body to the frame. (Welds are
versatile but usually requires drilling holes in the rigid whereas frames must have some
frame rails. Refer to “Reinforcements” flexibility.)
previously outlined in this section for more 2. \f the mounting requires holes in the frame, try
information on fish plate attachments. to use existing holes.
2. CLAMPING DEVICES—These require less 3. Do not drill holes in the flanges.
installation time and are, therefore, relatively 4. { holes must be drilled in the web section of a
inexpensive. They also eliminate the need for rail, they should be located as closely as
additional holes in the frame of the vehicle. possible to the neutral axis of the web. (This is
Since they depend on friction and a maintained halfway between the rail flanges.)
clamping force, a bolted connection should be 5. Be sure drills are properly ground if new holes
used for safety. must be made.
3. CROSS-SILL—This is generally not Refer to “Reinforcements” and “Minimizing Frame
recommended. The platform tends to ride lower Failures” outlined previously in this section for other
to the wheels than if longitudinal-sill mounting is guidelines when drilling, welding and bolting.
used. The weight of a load will be concentrated

SPECIFICATIONS

WIDTHS BETWEEN THE WEB OF FRAME RAILS

At Front End of Rails 0.0.0.0... cece eees scene eceeeenereneanneseerannnees Lececeeeuaauseccuaceeeetaens 82 cm (32.3 in) (Inside to Inside)

to Inside)
At Rear End of Rails ............::cccccecececeeeneeesumueneeneceseaeeeuaaeneretinnecesseersaamaenarsareres 75 cm (29.5 in) (Inside

YIELD STRENGTH OF DIFFERENT METAL

344 750 kPa (50,000 psi)
SAE J+1392-O50 ...cccecceccccccescseeseeceecceraesusseresenseeeeseeeresneeteeetiteniereeseesseetenennnenenntstsrensed
137 900 kPa (20,000 psi)
SAE 1010 coccccccecccecevecsessceccreeenseeceeesuesnesessaeeeeeeeneeeneeeneneereeesaasonanneusaseenenipinenenrneseseageaes
ness 206 850 kPa (30,000 psi)
SAE 1020 coccccccccceceecsnsuesescessecceseeeerseeessnestesesnesnrerevenenerssseeeeseeseannegecesemergnecsaneeaer
248 220 kPa (36,000 psi)
SAE 1023 coccccccccccececsesscesseccnscenerseceeceeecssaeneeteesecneesnrormesensenesseeseestscnmensaeaerertenscgeaeensees
2A-14 FRAME AND BODY MOUNTS

SPECIFICATIONS (CONT.)
WELDING CHART

SAE J-1392-050
Materials SAE 1010
To be SAE1020
Welded SAE 1023
PROCESS GMAW SMAW
Electrode E708-3 E7011
E7016
E7018
Minimum
Yield of 413 700 kPa 413 700 kPa
Electrode (60,000 psi} (60,000 psi)
Chamfer used
when cutting
away the sides 60° 90°
of a crack to
be welded.

ELECTRODE CHART

Electrodes
E-7011 # E-7016 # E-7018 # E-11018

Available Sizes Flat Welding

MM iN x MM IN Current Arc
Range Voltage

1.984 0.078 x 229 9 30-60 20-22

2.381 0.094 x 305 12 45-80 21-23
3.175 0.125 x 356 14 80-115 21-23
3.969 0.156 x 356 14 125-165 22-24
4.763 0.188 x 356 14 160-200 22-24
5.556 0.219 x 457 18 200-250 22-24
6.350 0.250 x 457 18 250-320 23-25
7.938 0.313 x 457 18 320-400 24-28

Overhead Welding

2.381 0.094 x 305 12 45-75 20-22

3.175 0.125 x 203 8 80-125 20-24
3.969 0.156 Xx 356 14 120-190 21-24
4.763 0.188 xX 356 14 150-240 21-24
 FRAME AND BODY MOUNTS 2A-15

SPECIFICATIONS (CONT.)
PLUG WELD CHART

Thickness of Diameter of Depth of

Material Plug Plug

MM IN MM IN MM IN

6 1/4 19 3/4 6 1/4

9 3/8 25 1 9 3/8
13 1/2 28 1-1/8 11 7/16
16 5/8 31 1-1/4 13 1/2
19 3/4 34 1-3/8 14 9/16
25 1 38 1-1/2 14 9/16
MEMO
 CAB MAINTENANCE 2B-1

SECTION 2B

CAB MAINTENANCE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE

Interior MainteMance....c...ccccccccssesessssecsersseseerssessenenaysenscassusnaressenssnsnsancananencatansasensansoeatanuscausrassserereneataansenens 2B- 1

Care and Cleaning of the Interior .............::se susuausuossenyenceeseseesuansentanouaeausseaedensseuvonvonsesssonesenenenennasenaeas 2B- 1
Steering Wheel Refinishing .............csecccccceoreeerusstesveacsaieneenssasunsenssnenesensunnnensecamnenenrscananinanvaneacianeaveneansnens 2B- 2
Water L@akS........scccsscsssscccssssssscesesesersnnsceesseseneassuseesnscensousanerssusenassinsesunenessneedmavenaenentamesnnncuunzensonnvenstuazannanes 2B- 3
DUSt L@@KS......c:ccccssesssssccccecsersssssescocsseessusessoesnsesanenn:susetaucassousapersunecesersesysuneseueaunevannedqunsauntonnensagsusaeessoerseseae 2B- 4
Exterior Maintenannce..........0:ccccecsscsssuisssneeessnsansserusesssectanecnsenndussouaenveyseneusasenanseusannaastenages seetesnensseeuscnnencannasenee 2B- 4
Cab Repairs ........scccscsssssssessecssssssnesecsseresenteussessessreressatsseraccassanenenseronesarceseguenensseseeanenesnesusutaneauansaueneeasententyns 2B- 4
Cab Alignment and Straightening ........--.:ssssessnssenessensensnenncemsnsersoteatersasarsneeasanusananareasatasrsenneneasenennee 2B- 5
Dinging and Finishing ........-..ssesccssesesncersessessersntsnsesesenssesseensennesanesersnesiesnercarsausnassansecnssasnsansssencavansnanesennnas 2B- 5
Painting Sheet Metal...........ccsccsssecssssssssssssesersssarensnseserscasennsecsenesseennnssereatenensacenitouseantiseanennnenerans sescenene 2B- 5
Stationary GIaSS.........-.sssessssssenesesesssscsseeeeseesnssensscussssnnaeensuseysentaneaceesouseasensaeesuraunnsacuensoricesnarauaneanenesaensensens .. 2B- 6
Outside Rear View Mirror Replacement ............:.cc:cesssinsessereenseserssessrnsnsarsesanaecosnennenssecansnaaanescesamiusanenats 2B- 6
Windshield Glass Replacement ..........:scsssesecsensercrsessenensacnesnensseecscnsereensacennsnannneracenraneannecnensnansauasentanseent 2B- 6
Rear Window Replacement ........... susvecesusocareneeausansnsassauanacenses caevsesayseceeauaaeaeaeesoeaseaorsutsenenousuaessussnusnacssasennens 2B-10
Glass POlSHING........:sseccessssenennseersenuneeereeseeesisetsueneersnsnnasersnsensrenseneucuerecatnenananaunonanaracesunyaneas seeeseveavaceanensranees 2B-11
2B-12
Model and Series Designation Plate Replacement............ssssssssssesaencncassncesterssssncaneensearsensisarzarenenansenes

INTERIOR MAINTENANCE
CARE AND CLEANING OF THE INTERIOR with the trim materials.
With materials made of synthetic plastics and/or
Care of the interior is a fairly simple but important man made fibers, it is EXTREMELY IMPORTANT to
matter. A buildup of dirt mars the appearance of the use proper cleaning methods and cleaners. Failure
interior. It can also turn into a hard, gritty substance to do this on the first cleaning may result in water
spots, spot rings, or setting of stains.
that will cut into the surface of seats, trim panels,
dash pad, floor mats, etc. Dust and loose dirt should be removed often with
Be sure the vehicle is well ventilated while using a vacuum cleaner, wisk broom or soft brush. Vinyl
cleaning agents. Follow the manufacturer's trim should be wiped regularly with a clean damp
directions when using such products. To avoid cloth.
possible permanent discoloration of light colored NEVER use gasoline, nail polish remover or
seats or door trim, DO NOT allow materials with acetone lacquer thinners, bleaches, etc. Some
unstable dyes (colored denims, corduroys, leathers, basic points should be followed when cleaning.
suedes, decorative paper, etc.) to come in contact
2B-2 CAB MAINTENANCE

1. Remove stains as quickly as possible before detergent:

they become “set.” 1. Work up a thin suds on a piece of cheesecloth
2. Use a clean cloth or sponge and change to a and apply it to the soiled area.
clean area frequently. (A soft brush may be 2. Allow the suds to soak for a few minutes.
used if stains persist.) 3. Rub briskly with a clean, damp area of the
3. Use salvent-type cleaners in a well ventilated cloth.
area. Do not saturate the stained area with 4. Remove any remaining suds and dirt residue
solvent. with a clean, damp section of cloth.
4. lf a ring should form after spot cleaning, the 5. Finish by wiping lightly with a dry, soft cloth.
entire area of the trim assembly should be When cleaning with a vinyl cleaner, follow the
cleaned immediately. directions of the manufacturer.
5. The cleaning action should be from the outside
of the stain, feathering in toward the center of Floor Mats
the stain. Floor mats are rubber. Use any household soap
65. When using commercial cleaners, follow the and hot water for cleaning. Stiff brushes can be
instructions provided with them. used. Rinse with clean water.
Some types of stains or soilage such as lipstick,
some inks, certain types of grease, etc., are very Door Trim Panels/Steering Wheel
difficult and, in some cases, impossible to
These parts of the vehicle are plastic. They
completely remove. When cleaning this type of
should be cleaned with a mild soap or liquid
stain or soilage, care must be taken not to enlarge
household detergent and lukewarm water. See the
the soiled area. It is sometimes more desirable to
procedure outlined previously under “Seats/The
have a small stain than an enlarged stain as a
Covering of Noise Insulation/Sun Visors/Dash Pad.”
result of careless cleaning.
Stubborn stains can be removed with a
multipurpose powdered cleaner. Follow the
CAUTION: Some cleaners may be poisonous or
directions of the manufacturer.
flammabie, and their improper use may cause
personal injury or damage the inside of the
Painted Steel Surfaces
vehicle. Therefore, when cleaning the inside of the
vehicle, do not use volatile cleaning solvents such These surfaces can be cleaned with a mild soap
as: acetone, lacquer thinners, enamel reducers, or household detergent and lukewarm water. Use
nail polish removers; or such cleaning materials the procedure outlined previously under “Seats/The
as laundry soaps, bleaches or reducing agents, Covering of Noise Insulation/Sun Visors/Dash Pad”
except as noted in the fabric cleaning advice on in this section.
stain removal which follows. Never use carbon
tetrachloride, gasoline, benzene, or naptha for any Lap Belts
cleaning purpose. Use a mild soap or liquid household detergent
Over exposure to these vapors may result ina and lukewarm water. Follow the procedure outlined
health problem. This is even more likely to occur previously in this section under “Seats/The
in small, unventilated spaces. It is recommended Covering of Noise Insulation/Sun Visors/Dash Pad.”
that all vehicle doors be opened for ventilation Do not bleach or dye belts; this may severely
when any cleaning agents or other chemicals are weaken them.
used in the interior. Approved respiratory
protection equipment may be needed. Follow the STEERING WHEEL REFINISHING
manufacturer's advice whenever cleaning agents
or other chemicals are used, inside or outside the Plastic steering wheels that are not textured or
vehicle. imprinted with a grain can often be refinished if they
become nicked or scratched. The following
Seats/The Covering of Noise procedure is intended only for the repair of minor
insulation/Sun Visors/Dash Pad damage. Do not attempt to refinish any area of a
These items are vinyl. They can normally be steering wheel that has a grained surface molded
cleaned with lukewarm water and a mild soap or into it.
liquid household detergent. A saddle or oil soap can Refinishing may be accomplished without wheel
also be used. For difficult to remove stains, use a removal in most cases. It is suggested, however,
cleaner especially made for use on vinyl. Do not that the procedure be tried on a discarded wheel
use furniture polishes, oils, varnishes or ammonia. before it is done to the wheel of the vehicle.
When cleaning with a mild soap or household Any nicks, scratches or other blemishes must be
 CAB MAINTENANCE 2B-3

worked out of the wheel to match the contour of the

surrounding area. Normally, solvent solution, a
cheesecloth, and sandpaper are enough to do the
job. Steel wool and a file may prove useful.

CAUTION: Be sure procedures are performed in a

well ventilated area away from any fire or flame
source. Avoid prolonged breathing of solution
fumes. When using MEK (methyl ethyl keytone)
wear rubber gloves; the solution can be harmful to
the skin.

Necessary or Useful Working Materials

1. Solution of 50 percent MEK and 50 percent
alcohol (or a solution of acetone}.
2. Bleached, cotton cheesecloth (or white linen}. Figure 1. Steering Wheel Rubbing Pattern
3. A soft, clean, dry cloth.
WATER LEAKS
4. Fine sandpaper, 300 to 400 fine.
5. Rubber gloves. if water has leaked into the cab, it is possible to
6. Fine steel wool, grade 0000 to 000. test for the leakage points. Spray water under
7.A small, fine metal file. pressure against the cab in the general area where
the leak is believed to be located. Have an
Refinishing Procedure assistant inside the cab locate, and mark, the
1. Cover vinyl, rubber, or other plastic parts of the point(s) where any water appears.
vehicle to protect from solvent. Water that shows up at a certain place inside the
2. Soak the cheesecloth or linen in the solvent; cab may actually be entering the cab at another
wring out the excess. point. It may be necessary to remove the floor mat,
3. Rub along the damaged area of the wheel with insulation, dash pad, instrument carrier, etc.
a quick, continuous motion. Backtrack the path of water to point of entry. If it is
a. Pressure is important but rubbing too hard still not possible to locate the point of entry, another
will leave a rough surface from the cloth. It approach may help:
is best to make several passes using light 1. Close all windows and vents.
pressure. 2. Turn the air conditioner or heater blower motor
b. Lift the cloth from the wheel when stopping; to “High” position.
stopping first and then lifting the cloth from 3. Place the air lever in position to use outside air.
the wheel will cause an imprint of the cloth 4. Close the doors.
to be left in the plastic. 5. Run a small stream of water over the suspected
c. Follow the lines and contour of the wheel as areas of leakage.
shown in figure 1. 6. Check for pressure bubbles that indicate air is
d. Soak and wring out the cloth often to ensure escaping from the cab.
that it is wet but not dripping.
e. Keep folding the cloth so that the area in Corrective Measures
contact with the wheel stays clean; it will Corrective measures depend on the area of
have a tendency to pick up color from the leakage. If the leak is around a window held by a
wheel. weatherstrip, dry the area completely and apply
4. Let the wheel dry for several minutes. rubber cement both between the glass and the
5. Buff the wheel lightly with a soft, clean, dry weatherstrip, and the body and weatherstrip. If this
cloth. does not work, it may be necessary to remove the
Once the wheel has been buffed, do not touch or window and check the weatherstrip. If the
lay anything against the refinished area for at least weatherstrip is damaged, it should be replaced.
30 minutes; the plastic is soft and can be easily Check the flange that held the weatherstrip for any
marred. nicks or burrs that may have caused the damage.
After the wheel has dried thoroughly, white if the leak is around a door, it may be because
streaks may appear at the refinished area. These the door is not properly aligned. Realign the door
can be removed by rubbing with a clean, dry cloth. as described in STEEL TILT CAB (SEC. 10D) of
this manual. If the door is contacting the
2B-4 CAB MAINTENANCE

weatherstrip correctly, be sure the weatherstrip is 1. Remove the mats and insulation from the floor
seated on the flange of the opening and that it is and toe panel.
not damaged. If the weatherstrip is not properly . Drive the vehicle on a dusty road.

oo ho
seated, rubber cement can be used to hold it in . Examine the interior of the cab; dust in the
place. If the weatherstrip is damaged, it may be shape of a small cone or silt will usually be
necessary to replace it. found at the point of leakage.
if the ieak is between body panels, use an air 4. Mark the points of leakage.
drying body sealing compound. 5, With cab in an otherwise dark area, shine bright
lights on the underside of floor and cowl. While
DUST LEAKS doing this, have an assistant check inside the
cab for any points where the light shines
It is possible that dust wilt leak into a cab where through. Mark the points of leakage. Check
water will not, particularly in the lower portion of the weld joints and cab mounting areas closely.
cab. Forward motion of the vehicie can create a Sealing of leaks should be done with an air
slight vacuum which pulls air and dust into the cab. drying body sealing compound.
To determine the location of dust leaks:

EXTERIOR MAINTENANCE

Panels are welded together by spot and/or parts of body is not recommended since heat will
continuous welds. affect the structural characteristics of material. Any
The entire cab is an integrally welded structure. parts bent or buckled enough to show strain cracks
Repairs should be made by competent technicians after straightening should be replaced or properly
using proper tools and equipment. reinforced.
Major cab panels should be regularly checked for
damage. Note the condition of the paint and check Cab Panel Replacement
for corrosion. Give particular attention to chrome. Cab panels can be replaced by removing the
Checks should be made more often in freezing damaged part and welding a new piece in. For
weather due to the corrosive effect of road deicing proper alignment of the panei, clamp it in position
materials (salt, calcium chloride, etc.) on metals. before welding.
Broken welds, punctures, chipped paint, etc. should Any window fence should be spot-welded since it
be repaired. If checks reveal corrosion, paint provides a sealing surface.
failure, or bare metal, measures outlined in When repiacing a rear panel or a roof panel, give
“Painting Sheet Metal” (later in this section) should special attention to the proper sealing of joints with
be taken as soon as possible. Punctures should be sealing and cauiking compounds.
repaired as outlined under “Splits and Holes” (also,
later in this section.) Cab Sill Replacement
Remove the damaged sill(s) and smooth the area
CAB REPAIRS before installing replacement part(s). The
recommended method of installation is plug welding
Cab repairs may require reinforcements. Before or chain welding.
reinforcing any part of the vehicle, find the cause of
the failure. Cab panels and framing are integral; Splits and Holes
therefore, driving stresses and strains are
transmitted throughout the cab. Reinforcing a point 1. Holes of less than 6 mm (7/4 in) diameter in
of apparent failure without correcting the underlying sheet metal panels can be weided and metal
finished without backing:
cause of the failure may transfer the stress to other
parts not engineered for stress, with the result that a. Degrease and mechanically clean the area
on the panel(s) with emery or abrasive
new failures develop.
wheel.
To maintain proper body strength, replace the
b. Weld up the hole using E70S-3 filler rod.
damaged panels or other structural parts with new
c. Ifthe panel surface is visible, metal finish
ones from the factory.
Any parts used that are not steel, but will contact the area.
2. Holes greater than 6 mm (1/4 in) in diameter but
a steel part, including bolts, washers, nuts or rivets,
less than 51 mm (2 in) in diameter can be
should be coated with paint or plating to prevent
welded by backing the hole with the same
corrosive action between the dissimilar metals.
material as the parent material.
The use of heat when straightening structural
 CAB MAINTENANCE 2B-5

a. Degrease and mechanically ciean the area avoid changing the characteristics of the metal.
on the panels with emery or abrasive wheel. Apply slight heat with a torch, if necessary, to slow
b. Weld in a backing plate of the same material cooling.
as the parent material. Minimum edge
overlap at the holes should be 3 mm (1/8 DINGING AND FINISHING
in). Use E70S-3 filler rod. Paint is quickly scuffed off sharp dents, leaving
c. If the panel surface is visible, metal finish metal exposed to rusting and corrosion; therefore,
the area. damaged panels should be repaired as soon as
3. Cracks in the sheet metal panels that are less possible. Repair damaged panels by forcing
than 76 mm (3 in) long and 3 mm (1/8 in) wide outward in the direction opposite to the force that
can be welded and metal finished without caused the damage. in this way, metal strains, set
backing. up when the damage occurred, are relieved.
a. Degrease and mechanically clean the The importance of proper metal finishing, to
panel(s) with emery or abrasive wheel. produce a fairly smooth surface, should not be
b. Establish the start of the crack with dye- underestimated. The application of a hammer
penetrant test. directly to a panel tends to stretch the metal and
c. End the split by drilling a hole at the root of cause a great deal of unnecessary work. Whenever
the split. The diameter of the hole should be possible, a spoon should be used under the
at least one and a half times the metal nammer when bumping a panel.
thickness.
d. Weld up the crack, using the E70S-3 filler PAINTING SHEET METAL
rod.
e. Ifthe panel is visible, metal finish the area. Repainting
1. Thorough cleaning is necessary. All corrosion,
Welding grease, and other foreign matter must be
All welding should be done to American Welding removed. Use of phosphoric base metal
Society (AWS) standards. conditioners is recommended in preparing steel
When welding steel panels of the cab, use TIG, for painting. These materials vary in method of
MiG or SMA (stick) welding. If resistance welding application and use; they should be used only
equipment is available, it also can be used. Always as directed by the manufacturer. Solvent
use good practices as recommended by the AWS. cleaning, pressure steam cleaning, wire
When welding a cut member, fill or weld the cut brushing, and hand sanding methods are
completely. Filler material should be of the same recommended.
material as the parts being welded. Use E70S-3 2. Completely remove the old paint by use of
filler rod. organic or alkaline solvents. However, if alkaline
removers are used, all traces of alkali must be
CAB ALIGNMENT AND STRAIGHTENING washed off before primer is applied. If the old
primer is very difficult to remove, and if there is
Before attempting the repair of a damaged cab, no evidence of metal corrosion, the old primer
the chassis frame must be checked and, if may be left in place.
necessary, aligned. A procedure for checking frame 3. Apply primer, preferably by spraying and allow it
alignment is given in FRAME AND BODY MOUNTS to dry. Use good oxide primer obtained from a
(SEC. 2A) of this manual. reputable manufacturer.
Never attempt to straighten the cab unless the 4. Apply the finish coats.
cab is firmly attached to the chassis. The inner a. For the understructure, or other parts not
paneling of the cab should be straightened first. A requiring color, apply two coats of good air
push-pull hydraulic jack together with an extension drying black or other automotive lacquer.
and adapters is recommended for this type of b. To exposed body parts, apply surfacer and
repair. Crosscheck with an adjustable tram bar as paint in accordance with standard practice.
work progresses.
After straightening, it is important that strains, Painting New Parts
which are set up in the framing, be relieved or New replacement parts should be thoroughly
“normalized.” Normalizing consists of heating the cleaned and painted, as outlined previously under
areas of greatest tension with a torch.Hold the torch “Repainting.” In addition, hidden surfaces of panels
about 50 mm (2 in) from metal and move it over an should be cleaned and coated with one heavy coat
area of 75 to 100 mm (3 to 4 in) until the metal of sheet metal deadener.
barely begins to turn red. Cooling must be slow to
2B-6 CAB MAINTENANCE

STATIONARY GLASS
OUTSIDE REAR VIEW MIRROR WINDSHIELD GLASS
REPLACEMENT REPLACEMENT
Outside mirrors need little servicing. Any rattle or | Remove or Disconnect (Figure 3-7)
loosening of the mirrors can usually be stopped by
CAUTION: Always wear heavy gloves when
tightening the attaching fasteners.
handling glass to minimize the risk of injury.
| Remove or Disconnect (Figure 2)
1. Remove the windshield wiper (1) as described
1. Sash holder screws (1) later in CAB AND CHASSIS ELECTRICAL
2. Stay to spacer screws (2) (SEC.8).
3. Outside rear view mirror assembly (3) 2. Remove the three fixing bolts of ornament
4. Mirror head assembly (4) corner piece.
5, Upper mirror support assembly (5) 3. Ornament corner piece/ molding (2) (figure 3).
6. Mirror stay bracket (6)
7. Mirror stay (7)
2. Ornament Corner Piece/Molding
x Install or Connect (Figure 2)

. Mirror stay (7)

ernie

2. Mirror stay bracket (6)

3. Upper mirror support assembly (5)
4. Mirror head assembly (4)
5. Outside rear view mirror assembly (3)
6. Stay to spacer screws (2)
7. Sash holder screws (1)

1
4
1
t
|
i
!
'
i
' Figure 3. Ornament Corner piece / Molding
eee

'
'
! 4, Remove the ornament panel upper molding (8)
i with a bladed screwdriver from portion A
eee

t
i (figure 5).
i
ee

|
'
eee

4
1
ee

a
{
j
1
ew]

t
t
'
Pee

Figure 2. Rear View Mirror

 CAB MAINTENANCE 2B-7

1. Windshield wiper
2. Ornament Corner Piece/Molding
3. Ornament Panel Upper Moiding
4. Windshield Molding
5. Windshield Glass Finisher
6. Windshield Glass

Figure 4. Windshield Glass Replacement

Section a-a
Tow-sided adhesive tape
Molding
Windshield glass

~ Front panel

®
Ornament
panel

Front window finisher

Figure 5. Ornament Panel Upper Molding Figure 6. Windshield Glass Finisher

5. Remove the windshield molding (4) according to

the same procedure as 4. Don't reuse it.
6. Windshield glass finisher (5) (figure 6). Don't
reuse it.
 2B-8 CAB MAINTENANCE

7. Windshield glass (6) (figure 7).

» Pass the piano wire of 0.5mm or so to the
room inside through the adhesive portion of
the windshield glass. Windshield glass finisher
Bind both ends of this piano wire to the
square bar and cut the adhering portions in
the whole periphery of the glass moving it
back and forth inside and outside the room.
Remove the glass.

Fok
CAUTION: Completely remove the adhesive
remaining on the body flange and perform
cleaning. If there is any cobvex or concave
portion, this causes imperfect contact when
installing the glass, leading to cracks or water
leakage. To reuse the removed glass, perform the
same treatment on the adhering surface of the Figure 8. Windshield Glass Finisher Installation
glass side as well as the flange side. When the
glass is an adhesion type, take care not to 2. Windshield glass. Temporarily set the glass,
damage the glass stopper which must be reused. performe positioning marking so that the left/
if the painted surface of the body flange is right clearance A of the Section A-A may be
screatched, this will cause rust. Accordingly, uniform. Next, when the clearance B of the
repair it completely. section B-B, is equal to the clearance A of the
Section A-A, proceed to the installation step. At
this time, if the clearance B must be adjusted,
remove the ornament panel and adjust the
glass stopper (figure 9).
Piano wire

Windshield _
glass

“Room
Square bar inside

Figure 7. Windshield Glass Removal

Section®@ Section®-B)

[oe] Install or Connect (Figure 4, 8-14)

CAUTION: Always wear heavy gloves when

handling glass to minimize the risk of injury.

+ Before starting installation, be sure check the

fixing positions.
1. Windshield glass finiser. Be sure to use new Clearance@) 7
finisher. Set the deposit in the central lower Finisher
part. Insert the flange in the order of 1 to 6 as
shown in the figure. After setting, proceed to the
next step without peeling off the exfoliate paper
Figure 9. Windshield Glass installation
of two-sided adhesive tape (figure 8).
 CAB MAINTENANCE 2B-9

Mounting / Dismounting Procedure for

Ornament Panel
« First, remove the washer nozzle as described in Section a-
STEEL TILT CAB (SEC. 10D) of this manual, cut
off the two-sided adhesive tape fixing the
eZ72773
ornament panel with a cutter and remove it from Application
the front panel. At this time, don't bend the of primer
ornament panel over 90°. Take care not to
scratch the painted surface of the body panel. if it
is scratched, repair it completely to prevent rust.
When installing the ornament panel, completely Windshield glass
finisher
remove the two-sided adhesive tape remaining on
the ornament panel side and install the ornament
panel with a new two-sided adhesive tape (figure
10).
Figure 11. Windshield Glass Finisher
CAUTION: After removing the washer nozzle, take
2. Windshield molding (4).
care not to drop the washer tube to the inside of
* Adjust the rising portion of the upper end of
the front panel. After removing the ornament
the molding corner mold to the match mark of
panel, connect the nozzle to the tube and fix.
the glass ceramic painted portion and fit the
upper end (left/ right) and fix the both sides.
Be sure to use a new windshield molding
(figure 12).
Ornament
CAUTION: Before reusing the glass, completely
remove the residual adhesive and perform
cleaning.

Molding

Don't bend over 90°

Glass ‘
Match mark
Figure 10. Dismounting of Ornament Panel

When installing an adhesion type after removing Zu Glass Ceramic painted

portion
an adhesion type
—~ Molding

1. Windshield glass finisher (5).

« Be sure to use a new finisher.
+ Apply the primer to the ahole periphery of
portion A shown in figure 11. Figure 12. Windshield Molding

3. Windshield glass (6).

CAUTION: Check that there remains no adhesive * Apply the primer to the outer periphery on the
on the flange surface to which the primer is to be room side of the glass. Apply it over 20mm
applied. If the primer is applied on the residual (0.78in) from the end (figure 13).
adhesive, the contact of the adhesive for glass to
be applied later may be imperfect, resulting in CAUTION: Before reusing the glass, completely
cracks or water leakage. After applying the primer, remove the residual adhesive and perform
keep the status for three minutes or more. cleaning. If the primer Is applied on the residual
adhesive, the contact of the adhesive for glass to
Primer: PRIMER RC-50E for painting be applied later may be imperfect, leading to
manufacutured by the Yokohama Rubber Co., Ltd. cracks or water leakage. After applying the primer,
or equivalent. keep the status for three minutes or more.
2B-10 CAB MAINTENANCE

Primer: PRIMER MS-80 for both sides of glass 4. Ornament panel upper molding (3).
manufactured by the Yokohama Rubber Co., Ltd. 5. Ornament corner piece/ Molding (2).
or equivalent. « Be sure to use a new two-sided adhesive tape
for the moiding.
* After keeping the status for three minutes or more 6. install the front wiper (1) as described later in
after primer application, apply the adhesive. Apply STEEL TILT CAB (SEC. 10D).
it to the whole outer periphery and make a 30mm
(1.18in) lap allowance (figure 14). Caution after installation:
« As described before, fix the periphery by using a
Primer: ADHESIVE WS-90F for giass
gummed tape as an auxiliary means in the period
manufactured by the Yokohama Rubber Co., Ltd.
of 24 hours when the adhesive for the windshield
or equivalent.
glass is hardened.
* After installation, avoid driving vehicle for at least
CAUTION: Install the glass on the cab withon five
24 hours.
minutes after applying the adhesive. At this time,
After installation, open or close the door with the
peel off the exfoliate paper of the two-sided
side window glass or roof ventilator open. When
adhesive tape of the windshield glass finisher and
the door must be opened or closed inevitably in
set the glass by press accurately at the
the closed status, open it slowly without giving
installation position determined in the positioning
any vibration or shock to it.
procedure described on the previous page.
* Make a water leakage test.
Harden the adhesive at 20 - 30°C for 24 hours.
Press the periphery by using a gummed tape as
REAR WINDOW REPLACEMENT
an auxiliary means. Imperfect press fitting will
cause water leakage. [es] Remove or Disconnect

CAUTION: Always wear heavy gloves when

handling glass to minimize the risk of injury.

* {fa glass is cracked but still intact, it should be

Windshield glass crisscrossed with masking tape to reduce the risk
b
of injury and/or damage to the vehicle. If a crack
extends to the edge of the glass, mark the cab
with a piece of chalk at the point where the crack
b Saction b-b meets the weatherstrip. This will aid the
inspection later.
czzza Primer application 1. Weatherstrip seal by running a putty knife
20 mm
range or more between the flange and weatherstrip (inside and
outside the cab).
« Have an assistant outside the cab by the
window.
Figure 13. Primer Application Range 2. Weatherstrip and glass from the flange.
* Force the weatherstrip from the flange from
the inside with a putty knife.
3. Window.

Windshield glass
c Molding

7 Section c-c
Section d-d
Lap allowance
_ 30mm — 7mm
—, Adhesive
(74 application a
range = l2@mm“™/

Figure 14. Adhesive Application Range

 CAB MAINTENANCE 2B-11

foe] install or Connect

CAUTION: Always wear heavy gloves when

handling glass to minimize the risk of injury.

* To ease installation, the weatherstrip can be

heated with a non-flame source. At higher
temperatures, the weatherstrip is more pliable. Do
not heat above 52°C (125°F), or for more than 1-
1/2 hours.
* Avoid hitting the glass on anything that may chip
its edges.
Pressure on the glass will tend to concentrate at
the chipped areas, causing cracks. If the glass is
accidentally chipped, the edge should be ground
smooth.
1. Weatherstrip to the glass.
2.A 6mm (1/4 in) cord in the weatherstrip groove.
The ends should overlap about 15 cm (6 in) at Figure 15. Installing the Rear Window
the window bottom.
3. Window and weatherstrip on the flange from Polishing Procedure
outside the cab. 1. Mix at least 4 ml (1.5 oz) of cerium oxide with
- Brush soapy water on the flange. enough water to obtain a creamy consistency.
« Have an assistant pull the cord from inside the (If the mixture is too thick it will cake on the felt
cab to seat the lip of the weatherstrip on the pad more quickly. If it is too runny, more
flange (figure 15). polishing time will be needed.)
2. Draw a circle around the scratches on the
GLASS POLISHING opposite side of the glass with a marking
Minor Scratch and Abrasion Removal crayon, or equivalent (figure 16).
3, Draw a line directly behind the scratch(es) to
Minor scratches and abrasions can be removed
serve as a guide for locating the scratch while
or reduced by following the procedure outlined
polishing.
below. Precautions must be taken, however, to
4. Cover the surrounding area with masking paper
prevent distortions of vision; double vision may
to catch the drippings or spattered polish.
result if an attempt is made to remove deep
5. Dip the felt pad attached to the polisher into the
scratches. Deep scratches should not be removed
mixture. Do not submerge the pad or allow the
from an area in the driver’s line of vision; in such
pad to stay in the mixture as it may loosen the
cases, the glass should be replaced.
bond between the pad and the metal plate.
The procedure that follows was developed using
a cerium oxide compound. Follow manufacturer's
NOTICE: Never hold the tooi in one spot or
direction if other materials are used.
operate the tool on the glass any longer then
30 to 45 seconds. If the glass becomes hot to
Recommended Equipment
polisher. the touch, let it air cool before proceeding
1. A low speed (600-1300 rpm) rotary
mm (3 in) in further.
2. A wool, felt, rotary polishing pad 76
Cooling with coid water may crack heated
diameter and 51 mm (2 in) thick.
water. This glass. Avoid excessive pressure. It may cause
3. Powdered cerium oxide mixed with
overheating of the glass.
is the abrasive compound.
4. A wide-mouth container to hold the abrasive
6. Polish the scratched area, but note the
compound.
following:
a. Agitate the mixture as often as needed to
maintain the creamy consistency of the
compound.
b. Use moderate but steady pressure.
c. Hold the pad flat against the glass.
d. Use a feathering-out motion.
e. Dip the pad into the mixture every 15
2B-12 CAB MAINTENANCE

seconds to ensure that the wheel and the

glass are always wet during the polishing
operation. (A dry pad causes excessive heat
to develop.)
f. Keep the pad free of dirt and other foreign
substances.
7. After removing the scratch, wipe the area clean
of any poiish.
8. Clean the polishing pad.

1. Feather-Out
2. Guidelines

Figure 16. Scratch Removal Guidelines

MODEL AND SERIES DESIGNATION

PLATE REPLACEMENT
To remove a plate, carefully pry it off with a flat surface is clean and dry. Peel the paper off the
bladed tool. To install a plate, ensure that the door back of the plate and press the plate on the vehicle.
 SHEET METAL 2C-1

SECTION 2C

SHEET METAL
from which they were
NOTICE: When fasteners are removed, always reinstall them at the same location
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
PAGE
SUBJECT
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gene enenseeeegsse00 6008 2C-
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Bumper and Brackets Replacement ...........scsssccsssesesscscsstensseernecsonssseeraacsnnanenscantannnessenenenes 2
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INTRODUCTION
Sheet metal removal and installation is covered in covered in this section, refer to STEEL TILT CAB
this section. For related body information not (SEC. 10D) or CAB MAINTENANCE (SEC. 2B).

ON-VEHICLE SERVICE

GRILLE REPLACEMENT [oe] Install or Connect (Figure 1)

[9] Remove or Disconnect (Figure 1) +. Bumper brackets.

— Align marks made during removal.
1. Grille fixing screw.(1).
2. Grille (2). 2. Bolts securing bumper brackets to frame.
3. Bumper.
3. Fixing clips (3).
4. Bolts securing bumper to brackets.
foe] Install or Connect (Figure 1) 5. Splash guard.
6. Screws securing bumper splash guard.
1. Fixing clips (3).
2. Grille (2).
3. Grille fixing screw.(1).

BUMPER AND BRACKETS

REPLACEMENT
[+>] Remove or Disconnect (Figure 1)

1. Six screws securing bumper splash guard.

2. Splash guard (4).
3. Bolts securing bumper to bumper brackets.
4, Bumper (5).
5. Bolts securing bumper brackets to frame.
—- Mark the parts for ease of assembly later.
6. Bumper brackets.
2C-2 SHEET METAL

BATTERY BOX REPLACEMENT

[+s] Remove or Disconnect (Figure 2)
1. Cover.
2. Batteries. Refer to ENGINE ELECTRICAL
(SEC. 6D).
3. Bracket to frame bolts.
4, Box.

[oe] install or Connect (Figure 2)

1. Box to the frame rail.

2. Bracket bolts.
3. Batteries. Refer to ENGINE ELECTRICAL
(SEC. 6D).
4, Cover.

1. Grille fixing screw.(1).

2. Grille (2).
3. Fixing clips (3).
4. Splash Guard (4)
5. Bumper Assembly (5)

Figure 1.Grille and Bumper

2. Box
3. Spacer
4, Bracket

Figure 2. Battery Box

 SHEET METAL 2C-3

SHEET METAL REPAIR A heavy-bodied caulking material should be

used on all open joints that require sealer to
close a gap.
To help prevent rust, special anti-corrosion
materials are used on interior surfaces of metal
4. Applying Color
panels.
If areas such as underbody, hem flanges,
These materials include special metals such as
one-sided and two-sided galvanized, zincro-metal exposed joints and engine compartment need
color, follow conventional refinishing
and zinc-iron alloy steels. These specially treated
preparation, undercoat build-up, and color
metals are used in fenders, doors, quarter panels,
application procedures. Rubout and extensive
rocker panels, floor pans, and other critical areas.
sanding of the undercoats is not necessary.
Spray-on materials such as zinc-rich primers and
waxes are also applied to interior surfaces. These
5. Applying Deadeners
are mainly used in areas where moisture might
Use a heavy-bodied undercoat with a
gather. Sealers are applied along exposed joinis
rubberized or asphaltic base. Areas for
and moisture-repelling asphaltic sound deadeners
application can be determined by original
applied inside wheel wells and doors, and on some
production application.
underbody parts.
If, while repairing damaged areas these special
6. Applying Anti-Corrosion Material
treatments are disturbed, the metals may be left
Use a light-bodied material designed to
unprotected. This could lead to corrosion; therefore,
penetrate between close metal-to-metal
these surfaces should be recoated with service-
surfaces such as pinch weld joints, hem
type anti-corrosion materials.
flanges, and other attaching points where metal
Steps for applying anti-corrosion materials should
surfaces are difficult to coat with conventional
be:
materials.
41. Clean Up and Preparation
7. Conventional Undercoating
Depending on the location of the area,
Apply to large areas such as doors, hoods,
sandblasting, scraping, wire brushing,
fenders, etc. Do not spray material into door
sandpaper, and steel wool can be used to
remove residue. hardware such as locks, run channels, and
window reguiator.
2. Applying Primer Coats
On the underbody the material should not be
All bare metal must be primed with an acrylic
chromate material. applied to any moving or rotating parts.
After undercoating, ensure that all body drain
holes are open.
3. Applying Sealers
All flanged joints, overlap joints, and seams
For more information on sheet metal repair, refer
should be sealed with a medium-bodied sealer
to “Cab Repairs,” in Section 2B of this manual.
which stays flexible and is paintable.
 FRONT END ALIGNMENT 3A-1

SECTION 3

STEERING, SUSPENSION, WHEELS AND TIRES

CONTENTS

SUBJECT PAGE
3A
Front End Alignment..........:csseceseeee: sausersenseseesnesasarancesseuuneeaueronsecununssonennesaiaanesies poe assnansersausanauensaensaasecornpentantens
3Bi
Steering LINKAGE! ........scsscssessssnneecstsenetsnsesscessavecsneensesrnsessateenenrasceanensnesenseransranennangnassnaanensseeaaazanneausrenseensressessnens4s
3B3
Power Steering .....sesssccosssecsssssssssosccessneesscssensersessnseatanssasenannsnenssanansersennetaenaassatanenatsacsassasnsanensananacennanaeaneasonsssenyetes
3B4
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3c
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3D
Rear SUSPENSION .........-ssssssssserscsessonsecssessessseusenenanessssccenneennanansararsnnsoneessaananeanasseranseconaconasencansanananaaarenenseansnensse4s
3E
Wheels and Tires......scccsssesececssssecessssssssssssssnentnronseensesisnsersunnevacscnesansenensonnrauaneaucusensauausuaeneacrasorscanasaunaseneanecquaasann®

SECTION 3A

FRONT END ALIGNMENT

which they were
NOTICE: When fasteners are removed, always reinstall them at the same location from If
needs to be replaced, use the correct part number fastener for that application.
removed. if a fastener
strength (or stronger) may be
the correct part number fastener is not available, a fastener of equal size and
d will be called out. The
used. Fasteners that are not reused, and those requiring thread locking compoun
it. If the above conditions are not
correct torque value must be used when installing fasteners that require
followed, parts or system damage could result.

CONTENTS
PAGE
SUBFECT
atte ate eee eee gs 3A-2
Description ....sscssesscsssssssssssssssssessssescesenessstensueesssnncensnnstessusenaanstnennssnnnssseeanasengessneanssnenensaeeneseeenssens 3A-2
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Checking and Correcting TOe-In ......--ssssssssssesnesessssseeceneeessasncunnsscesnsenssanenseasanrnnaensnseaesssa 3A-4
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Checking and Correcting Camber.......-..ssscsecsscrsterienneennenserannecsenentennunnien sestearensaarencensentens erecta 3A-5
Checking and Correcting Caster .........-.:sscsssssessssssesescenteessssaneenensnneusennastscnnanstanananensensnanessensesntass 3A-6
Checking and Correcting Kingpin INCLINATION .....0.-ccsccessssscscescesecesssereneesssencereneneuserssasaensraconenstsenensnneroncenas
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3A-2 FRONT END ALIGNMENT

DESCRIPTION

Alignment is the proper positioning or state of outlined in this section should be followed carefully,
adjustment of parts in relation to each other. as well as instructions covering related units such
Proper alignment of front wheels must be as brakes, springs, steering gear, hubs and
maintained to ensure efficient steering and bearings, and wheels and tires, which are given in
satisfactory tire life. The most important factors of other sections of this manual. The front end
front end alignment are wheel toe-in, whee! alignment chart (figure 1) indicates the points at
camber, and axle caster. Kingpin inclination is which the alignment dimensions are taken.
designed into the axle end. Front end alignment All alignment checking should be done with
should be checked at requiar intervals, and precision equipment and instruments. Refer to
particularly after the front axle has been subjected “Specifications” at the end of this section.
to heavy impacts such as a collision or a hard curb
impact. Before checking alignment, the wheel DEFINITION OF TERMS
bearings must be properly adjusted, since loose
wheel bearings will affect the instrument readings Wheel Toe-In
when checking the whee! toe in, wheel camber, and The distance between the front wheels is less at
axie caster. the front than at the rear of the axle (E and F, figure
When checking the alignment, the instructions 1}.

Vertical G Caster Angle

~ Kingpin
~\

yi
Front Axle Caster

- “)
|
Tr

Kingpin Inclination

ene e enwee Camber(inches )

bees Camber (Degrees Positive)
.... Kingpin Inclination (Degrees)
vente eae ..... 1oe-in (Inches)

neces Caster (Degrees Positive)

beens Kingpin inclination (inches)

Refer to “Specifications” for correct dimensions.

Figure t. Front End Alignment Chart

 FRONT END ALIGNMENT 3A-3

Wheel Camber FRONT AXLE AND SUSPENSION (SEC. 3C) for U-

bolt torque specifications. Generally, if the axle is
Camber (A, figure 1) is the amount in inches or twisted, the caster will be unequal for the right and
degrees the top of the front wheels are tilted left side.
outward or inward from the vertical position (C,
figure 1). Camber offsets wheel deflection, due to Kingpin Inclination
wear of front axle parts, and prevents a reverse or
Kingpin inclination is designed into the axle end
negative camber condition. A reverse or negative
and is the amount that the top of the kingpin is
camber is an inward inclination of wheels at the top.
inclined toward center of vehicle. Kingpin(s) are
If camber is extreme or unequal between the
inclined (D, figure 1) to assist front wheel return to
wheels, improper steering and excessive tire wear
center after a turn is completed.
will result.

Front Axle Caster Frame Angle

The front axle caster is defined as the kingpin The caster, camber, and toe-in dimensions are for
inclination from the vertical plane in the fore and aft vehicle at design load (with frame level). If frame is
not level on alignment equipment, the frame angle
direction of the vehicle (G, figure 1}. Incorrect
must be considered.
caster may result from sagging springs, bent axle,
This is especially important when making a caster
twisted axle, or uneven tightening of spring U-bolt
angle check to obtain a true setting.
nuts. Tighten all U-bolt nuts equally. Refer to

DIAGNOSIS

PROBLEM POSSIBLE CAUSE CORRECTION

Noisy Front End 1. Loose tie rod ends. 1. Replace ends.

2. Lack of proper Lubrication. 2. Refer to MAINTENANCE AND
LUBRICATION (SEC. 0B).
3. Loose shock absorber mounts. 3 Refer to Diagnosis of Shock
Absorbers (SEC. 3C).
4, Broken spring leaf. 4. Replace spring leaf.
5. Loose U-bolts or spring clips. 5. Tighten.

Wheel Bounce 1. Unbalanced wheels or tires. 1. Refer to WHEELS AND TIRES

(SEC. 3E).
2, Unequal tire pressure. 2. Refer to WHEELS AND TIRES
(SEC 3E).
3. Weak or broken front spring. 3. Replace
4, Excessive wheel or tire runout. 4. Refer to WHEELS AND TIRES
(SEC. 3E).
5. Worn shock absorbers. 5. Refer to Diagnosis of Shock
Absorbers (SEC. 3C).

1. incorrect wheel alignment. . Align wheels.

Excessive Tire Wear
ah

2. Failure to rotate tires. 2. Refer to WHEELS AND TIRES

(SEC. 3E).
3. Improper tire inflation. 3. Refer to WHEELS AND TIRES
(SEC. 3E).
4. Overloaded or improperly loaded. 4. Avoid overloading vehicle.
 3A-4 FRONT END ALIGNMENT

ON-VEHICLE SERVICE

For proper assembiy torques of various

components, refer to “Specifications” in STEERING
LINKAGE (SEC. 3B1) or FRONT AXLE AND
SUSPENSION (SEC. 3C) in this manual.
Before checking the front end alignment, the
following front end inspection should always be
made:

inspect

1. Tires for proper inflation pressure. Note that the

rim-to-floor height should be the same at each 1. Tie Rod
wheel. 2. Nut
2. Wheel installation and runout.
3. Wheel bearing alignment.
Figure 2. Toe-In Adjusting Location
4. Steering tie rod and drag link ends for
Looseness. CHECKING AND CORRECTING
5. Kingpins for looseness. CAMBER
CHECKING AND CORRECTING Camber variations may be caused by wear at
TOE-IN wheel bearings and steering knuckle bushings, or
by a bent steering knuckle or axle center. Camber
Incorrect toe-in results in excessive tire wear specifications are listed at the end of this section.
caused by side slippage and also unstable steering 1. Before checking the camber, inspect for
with a tendency to wander. kingpins as follows:
Toe-in may be measured from the center of the a. Jack up the front of the vehicle, pull the
tire treads or from the inside of the tires. Measure bottom of the wheel outward, and take a
at both the front and rear of the axie (E and F, camber reading. Then pull the top of the
figure 1). Note that the toe-in measurements must wheel outward and take a camber reading. If
be made at the horizontal axis of the wheel. the readings vary more than 15 minutes,
When seiting the toe-in adjustment, the front make the following adjustments:
suspension must be neutralized; that is, all b. Adjust the wheel bearings as directed in
component parts must be in the same relative FRONT AXLE AND SUSPENSION (SEC.
position when making the adjustment as they will 3G), then take the center readings as shown
be when in operation. To neutralize the suspension, on “Front End Alignment Chart’ (figure 1).
the vehicle must be rolled forward 3.5 to 4.5 meters c. Remove the front hub cap.
(12 to 15 ft). By rolling the vehicle forward, all Install camber, caster, and kingpin
tolerances in the front suspension are taken up and inclination gage on end of the knuckle
the suspension is then in normal operating position. spindle horizontally (figure 3).
Neutralizing the front suspension is extremely When removing the hub cap, take care so
important, especially if the vehicle has been jacked as not to cause damage to the gage fitting
up in order to mark the tires; otherwise, the front tace at the end of the spindle.
wheels will not return to the normal operating if end of the spindle has been scratched or
position due to the tires gripping the floor surface damaged, correct before setting the gage.
when the vehicle is lowered on the jack. Reading of the camber scaie directly
Toe-in is corrected by loosening the nut at the tie indicates the camber angie.
rod ends, then turning the tie rod with a wrench or If the readings still vary over 15 minutes,
tool that will not damage the tie rod, until wheels replace the steering knuckle bushings and
have proper toe-in (figure 2). Right- and left-hand kingpins as instructed in FRONT AXLE AND
threads are provided to facilitate toe-in adjustment. SUSPENSION (SEC. 3C).
d. Check the wheel runout as instructed in
WHEELS AND TIRES (SEC. 3E). If the
runout is excessive, straighten or replace
the wheel.
2. Place the vehicie on a level surface, with the
 FRONT END ALIGNMENT 3A-5

normal weight of the vehicle on the wheels, then frame angle means the frame is high (above
take the final camber reading. If a camber gage level) in the rear. Positive frame angle is when
is not available, the readings can be taken as the frame is low (below level) in the rear.
shown on the “Front End Alignment Chart” in 3. Determine the caster angle for the right wheel
figure 1. Place the square as shown and using the alignment equipment.
measure distances A and B. B SHOULD 4. Calibrate the scale of the turning radius gage to
EXCEED A. zero and turn the steering wheel clockwise
Camber dimensions of the right wheel should (counterclockwise for checking caster angle and
not vary over 2.4 mm (3/32 in) from camber kingpin inclination on the left side front wheel)
dimensions of the left wheel. If the final camber until the front wheels are steered 20 degrees
reading is incorrect, either the steering knuckle from the straight-ahead position (figure 5).
or the axle is bent. Turning the steering wheel with the brake
3. To determine which part is bent, check the pedal depressed and using a brake pedal
kingpin inclination (D, figure 1). Camber plus pusher will produce a more accurate reading.
kingpin inclination is the included angle of
steering knuckle. If the kingpin inclination angle
is to specification and the included angle or the
camber angle is out of specification, then the
knuckle (spindle) must be replaced. Excessive
positive camber results in irregular wear of tires
at the outer shoulder. Negative or reverse
camber causes wear at the inner shoulder.
Ease of steering is affected by any incorrect
camber setting.

A. Inclinometer
B. Typical Negative Frame Angle “FA”
C. Level Line

Figure 4. Checking the Frame Angle

1. Camber Angle

Figure 3. Checking Camber Angle-Typical

CHECKING AND CORRECTING CASTER

Models covered by this manual use shims for
adjustment purposes.
Caster dimensions are for a vehicle carrying its
design load. Design load is the load equal to the
capacity of the vehicle’s suspension, whereby the 1. Kingpin Inclination
frame in most cases would be level. If an alignment 2. Caster Angle
check is to be made with the frame NOT LEVEL,
the frame angle (figure 4) must be determined and Figure 5. Caster Angle Measurement - Typical
added to the caster angle to obtain a true caster
reading. To determine frame angle proceed as 5. When the front wheels are turned 20 degrees,
follows: calibrate the caster and kingpin scales to zero
1. Position the vehicle on a smooth level surface. by turning the camber, caster, and kingpin gage
2. Using inclinometer, measure the frame angle adjuster.
(FA) (figure 4). Frame angle is the degree of tilt 6. Add the frame angle (FA) found in step 2 to the
in the frame from the level position. Negative left wheel caster reading found in step 3 to
 3A-6 FRONT END ALIGNMENT

determine the corrected caster for right wheel. “Specifications” at the end of this section for
To determine corrected caster with various proper readings.
frame and caster readings, the following rules If adjustment is needed, adjust the stop screws in
apply: or out as needed (figure 7). Then tighten the jam
a. Negative frame angle must be added to nut.
positive caster reading.
b. Positive frame angle must be subtracted
from negative caster reading.
c. Negative frame angle must be subtracted
from negative caster reading.
d. Positive frame angle must be added to
negative caster reading.
Example: The vehicle wheel caster reading
of 30 minutes positive, and the frame angle
is negative (high in the rear) 10 minutes.
The positive caster reading is added to the
negative frame angle, giving a 40 minute
positive reading as the corrected caster for A. Inner Wheel Maximum Turn Angle
that wheel. B. Outer Wheel Maximum Turn Angle
Referring to “Specifications,” we find that 40
minutes positive caster is within the Figure 6. Stop Screw Adjustment - Definition of
Terms
specified setting.
7. Turn the steering wheel in the opposite direction
until the front wheels are steered 20 degrees in
the opposite direction for determining left wheel
caster. Reading of the caster and kingpin scales
directly indicates the caster and kingpin
inclination angles being checked.
If the caster is not within specifications, caster
can be corrected by installing proper caster shims
between the axle and spring.

CHECKING AND CORRECTING

KINGPIN INCLINATION
A. Stop Screw
Precision instruments must be used to check
kingpin inclination when axte is installed in the Figure 7. Stop Screw
vehicle.
Kingpin inclination is built into the axle. Incorrect
readings indicate a bent or damaged axle. lf the
axle is bent or twisted, refer to FRONT AXLE AND
SUSPENSION (SEC. 3C) in this manual for
corrective information. Straightening the axle to
correct kingpin inclination will also change camber.
Recheck camber after correcting kingpin inclination.

TURNING ANGLE MEASUREMENT

AND ADJUSTMENT

1. Place the front wheels on turning radius gages,

with the front wheels in the straight-ahead
position.
2. Set the gages to zero.
3. Turn the steering wheel ail the way to lock in
both directions, measuring the turning angle of
the front wheels.
4. Refer to figure 6 for definition of terms. Refer to
 FRONT END ALIGNMENT 3A-7

SPECIFICATIONS

FRONT END ALIGNMENT SETTINGS

TOMI ooccseccsesscsecccsssceneccensnsuseeeenescenesousespsensaursorcauseseannessuanevaneneeesseaneesienenanseayas
CAMDES ......ccccccccceccecccosccesseseseesecessesssosesseacnssosseoesarcorsssencenseetenstieesacednsusauscaveusveaisseaaneseesasenesanseceensussansnseneeseeed —30' to 1°
CASHEL oie entcccescesresecceesesseseesconsnecsenenenseesseessseauecaenaresaaraaies 1°45’ to 3°45’ (positive)
Kingpin Inclination (MAXIMUM) . . . . . s c e c e c e s e s e n e e e s e s e c s e n e n e r t e n e n s e c a t o n s tscs e nsas s vaneneasenansasesenensensan enaes 11°45’ (positive)
Turning Angle (MaxiMUm)...........ccc cceesesseeenetenenreene nsccnenseensersensnenss sesessenenenserseneansa neneneeussesaaannnseas inner Wheel 43°
Outer Wheel 33°
MEMO
 STEERING LINKAGE 3B1-1

SECTION 3B1

STEERING LINKAGE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE

DeSCription. ........:.ssesessessscrenerssecssnmessetsssseestenuaconseanenssasuenenssessnnseaeesassnecasenenensseaesuousaneasranmeasauaanuevareneastacasaentas 3B1- 1

Diagnosis of Steering Linkage ...........ccsscsesnesssueacsienssesseersinsessrseneetssnennensseaenntossenanagtunnauetaneressansonasaeanes 3B1- 1
Steering Linkage On-Vehicle Service. .........csessercersesessensiscsseensenensestenssenscsentanssaesessaseneaenensunaroveatecoranenees 3Bi- 2
Maintenance ........scccccsersssssconeuseonssecccanasesnerenconseneeunenseuserseesnecsaccassuseseseoaamenseessanenseanseusseoasanunssuanenneestassaneanas 3B1- 2
Pitman Arm Replacement ........ccsesasssecsssssssecensencersseeesssasssesenssssssnesanssonseanenenntonsentensersensnaraeaatoasaeanensnans 3Bi- 2
Drag Link Replacement ........cccsssenssecersnesnsnensssauessneenserenesesasnsnnvaraanengs sneneetenavanensuesanasmnenesarsaneusunsoutnensazeasss 3Bi- 3
Tie Rod Replacement .........cscsscsssssecssssescsnsensseneanaesneessennenennesnsessuasveunanssensseersnessacisneseaensarseeninensanenseseonaanzans 3Bi- 4
Steering Arm Replacement......csscscssssocusseneerseesessuaeensonsnsarsssicinersnensenssseesancernecaesanenstasensnennensaaveneonansonseas 3Bi- 5
Specifications... sssecsessssnsssscsssesseeeneeanssseecsmnsseananensacansaesonsessssessensssenseatsnentensseareennerseceatensenerasaeateasnunacensae 3B1- 7
Fastener TOrqQues.....cccsccosssscscrssrseensnsastecsessaesenianennesearnsnensnensanscoeras paveuarsuanennecseousdsansanensseersooseusuaussesaonenenes 3B1- 7
Special TOONS... ccssssessessessnsssesssesseeseesesnssnssesnensnsennseasunnssnnansasenernssvanssensnneneeneansnmeaesmvecsncumeanseauarencnacenssan sess 3B1- 7

DESCRIPTION

The steering linkage consists of the pitman arm tube, and are locked by two nuts. The tie rod ends
drag link, steering arms, and tie rod. are replaced as a unit.
The pitman arm is attached to the steering gear The overall condition of the steering linkage
with a nut and spring washer. affects steering performance. If parts are bent,
The drag link connects the pitman arm and left damaged, worn, or poorly lubricated, improper and
steering arm. It is not adjustable for length. The possibly dangerous steering action will result.
drag link cannot be overhauled. Whenever any steering linkage components are
The left steering arm, which is located on the left repaired or replaced, it is recommended that
side, bolts directly to the steering knuckle. The steering geometry and front end alignment be
steering arms are a taper fit in the knuckles, and checked as described in FRONT END ALIGNMENT
each is retained by a single nut. (SEC. 3A) of this manual.
The tie rod connects the left and right steering
arms. The tie rod ends are threaded into the tie rod

DIAGNOSIS OF STEERING LINKAGE

Refer to POWER STEERING (SEC. 3B3) in this

manual.
3B1-2 STEERING LINKAGE

STEERING LINKAGE ON-VEHICLE SERVICE

MAINTENANCE PITMAN ARM REPLACEMENT

The following service should be performed at | Remove or Disconnect (Figures 1, 2 and 3)

regular intervals, as specified in MAINTENANCE Tools Required:
AND LUBRICATION (SEC. 0B) in this manual. oars mequired:
1. Check the pitman arm nut for tightness. J-26813-B Steering Linkage Puller, or
2. Lubricate the steering linkage with chassis equivalent.
. . .
lubricant as specified in MAINTENANCE AND J-35707 Drag Link Remover or equivalent
. Cotter pin (6 ).
LUBRICATION (SEC. 0B) in this manual.

mh
. Inspect for any loose, missing or damaged 2. Loosen nut (7).
parts. 3. Drag link (5) from the pitman arm (2), using J-
Check for deteriorated drag link or tie rod end 35707 tool or equivalent (figure 2).
4. Nut (4) and split washer (3).
seals, loose fasteners, etc.
. If excessive looseness is found in the steering -- Mark the pitman arm (2) and sector shaft
linkage, investigate the cause. Replace any {1}, so the pitman arm can be returned to its
questionable parts. original position at assembly (figure 3).
5. Damaged or broken steering linkage 5, Pitman arm (2), using J-26813-B tool, or
components must always be replaced. Never equivalent (figure 4).
attempt to repair these parts by welding.

. Sector Shaft
=

. Pitman Arm
RwWrhy

. Split Washer
Nut
. Drag Link
CONAN

. Cotter Pin
Nut
. Cotter Pin
. Nut

Figure 1. Drag Link and Related Parts

 STEERING LINKAGE 3B1-3

J-35707 or Equivalent | install or Connect (Figure 1)

1. Pitman arm (2) to the sector shaft (1). Align the

marks made during removal.
2. Split washer (3) and nut (4)

NOTICE: See “NOTICE” on page 381-1 of this

section.

FR] Tighten

> Nut (4) to 294 N-m (217 lb-ft)

3. Drag link (5) to the pitman arm (2).

[2] Tighten
« Nut (7) to 167 N-m (123 tb-ft)
Figure 2. Removing Drag Link
5. A new cotter pin (6) of the correct size.

DRAG LINK REPLACEMENT

[+>] Remove or Disconnect (Figure 1)

Tool Required:
J-35707 Drag Link Remover or equivalent
1. Cotter pin (6 and 8).
2. Loosen nut.
3. Drag link (5) from the pitman arm (2) and
steering arm, using J-35707 tool or equivalent
(figure 2).

Inspect (Figure 1)

— Drag link end boot for damage, grease leak, etc.

A. Punch Marks -—- Drag link (5) for bending or damage.

Figure 3. Marking Pitman Arm fe] Install or Connect (Figure 1)

1. Drag link (5) to the pitman arm (2) and steering

arm.

fA] Tighten

« Nut (7) and (9) to 167 N-m (123 Ib-ft)

2. New cotter pins (6 and 8) of the correct size.

B. J-26813-B or Equivalent
2. Pitman Arm

Figure 4. Removing Pitman Arm

 3B1-4 STEERING LINKAGE

TIE ROD REPLACEMENT

[+] Remove or Disconnect (Figures 5 and 6)

Tool Required:
J-24319-01 Tie Rod Remover, or
equivalent.
1. Cotter pin (4) and nut (5).
2. Tie rod assembly from the lower steering arm
(2). Use suitable tie rod end tool.

[$] Disassemble (Figure 5)

1. Jam nuts (10).

2. Tie rod ends (7). Count the number of turns
needed to remove the tie rod ends.

Inspect (Figure 5)

1. Tie rod tube (9) for bending, or damaged

threads. . Nut
2. Seals (6) for deterioration or damage.
NOOhoan=
. Steering Arm
3. Threads on tie rod ends (7) for stripping or . Knuckie
damage. . Cotter Pin
Nut 9. Tie Rod
Assemble (Figure 5) . Seal 10. Jam nut
. Tie Rod End 11. Axle
1. Apply grease to the tie rod tube (9) threads (if
the tie rod ends (7) were removed).
Figure 5. Tie Rod and Reiated Parts.
2. Tie rod ends (7) to the rod tube (9) (if removed).
3. Screw on the tie rod assembly (9) the same
number of turns as when removed.

fre] install or Connect (Figure 5)

1. Tie rod assembly to the lower steering arms (2).

2. New nuts (5).

NOTICE: See “NOTIGE” on page 3B 1-1 of this

section.

[RJ Tighten

* Nuts (5) to 108 N-m (80 Ib-ft), then install the

cotter pins.

Adjust
* Toe in Refer to FRONT END ALIGNMENT
(SEC. 3A) in this manual.

fA] Tighten
* Nuts (10) to 113 N-m (83 lb-ft).

1. J-24319-01 or Equivalent
2. Tie Rod
3. Steering Arm

Figure 6. Removing Tie Rod End

 STEERING LINKAGE 3B1-5

STEERING ARM REPLACEMENT fos Install or Connect (Figure 7)

Left Steering Arm NOTICE: See “NOTICE” on page 3B1-1 of this

section for steps 2 and 4.
| Remove or Disconnect (Figures 6 and 7)
1. Right steering arm (4) to the steering knuckle
1. Drag link, as outlined previously in this section.
(6).
2. Tie rod, cotter pin (11) and nut (9). Remove left
2. Nut (8).
end of tie rod assembly from left steering
knuckle. Use removal tool, if necessary, and Tighten
discard.
3. Nut (7). « Nut (8) to 441 N-m (326 Ib-ft).
4. Left steering arm (3) from knuckle (5).
. Tie rod end assembly to the right steering arm

“3
Inspect (4).
4, Seal (14) and nut (10).
Steering arm (3) for damage.
Tighten
| Install or Connect (Figure 7)
* Nut (10) to 108 N-m (80 lb-ft). Install cotter
NOTICE: For steps 1 and 3, see “NOTICE” on
pin.
page 3B1-1 of this section.
Adjust
1. Left steering arm (3) and nut (7) to knuckle(5).
« Toe in. Refer to FRONT END
[J Tighten ALIGNMENT(SEC.3A) in this manual.
¢ Nut (7). Torque to 441 N-m (326 Ib-ft).

2. Instail tie rod end (15) and seal (13) onto steering
arm.
3. Install nut (9).

fQ] Tighten
« Nut (9) to108 N-m (80 lb-ft). Install cotter pin.

4. Drag link, as outlined previously in this section.

Right Steering arm

| Remove or Disconnect (Figures 6 and 7)

Tool Required:
J-24319-01 Steering Linkage Puller, or
equivalent.
1. Cotter pin (12) and nut (10).
2. Tire rod end (16) from the right steering arm (4).
Use tool J-24319-01, or equivalent (figure 7).
3. Nut (8).
4. Right steering arm (4).
a. Tap on the threaded end of the steering arm
with a hammer until it is loose.
b. Remove the nut (8) and discard.
c. Remove the steering arm.

Inspect
« Steering arm (4) for damage.
3B1-6 STEERING LINKAGE

1. Axle 9. Left Tie Rod End Nut

2. Tie Rod 10. Right Tie Rod End Nut
3. Left Steering Arm 11. Cotter Pin
4. Right Steering Arm 12. Cotter Pin
5. Left Steering Knuckle (Spindie) 13. Seal
6. Right Steering Knuckle (Spindle) 14. Seal
7. Left Steering Arm Nut 15. Left Tie Rod End
8. Right Steering Arm Nut 16. Right Tie Rod End

Figure 7. Steering Arms and Related Parts

 STEERING LINKAGE 3B1-7

SPECIFICATIONS

FASTENER TORQUES

Pitman Arm Nubia... ccc ccccceccccseeancsscenereensceeeeaneeeaeteseuseusessaauecauaesnsesseneeeenenesneenssenamneaeneeeres 294 N-m (217 lb-ft)

Drag Link Nut... ceccscscsssssssenscesescseseseeenescacescentesecesenientanseneasniecsiessisensearasinesnassseeeaaes 167 N-m (123 lb-ft)
Tie Rod Tube Jam Nuts ..............0:::cccccseeseeceresssececenumncaenmsaueumeaeeeseeceeunesuessaeeeuagenenegeneesaerees 113 N-m ( 83 Ib-ft)
Tie Rod End Nuts................ccccccesccesenensseeseccescnseacneesenonecneeneaaeaneeeusauacauaracasesaeaameanaumeeaasaaaunnas 108 N-m ( 80 lb-ft)
Steering Arm Nuts... ee ccccseeceseeetesesecesseecnsesneesernescerenesenieeteestinecsasasseusneaaseeempesecieenenaens 441 N-m (326 Ib-ft)

SPECIAL TOOLS

TOOL NO.
ILLUSTRATION TOOL NAME

KRG J-26813-B
A y Pitman Arm Puller

J-24319-01
Tie Rod Remover

J-35707
Drag Link Remover
MEMO
 POWER STEERING 3B3-1

SECTION 3B3

POWER STEERING
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

De@SCTIPTION ........csccsseeeesesesestsenssesesnersensercesmnenenenetansuuseneunuesunarsusuvansessuserersnnsaennentents casnanenssteasaaedenseessananevanesoons 3B3- 1

Diagnosis of Power Steering SyStem ..........:cecesscssssnssestsueseenenencssnnentannerssarenessesesannsnnnnraeneatsansageausasane® 3B3- 2
Power Steering System TeSt........csscssssnessssssscssssunenresrenesesenseneesonedansenecuusenmismsnedensoatersivennunsnennesuoessies 3B3- 6
Power Steering System On-Vehicle Service ............... auneueenoesonseseceasunsevavonnouaeanuanevsuees ceceeedenesavnaeearuasaceesens 3B3- 7
Maintemannce ...........:.0::ccsecssssssscscensseanessansecseeeserensenssdususcunassecuasnveuasuaneamenstonseessensameseeaserentanessanenpensegecnaeenaey 3B3- 7
Power Steering Fluid and Filter Service ............:scsescscssneeenenetssnseneesusinensnsaessscenneatesgeasaneaunantrousasneneasees 3B3- 7
Steering Gear Replacement.............scccsscsseesssesennesmeitecanerenutenssseraneusennsnantanngen stsecgensaassntsavsuaseusuusouensass 3B3- 8
Steering Gear AdjUStMEN ..........csscsecesseeceereneenseceereeensesisnnncssarentsunnensseecenvauanassnentansnenssesessusunuenennaeeaens 3B3- 9
Hydraulic Pump Replacement ...........cccscssssssssesessneemnsernssussensensncensscensenennesanenananansoussennessaananniananetaeasens 3B3- 9
Tandem Hydraulic Pump Assembly Replacement ..........cscssseseenernssseserseneernensanenersennennnenaennanteases 3B3-10
Bleeding the Hydraulic System .........ccsssseseseerssesessseessterarsensetanenersentauenerensvenstsssussnenssunnsneesenseaceeaanongas 3B3-11
Hydraulic System FIUSHING...........-ccrcrenccsseserreneensnenessnsenseenseseenen evseeuutecenseoussersuusaveeeunuscpuseessevensuenenass 3B3-11
Power Steering Gear Unit Repair ........cccccssesssesssssesorsseersneenerenssninreesnsacnantsnsneroeaneuseruneessnnosauannesnnanvanseeneases 3B3-12
Removal of Major Sub-assemblies From Power Steering Gear Ut «0... eceescoeesteesnecscaeseeseanersaranenssae 3B3-13
Cleaning, Inspection and Repair ............ssccesessesssiseensneresrssesscnenanesnenensenentensasenensnennersnaneaesenrenensenensnansens 3B3-15
Assembling Major Sub-assemblies into Power Steering Gear Unit..........:cssenereesessssesssneees — 3B3-17
Hydraulic Pump Unit Repair ........ssccccssecsereereeeennusensonssnseranenenncsnsscsnenneesssesanssanraesanenneresaneeteasaneannaceanaanes 3B3-18
Tandem Hydraulic Pump Unit Repair..........cscscsecsecsnesiecseneennerseusacsunsorssesrnsnseersnnssnacensanenesensnssensaeatanennuens 3B3-21
Specifications...........eeceseesesessersessereeeseessannneasansaersesssnenensensennstenenceans saeeeneeouseeseonssaduensaeusansanevonssesennaseasese 3B3-25
tenes 3B3-25
Fastener TOrques. ........--sssesssssssesssussssesnensesesnsconsesseteensneeceeanserssucausanseseusseaeonsnnanensanennnansuarsureaenananansena
Special TOOIS..........csccsseccsscsesesrnessensesserensenevtaueenssscasssavanenenessnansennnansneteaceraseaneasaeacassavansnscnets sevvonsuenesneatsueaeees 3B3-25

DESCRIPTION

Vehicles covered by this manual are equipped A vane-type hydraulic pump with remote reservoir
with power steering as standard equipment. is used. The hydraulic pump is gear driven.
An integral steering gear is used. In an integral The power steering fluid reservoir is equipped
steering gear, the power cylinder and control valve with a screen and fluid filter to help keep the
are integrated into the steering gear. No separate system fluid clean.
power cylinder is necessary.
3B3-2 POWER STEERING

DIAGNOSIS OF POWER STEERING SYSTEM

PROBLEM POSSIBLE CAUSE CORRECTION

Objectionable “Hiss” Noisy relief vaive. There is some noise Do not replace valve unless “hiss” is
in all power steering systems. One of extremely objectionable. A
the most common is a hissing sound replacement valve will also exhibit
most evident at standstill parking. slight noise and is not always a cure
Hiss is a high frequency noise similar to for the objection.
that experienced while slowly closing a
water tap. The noise is present in every
valve and results from high-velocity
fluid passing through valve orifice
edges. There is no relationship
between this noise and performance of
the steering. “Hiss”
may be experienced when the steering
wheel is at the end of travel or when
slowly turning at standstill.

Rattle or Chuckle Noise in 1. Gear loose on frame. 1. Check gear mounting. Torque
Steering Gear bolts to specifications.
2. Steering linkage looseness. 2, Check linkage pivot points for
wear. Replace if necessary.
3. Pressure hose touching other parts 3. Adjust hose position. Do not
of truck. bend tubing by hand.
4, Loose pitman shaft over center 4. Adjust.
adjustment. A slight rattle may
occur on turns because of
increased clearance off the “high
point.” This is normal and clearance
must not be reduced below
specified limits to eliminate this
slight rattie.
5. Loose pitman arm. 5. Torque pitman arm nut.

Groan Noise in Steering Low oil level. Fill reservoir to proper level.
os

—_

Pump 2. Air in the oil. Poor pressure hose 2. Torque connector. Bleed system.
connection,

Rattle or Knock Noise in Loose pump gear nut. Torque nut.

Steering Pump

Rattle Noise in Steering 1. Vanes not installed properly. 1. Install properly.

Pump 2. Vanes sticking in rotor slots. 2. Repair or replace.

Swish Noise in Steering Defective flow control valve. Repair or replace.

Pump

Whine Noise in Steering Pump shaft bearing scored. Replace housing and shaft.
Pump Flush and bleed system.

Growl Noise in Steering Excessive back pressure in hoses ar Locate restriction and correct.
Pump steering gear caused by restriction. Replace part if necessary.
 POWER STEERING 3B3-3

DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Growl Noise in Steering . Scored pressure plates, thrust plate . Replace parts and flush system.
Pump (Particularly or rotor.
Noticeable at Standstill . Extreme wear of cam ring. . Replace parts.
Parking)

Excessive Play or . Front wheel bearings loosely . Adjust bearings or replace with
Looseness in Steering adjusted. new parts as necessary.
System (Steering . Worn coupling or steering shaft . Replace.
Wanders) U-joints.
. Steering wheel loose on shaft, . Torque to proper specifications.
joose pitman arm, tie rods,
steering arms, or steering linkage
ball studs.
. Steering gear worm bearing loosely . Adjust preload.
adjusted.
. Excessive pitman shaft to bali nut . Adjust preload.
lash in steering gear.
. Toe-in out of adjustment or worn . Replace tie rod ends if worn.
drag link or tie rod sockets. Adjust to correct toe-in, and
inspect steering arm and tie rod
for a bent condition.
. Steering system out of alignment. . Align steering complete, caster,
camber, and toe-in. Inspect
spring components for condition
and wear. Repair or replace as
required.
. Tires badly worn, .edge of tires are . Install new tires, and check
rounded off. alignment; abnormal tire wear
indicates improper alignment.
9. Lack of lubrication in linkage and 9. Free up and lubricate any
kingpins. components that are frozen and
will not take lubrication.
10. Air in system. 10. Add oil to pump reservoir and
bleed. Check hose connectors
and proper torque.
11. Steering gear mounting loose. 11. Tighten attaching bolts to
specified torque.

Vibration and Shimmy 1. Seal damage and leakage resulting 1. Replace damaged parts as
in loss of lubricant, corrosion and necessary.
excessive wear.
2. Tires, wheels, or brake drums out 2. Balance tires and wheels,
of balance. preferably with on-vehicle type
balancer, as this method
balances entire wheel and drum
assembly.
3B3-4 POWER STEERING

DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Vibration and shimmy . Bent wheel or out of round tire. . Replace wheel, and remount tire,
(cont.) Wheel nuts torqued unevenly. or repair.
. Loose steering linkage . Adjust, torque, and repair linkage
components. as necessary.
. Wheel loose on hub. . Inspect wheel bolt holes for

an
damage, and replace wheel or
torque nuts.
. Driveline universal joints rough, or . Repair driveline.
defective. This condition may be
confused with steering vibration.
. Engine misses or is out of . Correct miss in engine, or repair
balance, this may also be out of balance condition, clutch,
confused with steering shimmy. pressure plate, or harmonic
balancer, etc.
8. Faulty shock absorbers. 8. Replace shock absorbers.

Hard Steering Excessive 1. Low or uneven tire pressure. 1. Inflate to specified pressures.
Effort Required at Steering 2. Steering linkage kingpins or bail 2. Lubricate, and free up kingpins
Wheel joints need lubrication. or ball joints. Make certain all
fittings take lubricant properly.
. Tight or frozen drag link or tie rod. . Lube or replace as necessary.
. Steering gear to column . Align column.
&

misalignment.
. Steering gear preload too tight. . Adjust preload.
. Front wheel alignment incorrect. . Check alignment and correct as
necessary.
. Steering gear selector snaft . Adjust selector shaft.
adjusted too tight.
. Frozen or tight shaft bearings. . Replace bearings.
oO

Oo

. Lower U-joint flange rubbing . Loosen balt, assembly and

co

against adjuster. torque properly.

10. Tight or binding conditions in 10. Adjust steering column.
steering column.

Pump Inoperative, Poor, or . Low oil level. 1. Fill reservoir to proper level.
os

no Assist (Hard Steering) . Air in the oil. . Locate source of air leak and
ho

correct.
. Defective hoses or steering gear. . Repair or replace.
CG

. Flow contro! valve stuck. . Repair or replace.

Or f

of

. Loose nut in end of flow control . Torque nut not specifications.

valve.
. Pressure plate not flat against ring. . Repair or replace.
“mS

. Extreme wear of pump ring. . Repair or replace.

. Scored pressure plate, thrust . Repair or replace.
plate.
. Vanes not installed properly. . Repair or replace.
. Vanes sticking in rotor slots. 10. Repair or replace.
. Fauity flow control valve assembly. 11. Repair or replace.
 POWER STEERING 3B3-5

DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Momentary Increase in . Low oil level in pump. . Add power steering fluid as
Effort when Turning Wheel required.
Fast to Right or Left . High internal leakage in hydraulic . Check pump pressure. (See
pump. pump pressure test.)
. High internal leakage in steering . Repair source of leak.
gear.

Steering Wheel Surges or . Low oil level. . Fillas required.

Jerks when Turning with Insufficient pump pressure. . Check pump pressure. (See
Engine Running pump pressure test.) Replace
Especially During Parking relief valve if defective.
. Defective gear relief valve. . Replace gear relief valve.
. Sticky flow control valve. . Repair or replace.

Steering Pulls to Left or . Camber or caster incorrectly . Adjust camber and caster.
Right adjusted. Steering will generally pull
to side of axle having greatest
positive camber.
. Low air pressure in right or left tire. . inflate tire to correct pressure,
Steering will pull to side having low check for air leak and repair as
air pressure. required.
. Axle loose and shifted at spring U- . Align axle, and torque U-bolt
bolts. nuts. Inspect for damaged parts.
Replace if required.
. Rear axle loose at spring. U-bolt if . Align rear axle and replace
shifted at one side will cause defective parts, if any. Torque U-
steering to pull. bolts to specifications.
. Unbalanced steering gear control or . Replace valve.
spool valve. If this is caused,
steering effort will be very light in
direction of lead and heavy in
opposite direction.

Poor Return of Steering 1. Lack of lubrication in linkage. . Lube linkage.

Wheel . Steering gear to column . Align steering column.
NS

fh

misalignment.
. Tires not properly inflated. . Inflate to specified pressure.
moO ©
G

. Improper front whee! alignment. . Check and adjust as necessary.

. Steering linkage binding. . Replace pivots as required.
Oo

. Steering wheel rubbing against . Adjust steering jacket.

directional! signal housing. (Turn
steering wheel and listen for
internal rubbing in column.)
. Tight steering shaft bearings. . Replace bearings.
oOnwon

. Sticky or plugged valve spool. . Repair or replace valve.

. Steering gear out of adjustment. . Check adjustment. Adjust as
required.
10. Tight kingpin bushings. 10. Lubricate or replace as required.
17. Lower U-joint flange rubbing 11 . Loosen pinch bolt and assembly
against steering gear adjuster properly.
plug.
3B3-6 POWER STEERING

DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Snapping or Chucking in 1. Loose steering gear at frame. 1. Torque mounting bolts to

Steering Column or Wheel specifications.
2. Worn steering shaft universal 2. Replace and repair joints as
joints. necessary.
3. Worn steering linkage components 3. Adjust, torque, and repair
will telescope through steering components.
system and be felt in steering
wheel.
4. Steering gear incorrectly adjusted. 4. Adjust steering gear.

Excessive Road Shock 1. Tire pressure too high. 1. Deflate to correct pressure.
2. Wheel bearings adjusted too loose. | 2. Adjust bearings.
3. Camber adjustment incorrect. 3. Adjust camber to specifications.
4. Weak or broken front spring. 4. Replace spring.
5. Defective shock absorbers. 5. Replace shock absorbers.
6. Loose suspension components. 6. Inspect, adjust or repair, and
replace as necessary.

POWER STEERING SYSTEM TEST analyzer has been used before, bleeding will
probably not be necessary. This is because the
Hydraulic System Test power steering fluid is kept in the analyzer by
This test requires the Power Steering Analyzer the quick disconnect couplings once it has been
J-26487-A, or equivalent, along with Adapter Kit used.
J-35719. The analyzer consists of a 0-3000 psi 4, Run the engine at idle speed with the gate valve
pressure gage, a gate valve, and a 0-10 gpm flow open for a few minutes to bleed the system of
any air that may still be in it.
meter (figure 1).
1. Be sure the system reservoir has the right kind 5. Check the pressure gage reading with the
of fluid and is filled to the mark on the dipstick. engine idling. The gage should read about 70
Tests should be done with the system at normal psi. If the reading is greater than this, the
control valve, fluid filter, or hydraulic lines are
operating temperature.
2. install the analyzer (1) in the pressure line (3) restricted or plugged.
6 Increase engine speed to 2000 RPM.
between the pump and the steering gear (2)
using Adapter Kit J-35719. The gate valve
NOTICE: Do not keep the gate valve closed
should be fully open.
a. Trace the pressure line from the pump to the longer than 10 seconds. To do so may damage
the hydraulic pump.
steering gear.
b. Disconnect the pressure line at the steering
NOTICE: A malfunctioning pressure relief
gear.
valve may not properly relieve pump
Place a container under the steering gear to
pressures. Constantly watch the pressure
catch fluid when disconnecting hoses. Clean
gage while closing the gate valve. If pressure
the surfaces around fittings before removing
rises rapidly, or appears uncontrolled, do not
them.
completely close the gate valve, as excessive
c. Thread the adapter from the adapter kit into
pressure buildup may cause hose rupture or
the steering gear. Thread the other adapter
pump damage.
onto the pressure line.
d. Connect the analyzer to the adapters.
3. If the analyzer has never been used, it will be
necessary to bleed the hydraulic system to
remove all air, as directed later in this section.
The analyzer gate valve must be open. if the
 POWER STEERING 3B3-7

7. Gradually close the gate valve and read the

pressure gage. IMMEDIATELY OPEN THE
GATE VALVE.
The gage should read 1493 psi. A higher reading
indicates a faulty relief valve in the hydraulic pump.
A lower reading indicates a worn or malfunctioning
hydraulic pump.

1. Power Steering Analyzer J-26487-A

2. Steering Gear
3. Pressure Line
4. Return Line

Figure 1. Steering Gear Analyzer and

Connections

POWER STEERING SYSTEM ON-VEHICLE SERVICE

MAINTENANCE detailed in “Bleeding the Hydraulic System” later in

this section. If it is exceptionally dirty, both the
The hydraulic system should be kept clean. At pump and the gear must be completely
regular intervals the power steering fluid level in the disassembled before further usage.
reservoir should be checked and fluid added when All tubes, hoses, and fittings should be inspected
required. Refer to MAINTENANCE AND for leakage at regular intervals. All fittings must be
LUBRICATION (SEC. OB) of this manual for the tight. Be sure clips, clamps supporting tubes and
type of fluid to be used, and intervals for filling. hoses are in place and properly secured.
The power steering fluid and filter should be
changed at regular intervals. Refer to POWER STEERING FLUID AND FILTER
MAINTENANCE AND LUBRICATION (SEC. OB) for SERVICE
service intervals.
Correct any hose contact with other parts of the . Remove the cover (1) and cap (2) (figure 2).
Gono

vehicle that could cause chafing or wear. . Remove the filter(3).

Power steering hoses and lines must not be . Clean the filter (3) in clean soivent. Then blow
twisted, kinked, or tightly bent. filter dry with compressed air.
Because of the power assist from the power . Raise the front of the vehicle until the front tires
f

are off the floor. Block the frame with safety

steering system, it is more difficult to detect defects
in the steering system. Therefore, periodic stands.
maintenance is very important on a vehicle having
power steering.
If the system contains some dirt, flush it, as
3B3-8 POWER STEERING

. Cover

=
. Cap

OOhWONDM
. Filter
. Fluid Reservoir
. Reservoir Fluid Return Hose (A)
. Pump inlet Hose (A)
. Steel Tube
CON

. Reservoir Fiuid Return Hose (B)

. Pump inlet Hose (B)
10. Pump Outlet Flex Hose
11. Steering Gear Inlet Tube
12. Steering Gear Outlet Tube
13. Hydraulic Pump

Figure 2. Power Steering Fluid Reservoir

5. Disconnect the reservoir fluid return hose (B) (8) * Provide a pan for power steering fluid to drain
from the steering gear outlet tube (14). Direct both into, when hydraulic lines are disconnected.
the hose and tube into a container. Drain the fluid
reservoir (5). Remove or Disconnect (Figure 3)
6. Turn the steering wheel several times from lock to
1. Pitman arm (16) as outlined in STEERING
lock to pump the fluid from the steering gear.
LINKAGE (SEC. 3B1) in this manual.
DO NOT START THE ENGINE.
2. U-joint bolt (17).
7. Connect the reservoir fluid return hose (B) (8) to
3. Put reference marks on the U-joint (18) and
the steering gear outiet tube (12).
input shaft (19). Then remove steering shaft U-
§. Install the filter (3).
joint from the steering gear input shaft.
9. Fill and bleed the hydraulic system, as outlined
4. Hydraulic lines (20) from the steering gear (23).
later in this section.
5. Nuts (21) and bolts (22).
10. Install the cap (2) and cover (1).
6. Steering gear (23).
STEERING GEAR REPLACEMENT
* Place the steering wheel and front wheels in the
straight ahead position.
 POWER STEERING 3B3-9

16. Pitman Arm

17. U-Joint Bolt
18. Steering Shaft U-Joint
19. Steering Gear input Shaft
20. Hydraulic Line
21. Nut
22. Bolt
23. Steering Gear

Figure 3. Steering Gear Removal - installation

x install or Connect (Figure 3)

STEERING GEAR ADJUSTMENT

NOTICE: See “NOTICE” on page 3B3-1 of this Refer to “Power Steering Gear Unit Repair” in this
section for steps 2 and 5. section.

. Steering gear (23) to the frame. HYDRAULIC PUMP REPLACEMENT

2. Bolts (22) and nuts (21).
[es] Remove or Disconnect (Figure 4)
FR] Tighten
1. Braket (24).
« Steering gear bolts (22) to 103 N-m (76 lb-ft). 2. Pump inlet hose (B) (9).
3. Pump outlet flex hose (10).
. Hydraulic lines (20) to the steering gear (23). 4. Pump bolts (25), and pump (13).
. Steering shaft U-joint (18) to the steering gear
input shaft (19). Be sure to align the reference | Install or Connect (Figure 4)
marks.
Check to be sure the steering wheel is in the 1. New seal (O-ring) to the hydraulic pump (13).
straight ahead position. 2. Hydraulic pump (13) to the engine.
. U-joint bolt (17). 3. Steering gear pump bolts (25).
4. Pump outlet flex hose (10).
fl] Tighten 5. Pump inlet hose (B) (9).
6. Braket (24).
« U-joint bolt (17) to 39 N-m (29 Ib-ft).

. Pitman arm (8) to the sector shaft. Refer to

STEERING LINKAGE (SEC. 3B1) in this
manual.
— Bleed the hydraulic system as outlined in
this section.
3B3-10 POWER STEERING

436L W007
Figure 5. Tandem Hydraulic Pump Assembly

4. Remove power steering outlet flexible hose (1)

and nut.
9. Pump Inlet Hose (B) §. Remove hydraulic booster outlet pipe (2) nut.
10. Pump Outlet Flex Hose 6. Remove two clips for hydraulic booster lines on
13. Pump the flywheel housing.
24. Braket 7. Remove clip for hydraulic booster lines on the
25. Pump Bolt left sidemember.
8. Hydraulic booster inlet hose (3).
Figure 4. Power Steering Pump Removal or 9. Power steering inlet hose (4).
installation

6. Fill the hydraulic system with DEXRON®-IIE.

Bleed the system as outlined later in this
section.

TANDEM HYDAULIC PUMP ASSEMBLY

REPLACEMENT (HYDRAULIC BOOSTER
BRAKE MODEL)
| Remove or Disconnect (Figure 5 and 6)

* Block the vehicle wheels and apply the parking

brake.
« Battery ground cable.

1. Disconnect air intake hose at turbocharger side.

2. Raise the vehicle and remove front exhaust
pipe with exhaust brake. A436Lwoo2

» Remove bolts at manifold, silencer and Figure 6. Tandem Hydraulic Pump Removal
support bracket. or Installation
3. Place a container under the hydraulic pump
assembly to catch fluid when disconnecting 10. Remove hydraulic booster pipe from the pump.
hoses. Clean the surfaces around fittings before 11. Remove hydraulic pump assembly with
removing them. (Figure 5) bracket and O-ring.

foe] Install or Connect (Figure 6 and 7)

1. Attach new O-ring and install hydraulic pump

assembly to the engine.
 POWER STEERING 3B3-11

5. With the engine idling, turn the steering wheel

slowly from lock to lock in both directions several
times. Add fluid as needed.
6. Repeat step 5 until the fluid level stabilizes and
air bubbles no longer appear in the reservoir.
7. Stop the engine and fill the reservoir to the proper
level.
8. Lower the vehicle.

HYDRAULIC SYSTEM FLUSHING

Refer to figure 2.
1. Raise the front of vehicle off ground until the
wheels are free to turn.
2. Disconnect the return hose (8) at the steel tube
(7). Direct the hose into a drain pan.
3. Plug the return hose connector on steel tube (7).
496L.WO01
4. Remove the cap (2). Have an assistant ready to
Figure 7. Tandem Hydraulic Pump Assembly keep the fluid reservoir (4) full of fluid. Refer to
MAINTENANCE AND LUBRICATION (SEC.OB)
2. Install booster outlet pipe (2) and nut.
for fluid specifications.
fA] Tighten 5. Start the engine and run it at idle. Turn the
steering wheel from lock to lock.
» Nut to 23.5 N-m (17 lb-ft).
NOTICE: DO NOT hold the steering wheel at a
3. Install power steering outlet flexible hose (1) and nut. lock or fluid flow will stop and the pump will
be in the relief pressure mode. A sudden
fA] Tighten overflow from the reservoir may also develop
if the steering wheel is held at a lock.
+ Nut to 23.5 N-m (17 lb-ft)
6. Continue the process until all foreign material has
4. Connect hydraulic booster inlet hose (3).
cleared from draining fluid. [f foreign material is
5. Connect power steering iniet hose (4).
still evident, the individual components must be
6. Install clips for hydraulic booster lines.
flushed out as outlined in the following steps.
7. Connect air intake hose.
7. Stop the engine.
8. Install exhaust pipe with exhaust brake.
8. Remove all hydraulic lines and hoses. Drain ail the
9. Fill the power steering and hydraulic booster systems
lines and blow clear of fluid. Flush the lines with
with DEXRON®-III.
new power steering fluid, drain, and blow clear.
Bleed the power steering system as outlined in this
9. Disconnect the lines from the hydraulic pump (13),
section.
(9) and (10). Drain the pump and then cap or plug
Bleed the hydraulic booster system. Refer to
the line connections. Fill with new power steering
HYDRAULIC BOOSTER SYSTEM (SEC. 5A2).
fluid. Drain and check the fluid for foreign material.
Repeat the process as necessary.
BLEEDING THE HYDRAULIC SYSTEM
10. Install all lines, hoses, and components (if
[3] important removed) on vehicle. Fill the system with new
power steering fluid and bleed the system as
- Use only DEXRON®-IIE automatic transmission described in “Bleeding the Hydraulic System”
fluid as described in MAINTENANCE AND previously in this section. Operate the engine for
LUBRICATION (SEC. 0B) in this section. approximately 15 minutes.
11. Repeat steps 1 through 6. Check the draining fluid
1. Raise the vehicle until the front wheels are off the for foreign material. If the fluid shows foreign
floor. Block the frame. material, drain the system, refill, bleed system, run
_ Fill the reservoir with the proper fluid. engine and recheck for foreign material.
. With the engine stopped, turn the steering wheel if foreign material is still evident, replace all lines
oh

slowly from lock to lock in both directions. Add and repair or replace all hydraulic components.
fluid as necessary. Do not reuse any drained power steering fluid
4. Start the engine and let it idle for two to three 12. After the flushing operation, clean the power
minutes. steering fluid filter (3) as outlined previously.
3B3-12 POWER STEERING

POWER STEERING GEAR UNIT REPAIR

Power steering gear components are a that proper cleaning and protection of machined
combination of many machined, polished surfaces surfaces and friction areas is part of the repair
with very fine tolerances. procedure. This is considered standard shop
When these components are serviced, care and practice even if not specifically stated.
cleanliness are important. The workbench, hands, Components should be cleaned in a clean,
tools, and component parts must be kept clean at approved solvent that will not damage the rubber
all times. The entry of even small amounts of dirt parts.
into the component may cause an unsatisfactory In some instances, “automatic transmission fluid”
repair and possible damage to the component. The will be specified to lubricate parts upon assembly.
dirt may also be carried by the power steering fluid In these cases, use automatic transmission fluid as
to other components in the power steering system, specified in MAINTENANCE AND LUBRICATION
causing damage to other components as well. (SEC. OB) in this manual.
Throughout this section, it should be understood

1. Dust Seal
2. Jam Nut
3. Side Cover and Sector Shaft Assembly 10
4. Side Cover Assembly
5. Sector Shaft Assembly
6. Retainer
7. Adjusting Screw 15. Bail Nut Assembly
8. Worm Shaft Cover End Dust Seal 16. Teflon Rings
9. Lower Worm Shaft End Cover Jam Nut 17. O-Rings
10. End Cover 18. Teflon Rings
11. Seal (O-Ring) 19, Seal (O-Ring)
12. Bearing 20. Gear Housing Assembly
13. Valve Housing and Ball Screw Assembly A. Screws
14. Valve Housing Assembly B. Spacer

Figure 8. Steering Gear Major Components

 POWER STEERING 3B3-13

NOTICE: When repairing a power steering gear or

pump, if broken components or foreign material
are encountered, the remaining components of
the entire hydraulic system should be
disassembled, inspected, cleaned, and flushed
before servicing is completed or serious damage
to the system may result.

REMOVAL OF MAJOR SUB-ASSEMBLIES

FROM POWER STEERING GEAR UNIT
4. Side Cover Assembly
feo] Remove or Disconnect 5. Sector Shaft Assembly
7. Adjusting Screw
* Steering gear, as outlined previously in this
section. Figure 10. Sector Shaft Assembly/Disassembly

Clean 4. Sector shaft assembly (5) from side cover

assembly (4) by turning the adjusting screw (7)
« Exterior of steering gear with solvent. clockwise (figure 10).
5. Screw retainer (6) (figure 11).
[e] Disassemble (Figures & through 15)
» Flatten out staked portion of the screw
1. Dust seal (1). retainer (6) and remove retainer (figure 11).
2. Jam nut (2). * A tool (A) must be fabricated to remove and
3. Side cover and sector shaft assembly (3) from install the retainer (figure 11).
the rest of the unit. « Obtain a nut that will fit into the hex cutout in
* Align the sector shaft major components (5) to the screw retainer. Weld or braze the nut to a
a neutral position by turning the input shaft of suitable deep-well socket. Drill the nut out, if
the steering gear to lock and backing off necessary, so the tool will fit over the sector
approximately 2.5 turns. shaft adjusting screw (7) (figure 11).

6. Screw Retainer
4. Side Cover Assembly 7. Sector Shaft Adjusting Screw
5. Sector Shaft Assembly A. Fabricated Tool

Figure 11. Sector Shaft Retainer Removal

Figure 9. Sector Shaft and Cover Removal
6. Sector shaft adjusting screw (7) (figure 11).
- Turn the adjusting screw (7) counterclockwise
7. Worm shaft cover end dust seal (8) (figure 8).
slightly. Then remove the bolts from the side
cover assembly (4). 8. Lower worm shaft end cover jam nut (9) (figure
« Then remove the side cover assembly (4) and 8).
9. End cover (10) with a spanner wrench (figure
sector shaft assembly (5) by tapping on the
end of the sector shaft with a plastic hammer 8).
(figure 9). 10. Seal (O-ring) (11) (figure 8).
11. Bearing (12) (figure 8).
12. Screws (A) retaining valve housing and ball
 3B3-14 POWER STEERING

screw assembly (13) to gear housing assembly

(20) (figure 8).
13. Valve housing and ball screw assembly (13)
(figure 8).

fy] Important

» Always keep the valve housing and ball screw

assembly (13) in a horizontal position and
avoid holding it vertically, or ball nut will slide
out (figure 12).
* Remove this assembly from the housing by
tapping on the end of the ball screw assembly
with a plastic hammer (figure 12). 21. Side Cover
22. Seal (O-ring)
23. Seal
24. Needle Bearing

Figure 13. Sector Shaft Side Cover

13. Valve Housing and Ball Screw Assembly

20. Gear Housing Assembly

Figure 12. Ball Nut and Screw Removal

Side Cover Disassembly (Figure 13)

* Remove the seal (O-ring) (22), the needle bearing
(24), and the seal (23) from the side cover (21).

Valve Housing Disassembly (Figure 14)

« Remove the snap ring (25), oil seal (26), needle
bearing (27), and seal (O-ring) (29) from the valve
housing (28).

Gear Housing Disassembly (Figure 15)

* Remove the outer sector shaft seal (30), the
needle bearing (31), and the inner seal (32), from 25. Snap Ring
the gear housing (33) (figure 15). 26. Oil Seal
27. Needle Bearing
28. Valve Housing
29. Seal (O-ring)

Figure 14. Control Valve Housing

 POWER STEERING 3B3-15

[3] Important

« When making a test on the ball screw

assembly, exercise care not to strike the ball
nut against the end of the worm shaft, or
damage to the ball tubes will result.

Ball Nut Assembly

» Ball nut assembly and control valve assembly
include precision-finished parts of selective fitting.
» Always keep the ball nut assembly in a horizontal
position and avoid holding it vertically, or ball nut
will slide out.
« If any defects exist in the ball nut or in the control
valve, the assemblies should be replaced with
new parts.

Measure (Figures 8, 16, 17 and 18)

* Ball nut piston axial play. Use a dial indicator to

check the axial play as shown in figure 16.
if play exceeds 0.2 mm (0.008 in), replace the
worm/ball nut piston assembly. The bail nut
assembly (15), worm shaft (34), and balls are
30. Outer Sector Shaft Seal
selectively fitted and are not available separately.
31. Needie Bearing
- Ball nut assembly (15) to gear housing assembly
32. Inner Seal
(20) bore clearance (figure 8). Measure the ball
33. Gear Housing nut piston diameter, using a micrometer.
Figure 15. Steering Gear Housing Measure the housing bore inside diameter, using
an inside micrometer. Subtract the ball nut piston
CLEANING, INSPECTION AND REPAIR diameter from the housing bore inside diameter to
obtain the clearance. The production clearance is
Clean 0.1 mm (0.004 in). Replace the piston and/or
housing if clearance exceeds specification.
- All parts in clean solvent. Blow parts dry with
compressed air.

Inspect

Make necessary corrections or parts replacement

if worn, damaged or any other abnormal conditions
are found through inspection. Inspect the following
parts for wear, damage or other abnormal
conditions.
« Housing.
Sector shait.
Needle roller bearing.
.

Ball screw assembly

- Oil seal, dust cover, inner seal, seal (O-ring) and
snap ring.
15. Ball Nut Assembly
Ball Nut Rotation 34. Worm Shaft
Hold the worm shaft vertically and see if the ball
Figure 16. Measuring Ball Nut Axial Play
nut rotates smoothly. If lowering of the ball nut with
its own weight is not smooth, check the worm shaft
for bending and ball groove for burrs, dents and the
presence of foreign matter.
 3B3-16 POWER STEERING

Sector Shaft Assembly

Inspect (Figure 8)
1. Seai mating surfaces for nicks or damage.
2. Gear teeth for wear or damage.
3. Adjusting screw (7) for thread damage. The
adjusting screw must turn smoothly in the sector
shaft assembly(5), and not be excessively
loase.
Replace, if necessary, as outlined later.
4. Splines and threads for damage.

Measure (Figures 8, 17 and 18)

« Sector shaft outside diameter(5) with micrometer
(figure 17). The standard diameter is 38.082 mm
5. Sector Shaft Diameter (1.50 in). Replace the sector shaft if the diameter
is less than 38.0 mm (1.496 in).
Figure 17. Measuring Sector Shaft » Sector shaft (5) to needle bearing clearance
(figure 18).
* Install a dial indicator as shown in figure 18.
+ Measure the clearance. If more than 0.2 mm
(0.008 in}, replace the sector shaft and/or bearing
as needed.

Assemble (Figure 11)

* Discard used retainer and install a new one. Use

tool (A) fabricated during disassembly. Install and
fully tighten the screw retainer (6) and back off
180 °. Retighten to a torque 39 N-m (29 Ib-ft) and
back off 20 degrees. Check that the sector shaft
adjusting screw (7) turns smoothly.
5. Sector Shaft + Stake the screw retainer (6) in position.

Figure 18. Measuring Sector Shaft to Side Cover Assembly

Bearing Clearance
Inspect (Figure 13)
Ball nut assembly
+ Side cover (21) for cracks or damage to the
Assemble (Figure 8) sealing surface.

1. New teflon ring (18) to ball nut assembly (15). Assemble (Figure 13)
2. New seal (O-ring) (19) to ball nut assembly
(15). 1. Seal (23) into side cover (21).
3. New teflon rings (16) and new seals (O-rings) 2. Press needie bearing (24) into side cover (21).
(17) to ball nut assembly (15). 3. Seal (O-ring) (22) onto side cover (21).
4. Keep bail nut assembly (15) clean until ready to
assemble into gear housing assembly (20). Sector Shaft to Side Cover
+ Fit the sector shaft into the side cover (figure 10).
Housing Assembly
Adjust (Figure 10)
Assemble (Figure 15) Turn the adjusting screw (7) counterclockwise
1. Inner seal (32) into sector shaft bore. until the end of the sector shaft assembly (5),
2. Needle bearing (31) into sector shaft bore. bottoms in the side cover assembly (4) then turn
3. Outer sector shaft seal (30) into outer housing one full turn clockwise.
seal bore.
 POWER STEERING 3B3-17

Valve Housing Assembly

Inspect (Figure 14)

« For internal scoring and worn grooves.

» Valve housing (28) for cracks.
» Snap ring groove to be square.

Assemble (Figure 14)

1. Press needle bearing (27) into valve housing

(28).
10. End Cover
2. Press oil seal (26) into valve housing (28) with
CG. J-35767
lip facing bearing.
3. Snap ring (25) in groove.
Figure 19. End Cover Installation
4. Seal (O-ring) (29) onto valve housing (28).

ASSEMBLING MAJOR SUB-ASSEMBLIES

INTO POWER STEERING GEAR UNIT
Assemble (Figures 8, 19, 20, 21 and 22)

NOTICE: See “NOTICE” on Page 3B3-1 of this

section for steps 3, 5, 7, 8 and 12.

- Install gear housing (20) in a vise, clamped-by the

mounting flange with the ball nut bore horizontal.
» Lubricate the bal! nut assembly (15) with
automatic transmission fluid (figure 8).
1. Spacer(B) on the splined end of the input shaft.
2. Ball nut assembly (15) fully into the gear
housing assembly bore (20) (figure 8).
+ Lubricate the valve housing assembly (14)
bearing and seal with automatic transmission 35. Input Shaft
fluid (figure 8). D. Torque Wrench With J-35717
3. Valve housing assembly (14) onto the gear
housing assembly (20) (figure 8). Figure 20. Setting Preload on Ball Nut Assembly

FR] Tighten
Measure
* Valve housing bolts to 86 N-m (64 Ib-ft).
* Place torque wrench (D) and socket J-35717
on the input shaft (35) (figure 20).
4. Seal (O-ring) (11) on the lower worm shaft end
cover (10) (figure 8). « Tighten the end cover with J-35767 until a
« Lubricate the bearing (12) with automatic
starting torque reading of 0.4 N-m (0.3 Ib-in) is
observed on the input shaft.
transmission fluid and install them onto the
worm shaft of the ball nut assembly (15)
(figure 8). 6. End cover jam nut.
5. End cover (10) with spanner wrench J-35767
fR] Tighten
(C) (figure 19).
> Jam nut to 200 N-m (148 lb-ft).
« Recheck the starting torque and readjust if
necessary.

7. Center the ball nut teeth in the sector shaft

opening.
8, Lubricate the sector shaft and install it and the
side cover assembly in the housing bore (figure
21), aligning the center tooth of the sector shaft
with the center tooth of the ball nut.
 3B3-18 POWER STEERING

3. Sector Shaft and Side Cover Assembly 16. Pitman Arm

Figure 21. Installing Sector Shaft Figure 22. Measuring Sector Shaft Backlash

3) Turn the sector shaft adjusting screw until a

FQ] Tighten maximum of 0.33 mm (0.013 in) movement
+ Side cover bolts to 86 N-m (64 Ib-ft). of the pitman arm exists when measured at
the end of the arm.
9. Pitman arm onto the sector shaft until no 10. Jam nut (2) on end of adjuster screw (7) (figure
looseness or play exists between the arm and 8)
shaft.
fA] Tighten
Adjust * Jam nut to 69 N-m (51 lb-ft).
1) Center the sector and ball nut teeth in the
inspect
gear housing by turning the input shaft to
the limit of travel in each direction. Count * Recheck the total starting torque of the input shaft
the turns from end to end. (figure 20). When the unit is fully assembled, the
Then turn the input shaft one half that specification is 0.7 N-m (0.5 Ib-in).
number of turns from one end.
2) Set a dial indicator to read pitman arm (16)
movement (figure 22).

HYDRAULIC PUMP UNIT REPAIR

Power steering components are a combination of to the system may result.

many machined, polished surfaces with very fine
tolerances. | Remove or Disconnect
When these components are serviced, care and
cleanliness are important. The workbench, hands, » Hydraulic pump, as outlined previously.
tools, and component parts must be kept clean at
Clean
all times. The entry of even smail amounts of dirt
into the component may cause an unsatisfactory * Exterior of hydraulic pump.
repair and possible damage to the component. The
dirt may also be carried by the power steering fluid Disassemble (Figures 23, 24, 25 and 26)
to other components in the power steering system,
causing damage to other components as well. 1. Suction pipe (1), and seal (O-ring)(2) (figure 23).
2, Nut, washer (3), Gear and key (4)(figre 23).
NOTICE: When repairing a power steering gear or 3. Bolt (6) and end cover (6)(figure 23).
pump, if broken components of foreign material 4. Pin (7) and bushing (8)(figure 23).
are encountered, the remaining components of 5. Cartridge assembly (9), and Seal (O-ring)
the entire hydraulic system should be (10) (figure 23).
disassembled, inspected, cleaned, and flushed
before servicing is completed or serious damage
 POWER STEERING 3B3-19

18

1. Suction pipe 13. Seal (O-ring)

2. Seal (O-ring) 14. Pin
3. Nut and washer 15. Snap ring
4, Gear and key 16. Shaft assembly
5. Bolt 17. Bearing
6. End cover 18. Oil seal
7. Pin 19. Connector
8. Bushing 20. Seal (O-ring)
9. Cartridge assembly 21. Seal (O-ring)
10. Seai (O-ring) 22. Valve assembly
11. Side plate 23. Spring
12. Seal (O-ring) 24. Body

Figure 23. Power Steering Oil Pump

6. Side plate (11), seal (O-ring) (12), seal (O-ring)

(13), and pin (14)(figure 23).
7. Snap ring (15)(figure 23).
8. Shaft assembly (16)(figure23).
- Use a mallet to remove the shaft assembly
from the housing (figure 24).
9. Ball bearing (17)(figure 23). A press and rod will
be necessary to remove the ball bearing from
the shaft (figure 25).
10. Oil seal (18)(figure 23).
» Use a brass drift (C) to remove the oil seal
from the housing (24) (figure 26). 16. Shaft Assembly
24. Housing
11. Oil seal (O-ring)(20), comector (19), and oi! seal
(O-ring) (21) (figure 23).
Figure 24. Removing Power Steering Pump
12 Valve assembly (22), and spring (23)(figure 23).
Shaft Assembly From Housing
 3B3-20 POWER STEERING

assembly (9).
» Side plate (11) for wear at the thrust faces.
Replace if excessive wear is evident.
* Ball bearing (17). If the bearing is rough or loose,
replace it as outlined later in this section.
» Seal contact area of the shaft assembly (16). If
fretting or roughness is present, replace the shaft.
* Gear (4) for rough or chipped teeth.
« Flow control valve assembly (22) for scoring or
burrs. Also, inspect the flow control valve bore in
the pump housing (24) for burrs.

Assemble (Figures 23, 27, 28 and 29)

it r
NOTICE: See ‘NOTICE’ on page 3B3-1 of this
17. Ball Bearing section for steps 7, 10 and 11.
A. Press Ram
B. Rod or Bar 1. Pump shaft oil seal (18) into the pump housing
(24) using a proper size rod and press or
Figure 25. Rernoving Pump Shaft Bearing hammer (figure 27).
2. Press the shaft into the ball bearing (17) (figure
28).
3. Shaft assembly (16) into the pump housing
assembly (24) (figure 23).
4, Snap ring (15) into the pump housing assembly
(24) (figure 23).
5. Key, gear (4), washer, and nut (3) onto the shatt
assembly (16). The long hub of the gear faces
the pump housing assembly (figure 23).

Hold the gear (15) and torque the nut (13) to

24, Housing 59 N-m (43 lb-ft).
C. Brass Drift » Bend the washer.

e—«
Figure 26. Removing Oil Seal from Pump
Housing

CG Clean
* All parts in a suitable solvent and biow dry with
compressed air. Be sure to use clean solvent to
clean internal paris.

Inspect (Figure 23)

* Cartridge assembly (9). 18. Pump Shaft Oli Seal

— Vane tips of cartridge assembly for wear. 24, Pump Housing
— Vanes for scoring or wear.
— Inner surface of the ring for scoring, wear, Figure 27. Installing Seal into Housing
damage, etc.
— Fit of the vanes in the rotor. The vanes must 6. Vanes (26) in the rotor (25) with the flat edge
fit properly in the rotor slots, without sticking {E) facing inward (figure 29).
or excessive play. Also check for burrs in 7. Vanes (26) and rotor (25) into the cam. Any
the rotor slots, and excessive wear at the stamped marks on the cam or rotor face the
thrust faces. housing.
— if heavy wear is present, or if parts are
damaged, replace the entire cartridge
 POWER STEERING 3B3-21

fA] Tighten

* Suction pipe bolts to 8 N-m (69 Ib-in).

TANDEM HYDRAULIC PUMP UNIT REPAIR

Tandem Hydraulic Pump

A tandem hydraulic pump has two independent

hydraulic pumps inside one casing. Its main parts
can be classified into the following three.
— hydraulic pump (vane type)
— flow control valve
-- pressure relief valve
The following is a description of the functions and
operation of the main parts.
17. Ball Bearing
D. Press
Hydraulic pump
Figure 28. Installing Shaft into Bearing
Functions
8. Pin (14), seal (O-ring)(12,13), side plate (11), The heart of the system, namely the part that
cartridge assembly (9), seal (O-ring)(10), pin supplies hydraulic pressure, which operates the
(7), bushing (8), and end cover (6) to the pump hydro boost and the P/S. The hydraulic pump is
housing assembly (24) (figure 23). installed directly to the engine and is driven by
gears. It smoothly adapts itself to severe conditions
fA] Tighten of use, including a wide range of rotation speeds,
changes in the temperature at which it is used, and
¢ Cover bolts to 20 N-m (14 Ib-ft). frequent changes in load pressure, and it is able to
fully perform its functions.

Operation
its drive is transmitted by gears from the engine
to the drive shaft of the oil pump, and it turns a
rotor that is fitted into the spline part of the drive
shaft. When the rotor rotates, the ten vanes built
into the rotor groove fly out by centrifugal force, are
pressed against by the inside surface of the cam
ring, and rotate along the inside surface so that the
pump operates.

Suction and discharge of the hydraulic oil is done

by a pressure plate and side plate attached to both
25. Rotor 25 ends of the cartridge.
26. Vane Suction openings and discharge openings are
E. Flat Edge provided in two locations each in symmetrical
F. Rounded Edge positions with respect to the axis of rotation, and
because the load on the bearings due to the
Figure 29. Installing the Vanes discharge pressure is balanced, a tandem oil pump
is also called a balanced hydraulic pump.
9. Spring (23), flow contro! valve assembly (22), Because it has a double pump effect per rotation,
seal (O-ring)(20,21), and connector (19)(figure this pump provides large discharge flow in
23). proportion to the space it occupies. Also, some of
the hydraulic oil that is discharged is led to the
Tighten base of the vanes and ensures the quality of the
* Connector to 49 N-m (36 lb-ft). seal between the vane tips and the cam, and even
if the vanes and cam rings become a little worn, the
seal is hardly affected at all (with respect to
10. Seal (O-ring)(2), and suction pipe (1)(figure 23).
3B3-22 POWER STEERING

discharge, oil tightness).

P/S: Power Stearing

HBB: Hydraulic Booster
Brake

. Roter and Vane: P/S

. Pressure Piate
. O-ring
. Bolt
. O-ring
. Side Plate
. Roter and Vane: HBB
. Cam
. Pressure Plate
. Pin
. Shaft
. Retainer
. O-ring
. Oil Seal
1. O-ring 8. Valve 15. Nut 36. Pump Housing
2. Hose Connector: HBB ~— 9. Spring 16. Gear 37. Snap Ring
3. Hose Connector: PS 10. Connector: P/S 17. Key 38. Ball Bearing
4. O-ring 11. O-ring 18. Rear Body 39. Shaft
5. Connector: HBB 12. O-ring 19. Gasket 40. Retainer Ring
6. O-ring 13. Valve 20. Pin 41. Oil Seal
7. O-ring 14. Spring 21. Cam 42. Front Body
412LW002
Figure 30. Tandem Hydraulic Pump
 POWER STEERING 3B3-23

» Side place (30) for wear at the thrust faces.

[e>] Remove or Disconnect Replace if excessive wear is evident.
+ Hydraulic pump as outlined previously. « Ball bearing (38). If the bearing is rough or loose,
replace it.
Clean * Seal contact area of the shaft (32), (39). If fretting
or roughness is present, replace the shaft.
+ Exterion of hydraulic pump. + Gear (16) for rough or chipped teeth.
« Flow contro! valve assembly (8) (13) for scoring
i] Disassemble (Figure 30) or burrs. Also, inspect the flow control valve bore
in the pump housing (36) for burrs.
1. O-ring (1).
If heavy damage is present, replace pump housing
2. Hose connectors (2), (3).
assembly together with valves.
3. O-rings (4).
4. Connector (5), O-rings (6), (7), valve (8) and i] Assemble (Figure 30)
spring (9).
5. Connector (10), O-rings (11), (12), valve (13) 1. Oi! seal (41) into the front body (42) using a
and spring (14). proper size rod and press or hammer.
. Nut (15), gear (16) and key (17). « Install oil seal (41) as illustration shows.
OND

. Bolts, rear body (18) and gasket (19). (Figure 31)

. Pins (20), cam (21) and roter and vane (22). 2. Press the shaft (39), into the ball bearing (38)
. Pressure plate (23) and O-rings (24). as illustration. (Figure 31}
=—-OO

. Five bolts (25) and O-rings (26).

eh

. Pressure plate (30), cam (29), roter and vane

—_—t

(28), side plate (27) and pins (31).

12. Shaft (32), Retainer (33) and O-rings (34).
13. Oil seal (35) and pump housing (36). Shield Plate
- Use a brass drift to remove the oil seal (35)
from the pump housing (36).
14. Snap ring (37), shaft assembly and retainer ring
(40).
- Use a mallet to remove the shaft assembly
from the front body (42).
15. Ball bearing (38) and shaft (39).
- Apress and rod will be necessary to remove
the ball bearing (38) from the shaft (39). Starnping
16. Oil seal (41) and front body (42).
» Use a brass drift to remove the oil seal (47)
from the front body (42).
AOSLWO02
Clean Figure 31.
- All parts in a suitable solvent and blow dry with 3. Place the retaining ring (40) in the front body
compressed air. Be sure to use clean solvent to (42) and install the shaft assembly (39) (38) into
clean internal parts. the front body (42) using a press or hammer.
4. Snap ring (37) into front body.
Inspect (Figure 30) 5. Oil seal (35) into pump housing (36) using a
- Cartridge assembly (21) (22) and (28) (29). proper size rod and press or hammer.
— Vane tips of cartridge assembly for wear. 6. O-rings (34), retainer (33) and shaft (32) into
— Vanes for scoring or wear. pump housing (36).
7. Set pressure plate (30), Cam (29), roter and
— _ Inner surface of the ring for scoring, wear,
damage, etc. vane (28), side plate (27) and pins (31) in place
— Fit of the vanes in the rotor. The vanes must fit as illustration. (Figure 32)
properly in the rotor slots, without sticking or
excessive play. Also check for burrs in the rotor
slots, and excessive wear at the thrust faces.
— {f heavy wear is present, or if parts are
damaged, replace the entire cartridge
assembly (21) (22) and (28) (29).
3B3-24 POWER STEERING

11. Install gasket (19) and rear body (18).

Front View Front View Rear View [2] Tighten

Stamping * Bolts to 34 N-m (25 Ib-ft)

12. Key (17), gear (16) and nut (15) onto shaft (39).
+ The long hub of the gear faces front body (42).

[RI Tighten

* Nut to 103 N-m (76 lb-ft)

. Spring (14), valve (13), O-ring (12), O-rings (11)

AOSLWO04 and connector (10) into pump housing (36).
Figure 32.
Rl Tighten
8. Attach O-rings (26) into front body (42) grooves
and assemble front body (42) and pump « Connector to 54 N-m (40 Ib-ft).
housing (36) by tightening bolts (25).
14. Spring (9), valve (8), O-ring (7), O-rings (6) and
fa] Tighten connector (5) into pump housing (368).
* 4 (four) Bolts to 54 N-m (40 lb-ft) fA] Tighten
* 1 (one) Bolt to 25 N-m (18 ib-ft)
« Connector to 54 N-m (40 ib-ft)
9. Install O-rings (24) into pump housing (36).
10. Set pressure plate (23), roter and vane (22), 15. O-rings (4) and hose connector (3), (2).
cam (21) and pins (20) into pump housing (36)
as illustration. (Figure 33) Tighten

+ Bolts to 21 N-m (15 lb-ft)

Stamping
Oblo ng Hole 16. Attach O-ring (1).
vo

Front View
AOSLWO0G3
Figure 33.
 POWER STEERING 3B3-25

SPECIFICATIONS
Ball Nut Piston Axial Play ..........: cs cesccsusecserssnersassensnnsesnenseceretes pecaeeuneuceauesceseeeretammerersseeeeeuseseenesasees 0.2 mm (0.008 in)
Ball Nut Piston to Housing Bore Clearance uu... eeetecsesnecneenseneesanntnereratnerensuesseuauenseanerssecoresaranes 0.1 mm (0.004 in)
Sector Shaft Diameter... cccscccescsscssscecsnsccccesesenenenesaeessaveasinanuasaesenesseuruenneuntensaeseeseasannenaeenen 38.125 mm (1.501 in)
Sector Shaft to Needle Bearing Clearance ..........cesccssceseennersestceetreneanereres suapeanaeeencaenesssaceeseneneneacenens 0.2 mm (0.008 in)
Backlash (Measured at End of Pitan Arm).......cessscecereenererscenecineeensennerctisneersitersereaneessenenrenes 0.33 mm (0.013 in)
Starting Torque of Input Shaft .......... cee ccecsnees eereneseeceneneteeenenanssnsenusaneneseesanaseenanssecauenesteesensetenneny 0.4 N-m (0.3 Ib-in)
Final Starting Torque of input Shaft ......... cesses re eseneneeeeenenssseensscesenersmensssneenenerearsecesteaeertaaeey 0.7 N-m (0.5 Ib-in)

FASTENER TORQUES

Steering Gear to Frame Rail Bolts «0.0.0.0... c:cceseccseessnssereseseenseenssaceeenensnareneneneessnennenneaseseneasacarannnenares 103 N-m (76 Ib-ft)
Steering Shaft U-Joint Clamp Bolt ..........cccsecccsceceseeeeneerertsesenerssneersnmnsneanensesaaeneneateseserarenensnetenaey 39 N-m (29 lb-ft)
Sector Screw Retainer
(1) Fully Tighten Retainer and Loosen 180°.
(2) Torque to 39 N-m (29 Ib-ft).
(3) Loosen 20 degrees.
Steering Gear Valve Housing Bolts... scecscertseeeereeeseneretsesseaesnsntnsananeseeeneeessanneeteceeasennentaenaneaees 86 N-m (64 lb-ft)
End Cover Jam Nut... ccc csseseeesseseeeresseereneers buueevessaceeeensaseecusnensausscenaeeetenenenausaacanseearseeneeteuseass 200 N-m (148 lb-ft)
Steering Gear Side Cover Bolts ............cseccscsecescnentseccnserseneneiamaneneenesaaseresunsersnenrenessennenenaerenenasenas 86 N-m (64 Ib-ft)
Sector Adjusting Screw Jam Nut... .cccesccsecssessseseerensnsesisensreraneenenarsssensseneeencaticenisncannserernennaeseanty 69 N-m (51 ib-ft)
Steering Gear Fluid Tube Nuts ..........ccccceescesrseesensernnenseetensssstsstesiaenensansnnseessenensissneatacasressenenntaenty 45 N-m (33 Ib-ft)
Pump Gear Nut... cccecesccereeeeeeteeteenneeraniemessiemnearsrenssenseonsnasisenarenes bustaeaucueeaceeeveceaeterenerenareeseussaees 59 N-m (43 Ib-ft)
Power Steering Pump End Cover to PUMP HOUSING BOIts...........seceesecteeseenereenrsneeenneeetenieatiessestees 20 N-m (14 lb-ft)
Pump Flow Control Valve COmmector .........ccscccenescceeeesrersrstsisreneneeesssacecessansnsnsensnsacseennrenenreatinenentatins 49 N-m (36 lb-ft)
Suction Pipe to Pump Housing Bolts............cecscscscceneeecersereesnsensesseasesensanenansnensnrsasarenaceretenentanenaceaceay 8 N-m (69 Ib-in)
Tandem Hydraulic Pump Hose Connector Bolt «0.2... c.seresssecnseneenesneenressenasncaccntetetennensemnenesenaeg setae 21 N-m (15 Ib-fi)
Tandem Hydraulic Pump Valve Connector Bolt .........ecccecnsseseersrenssinnsessensnesnsestennensscentanensnrtnese 54 N-m (40 snes ib-ft)
Tandem Hydraulic Purp Gear Nut... cccscscssecceseneneinnensessrersnssuneansnenenenassseneasneereanersercasacasaneraeenenes 103 N-m (76 lb-ft)
Tandem Hydraulic Pump Rear Bodly Bolt ...........:cececcceseseeecreeentesenssererseeneenssnsuenesenencanneneneteenetanaesgys 34 N-m (25 Ib-ft)
Tandem Hydraulic Pump Front Body Bolt.........-eceecssssesessseeessnensssmnensenennensessesnsanancncennenccenaetannens 25 N-m (18 lb-ft)
Tandem Hydraulic Pump Housing Bolt ..........ccecccnesessisssesescessrseesnersenennennensacenicasenenstertaeesesngsasseanns 54 N-m (40 Ib-ft)
Tandem Hydraulic Pump Outlet Connector Nut... ess sessseisnserrssnenseeeneneneetsnnenertaneneasenasinarenens 23.5 N-m (17 Ib-ft)

SPECIAL TOOLS

TOOL NO. TOOL NO.

ILLUSTRATION TOOL NAME ILLUSTRATION TOOL NAME

LIy J-35719 J-35717

. Adapter Kit Steering Shaft Socket

J-35767
Cd ( } y 26807 nq Anal Power Steering Lock Nut
‘ Z )
Power Steering Analyzer Wrench
 STEERING COLUMN 3B4-1

SECTION 3B4

STEERING COLUMN
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

DeSCription ..........cscssssscsssssenserseesssssssesteeenscensassesneatnanenauensenenueatsnocuucsnoniennensueansensenrsnsaeneeneasnnacaserrenasanianssates .. 3B4- 1

Diagnosis of Steering ColUMn.......sssssescnsecressesseneceseneuessseessannearsoemstusorensatssssessneansserarensenensaseneninsenanenennes 3B4- 1
Steering Column On-Vehicle Service...........oscsecscereresssssenseentennssenseacaunsseetennsentonsenenesnesentensvacsssenuntanansenenens 3B4- 2
Steering Wheel Replacement ..........scsssesssersacsncsssessesessntenesnesusassoneansscvenntacsrsessssesssensanouaeneaanensnanineessy 3B4- 2
Steering Column Replacement ..........:sscsssssscsenssensanenseeseaterscesensesssenscecanseansonsssartenseanssenensunensneranenennont® 3B4- 3
Steering Column Unit Repair ............s-scsssssssessessscsercessessscerensnseessusanacanumeenessnnenrsenseaesearsesseneansnensacesentantasanes 3B4- 5
Steering Shaft Replacement ............scscseeesseressssessesrsnssnsensecsssonnsnsssnsantecutanseenesseenss sutvorsecesansusgeaatesusuaunsers 3B4- 5
Specifications... duepeeseunsausnesnenaveasenesacaneseususeuseneususuacnasreasossecersearegensesnenasauenessansaaunausonatensansenter 3B4- 6
Fastener TOrques. .......ccsccssssessesnenenssneas suvssussunsensocsauaeacennsoncssusuantuasanesansacensouansttanuanrssonsatsonsneeueaeennensenrersas 3B4- 6
Special TOOIS.........cscscescsssessseensessnercensneessnensensteeeecssenusnencessasanerenesares seecesetassssansenenonacacsaessunataneacacsonseneaneaes 3B4- 6

DESCRIPTION

The steering column used in the vehicle covered are controlled by multi-function levers on the
by this manual is two-way adjustable. The column steering column. The engine control switch is also
can be tilted forward and backward, and adjusted column mounted.
for height. The right-hand lock handle releases the The column shaft is supported at the upper end
column for height adjustment and for tilt by a sealed ball bearing and at the lower end by a
adjustment. bushing.
Headlights, turn signals, hazard flashers, The steering column is connected to the steering
windshield washers and wipers, and exhaust brake gear by a slip-type shaft with two universal joints.

DIAGNOSIS OF STEERING COLUMN

Refer to POWER STEERING (SEC. 3B3) in this

section.
3B4-2 STEERING COLUMN

STEERING COLUMN ON-VEHICLE SERVICE

STEERING WHEEL REPLACEMENT (11) and the lower cover (12) from steering
wheel (3).
| Remove or Disconnect (Figures 1, 2 and 3)
Inspect (Figures 1 and 2)
Too! Required:
J-24292-B Steering Wheel Puller, or * Steering wheel and steering shaft splines for
equivalent. damage.
1. Battery ground cable. * Horn contact plate (11), horn wire connection
2. Horn button (1). Grasp the horn button at the for corrosion or damage.
forward edge and pull it off by hand. (figure 1).
3. Nut (2). [><] install or Connect (Figures 1 and 2)
* Mark the steering wheel and steering shaft
1. Horn contact plate (11) and lower cover (12) to
(figure 2).
the steering wheel (3).
4. Steering whee! assembly using J-24292-B or
2. Steering wheel assembly to the steering shaft.
equivalent (figure 3).
* Align the marks made during removai (figure
5. Screws then separate the horn contact plate

a
Wo
—

1. Horn Button 7. Key Bolt

2. Nut 8. Column Lock System
3. Steering Wheei 9. Steering Shaft Assembly
4. Steering Cowl 10. Steering Column
5. Combination Switch 11. Horn Contact Plate
6. Key Cylinder with Key Switch 12. Lower Cover

Figure 1. Steering Column

 STEERING COLUMN 3B4-3

3. Nut (2). STEERING COLUMN REPLACEMENT

NOTICE: See “NOTICE” on page 384-1 of this {| Remove or Disconnect (Figures 1 and 3-7)
section.
Too! Required:
[XJ Tighten J-24292-B Steering Wheel Puller, or
equivalent.
¢ Nut (2) to 49 N-m (36 lb-ft). . Battery cable.

Nos
. Steering wheel assembly using J-24292-B or
equivalent (figure 3).
. Column lock system (8) and cowl (4) (figure 4).
. Starter and combination switch harness

&
connectors.
. Combination switch (5).

an
. Key cylinder with key switch (6).
» It may be necessary to cut a siot in the key
cylinder screw head (figure 6).
+ Remove snap ring.
1. Steering Wheel . Remove inspection window and mark steering
2. Steering Shaft worm shaft and U-joint yoke. Remove key bolt
A. Reference Marks (7) (figures 1 and 5).
. Disconnect the support spring.
oon ~

. Remove column support bracket nuts.

Figure 2. Marking the Steering Wheel and
. Steering column (10)
Steering Shaft
. Steering shaft assembly (9).
* Mark the steering shaft (figure 7).

Figure 4. Column Lock System

Figure 3. Removing the Steering Wheel

Inspect
4. Horn wire to the steering wheel terminal.
5. Horn button (1). Steering shaft for bending or damage.
6. Battery ground cable. Boot for wear, scoring, etc.
Yoke for cracking or damage.
inspect Universal joint bearing for looseness or
roughness.
* Horn for proper operation - Column bushing for wear or damage.
Switch wiring for cuts or damage

NOTICE: Universal joint cannot be

disassembled.
3B4-4 STEERING COLUMN

. tighten column support bracket bolts.

aon
. Column lock system (8).

fl Tighten

« Lower nut to 14 N-m (122 lb-in).

* Upper nut to 16 N-m (12 lb-ft).
* Lock lever bolt to 54 N-m (40 lb-ft).

7. Key cylinder with key switch (6).

» Use new screw (figure 6).
8. Combination switch (5).
« Connect wiring connectors.
9. Steering cowl (4).
10. Steering wheei assembly
« Align the marks made during removal (figure
2).
12. Horn pad (1).
12. Battery cable.
Figure 5. Marking Worm Shaft and U-Joint Yoke
Inspect

| install or Connect (Figures 1-6) * Operation of horn, headlights, turn signals,

hazard flashers, windshield wipers and washers,
and exhaust brake.
NOTICE: See “NOTICE” on page 3B4-1 of this
section for steps 3 and 6. STEERING SHAFT REPLACEMENT
7 Important Refer to the applicable steps of “Steering Column
+ The marks on the worm shaft and the U-joint Unit Repair’ in this section.
yoke must maich (figure 5).

Figure 6. Key Cylinder

1. Steering shaft (9)

2. Steering column (40).
« U-joint yoke anto the steering gear worm shaft
spline (figure 5).
3. Key bolt (7) in the yoke.

fA] Tighten

- Key bolt to 39 N-m (29 Ib-ft).

4, Connect the support spring.
 STEERING COLUMN 384-5

STEERING COLUMN UNIT REPAIR

STEERING SHAFT REPLACEMENT

[a Assemble (Figure 7)
[-9] Remove or Disconnect
* Lubricate the splined shaft.
¢ Steering column assembly, as outlined 1. Boot (3) to spline shaft (2).
previously. 2. Align the marks on the splined shaft and on the
yoke tube (4). Assemble the shafts.
>] Disassemble (Figure 7) 3. Wire (1).
» Use new wire.
1. Cut the wire (1).
fre] install or Connect
2. Spline shaft (2).
» Mark the spline shaft and yoke tube before * Steering column assembly, as outlined
removal of spline shaft. previously.
3. Yoke tube (4).
4, Boot (3).

1. Wire
2. Spline Shaft
3. Boot
4. Yoke Tube

Figure 7. Steering Shaft Replacement

inspect
— Spline shaft for bending or damage.
— Splines and threads for damage.
— Boot for wear, scoring, etc.
— Yoke tube for cracking or damage.
3B4-6 STEERING COLUMN

SPECIFICATIONS
FASTENER TORQUES

Steering Wheel Nut ........... ea teeeeeeeesusnaceeenseusussueneusens cesgseaesesenensseoaaeceesestensueesonsueessesessnaqanetens 49 N-m ( 36 Ib-ft)

Key Bolt oo... ceecseccsseeessneeseenesaeeeveaeeeossessaaeecoaaesesesnesssagausesenseeusseseasessensauscerseueetenuseseneaes 39 N-m ( 29 Ib-ft)
Support Bracket Lower Nuts... eee eecsseeeesssnseeecoeeecesssneeseseneseeeessanseeeeseeetssseeeuausnessnees 14 N-m (122 Ib-in)
Column Lock Lever Nut... cecccccccecceesesssssneeesceecessauecesseseuessusouauevesussnecuasusgersenceanacereeas 16 N-m ( 12 Ib-ft)
Column Lock Lever Bolt 0.2.0... eeecescneceeeeeeeseueeeceeessarasusveceseescaanaeevevensessnecesuswanseessussunssusvens 54 N-m ( 40 Ib-ft)

SPECIAL TOOLS

TOOL NO.
ILLUSTRATION TOOL NAME

J-24292-B
Steering Wheel Puller
 FRONT AXLE AND SUSPENSION 3C-1

SECTION 3C

FRONT AXLE AND SUSPENSION

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

Description ...........sccsne Jeevequresenssaevesonsnanenusacan jaupenuceusausvadereetventeceaezaenarcaesaevanevonascaaeduneesusssentanensaueaeessaeranessersees 3C- 1

Front Axle ....cccsccccsscsccsssesnecsneessensnesscanssnnssenccacsnsensanersnesneutaueessaesauaseneaoueusaenenmnusanedansaduevseesanenesndaneceaeuanssseenans 3c- 1
Front Suspension ..........scseseen sausonsuseauersosaeuesgansensenanesasensneecodeasudncuasceueneecnsaevanaresuqeansanssasneneaveesseesuaneractays 3c- 1
Front Hubs and Bearings ........cscsccuesssseesnsnsersnssesesneeseassnsnanennersnaniennentsenneneenannienserensseersanenaeeneents eeveaeaee 3c- 1
Diagnosis of Front Axle and SUSPeNnSiON ........-..sescsssteenerensessecnseeseessnersessnsmnsseesnesesmnsensenstaesnnenseneseresantas 3C- 2
Diagnosis of Front-Wheel Bearings ..........ccsececsscnsneteenteneseneererscssseseeseatinensersenssusnnanvensersnnensntnevenseneesentas 3C- 4
Tapered Roller Bearing Diagnosis ..........0cccescsesstesneneacsesneetsieeencuuensarssccinesecnevansessneaennarearanatacaeens 3C- 4
Diagnosis of Shock AbDSOrbel............ccsceecemesseesenees ceneneaeeespeeecnsnsesdsauanadesaataeatsusaesosvoumesauanavsensnavegutageransaess 3C- 7
Front Axle On-Vehicle Service........ denesnvucapesssaeussnedeouesncesaneeeeeusutenueguersonsuseeeuavasensousenrenneousrase eenetsseeeneenesonaeenasae 3C- 7
INtFOGUCHION ......ccccseecereessnessuneessneensnesuoseamnonterseauesunrervacsnitesnietaueeennasanirsanens ness pevenecevuesentoneevooussennuaerauanseneanevnens 3C- 7
Front Axle Replacement..........cecusssssmnesenunsecnssncsestenstansceressauieanensenssenuassenianteniensanaenuenstsnserenatasstsennesseen 3C- 7
Steering Knuckle and Bearing Replacement ............::ssceseenseessnenersenrnsnsnutsoesanesteonnuanenaneersnsnneasanocenneres 30-10
Front Suspension On-Vehicle Service..........cecsscceceenesserensteccransssnasenrcssestsnusenscsanstisecsnannnenesssnsesensenas 30-16
Front Spring Replacement.............. causneeacersasavesseqecedsnsucusaaeseaercuseneansedanunssaacscasusactayssdausntaonacadnasamsorsgeassutae
Shock Absorber Replacement... ccssssensecserseeseesscensseessnnanssnsansenuenmsennnsegeusasevesnuosenssseseonesoneeeaeanens
Shackle Replacement .....:.cecmessesennenecesenereniensiscennaneveniaciiaaiennenvoniseaneraneneteesssaes pannensenveanseuasensnauevoneunaesen
Front Hubs and Discs On-Vehicle Service ...........
Specifications.........cseccssssecseesssecsecssscncsnensnsureeenemnsnesssssnesannssnssussnunensueasevensneessasenessenrensessaenenssanencaninenaeeanananens
FrOnt Axle ....ccsccccceescssssssscuconseoesecveuscessuesseetsueenoeesseussinesounysgnususeunesensussunassanensnenateneqerenens sesunrsaeetonunasesenaaconeavons
SUSPONSION........-.cscesecessesessesssessesensneensanestsccnsescenserseceenaneancaneutsatentisencusransceneaneseenenenscaesnenenstnegennanensesenensentes
Fastener TOrques......ccsccceserssuenssccsresnenenteneneesennenenisces
Special TOOMS.........ccccsesensenseseneseerseneeesanssenrennanessescnnevancessonaeneaenaens ssneuseneeauessensuvsossavanesavcunsenaedegensenaenaeseenanas

DESCRIPTION

FRONT AXLE the front axle with U-bolts. The springs are attached
to the frame by means of a shackle at the rear and
The knuckles rotate on roller thrust bearings. an eye pin at the front.
The outer ends of the axle are machined to accept Conventional hydraulic shock absorbers are used.
the kingpins and knuckies.
The knuckles turn on roller thrust bearings. FRONT HUBS AND BEARINGS

FRONT SUSPENSION The front hubs turn on grease-lubricated, tapered

roller bearings. The brake disc is attached to the
The front springs are multi-ieaf type, attached to hub with socket bolts.
3C-2 FRONT AXLE AND SUSPENSION

DIAGNOSIS OF FRONT AXLE AND SUSPENSION

PROBLEM POSSIBLE CAUSE CORRECTION

Hard Steering, Excessive |. Low or uneven tire pressure. j. Inflate to specified pressures.
Effort Required at Steering | 2. Steering linkage or kingpins need 2. Lubricate and free up kingpins.
Wheel lubrication. Make certain all fittings take
lubricant properly.
3. Tight or frozen drag link or tie rod. 3. Lube or replace as necessary.
4. Steering gear to column 4. Align column.
misalignment.
5. Steering gear adjusted too tight. 5. Adjust.
6. Front-wheel alignment incorrect. 6. Check alignment and correct as
necessary.
7. Binding condition in steering 7. Check column mounting and
column. coiumn bearings. Adjust or
replace as needed.

Steering Pulls to Left or 1. Camber incorrectly adjusted. 1. Adjust camber.

Right Steering will generaily pull to side of
axle having greatest positive
camber.
2. Low air pressure in right or left tire. 2. Inflate tire to correct pressure,
Steering will pull to side having low check for air leak, and repair as
air pressure. required.
3. Axle loose and shifted at spring U- 3. Align axle and torque U-bolt nuts.
bolts. Inspect for damaged parts.
Replace if required.
4. Rear axle loose at spring. U-bolt 4. Align rear axle and replace
shifted at one side wiil cause malfunctioning parts, if any.
steering to pull. Tarque U-bolt nuts.

Poor Returnability 1. Steering linkage or kingpins need 1. Lubricate.

iubrication.
2. Steering gear adjusted too tight. 2. Adjust preload.
3. Front-wheel alignment incorrect. 3. Check alignment and correct as
necessary.
4. Steering gear to column 4. Align column.
misalignment.

Snapping or Chucking in | 1. Loose steering gear at frame. 1. Torque mounting bolts.

Steering Column or Wheel | 2. Worn steering shaft universal 2. Replace and repair joints as
joints. necessary.
3. Worn steering linkage components. 3. Adjust, torque, and repair
The effect of these components will components.
telegraph through steering system
and be felt in steering wheel.
4. Steering gear incorrectly adjusted. 4. Adjust steering gear.

Spring Noise 1. Loose U-bolts. 1. Tighten to recommended torque.

2. Loose or worn eye bushings. 2. Replace eye bushings.
3. Lack of lubrication. 3. Lubricate as required.
4. Worn shock absorbers. 4. Replace shock absorbers.
 FRONT AXLE AND SUSPENSION 3C-3

DIAGNOSIS OF FRONT AXLE AND SUSPENSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Spring Sag or Bottom 1. Worn shock absorbers. 1. Replace shock absorbers.

2. Broken spring leaf. 2. Repiace leaf or spring assembly.
3. Severe operation or overloading. 3. Check load capacity rating.

Spring Breakage 1. Loose U-boits. 1. Tighten to recommended torque.

2. Normal fatigue. 2. Replace spring.
3. Overloading. 3. Do not overload vehicle.

Excessive Road Shock 1. Tire pressure too high. 1. Deflate to correct pressure.
2. Wheel bearings adjusted too loose. | 2. Adjust bearings.
3. Camber adjustment incorrect. 3. Adjust camber.
(Negative camber coniributes fo
road shock.)
4. Weak or broken front spring. 4. Replace spring.
5. Worn shock absorbers. 5. Replace shock absorbers.
6. Loose suspension componenis. 6. Inspect, adjust, or repair, and
replace as necessary.

Excessive Play or 1. Front-wheel bearings adjusted too 1. Adjust bearings or replace with
Looseness in Steering loose. new parts as necessary.
Wheel (Steering Wanders) | 2. Worn coupling or steering shaft U- 2. Replace.
joints.
3. Loose pitman arm, tie rods, 3. Torque fasteners.
steering arms, or steering linkage
bail studs.
4. Steering gear worm bearings 4. Adjust preload.
adjusted too loose.
5. Excessive pitman shaft to ball nut 5. Adjust preload.
lash in steering gear.
6. Toe-in out of adjustment or worn 6. Replace drag link and/or tie rod
drag link or tie rod sockets. end parts if worn, adjust to correct
toe-in, and inspect steering arm
and tie rad for bent condition.
7. Steering system out of alignment. 7. Align steering complete, caster,
camber, and toe-in. Inspect spring
components for condition and
wear. Repair or replace as
required.
8. Tires badly worn, edge of tires are 8. Install new tires, and check
rounded off. alignment; abnormal tire wear
indicates improper alignment.
9. Lack of lubrication in linkage and 9. Lubricate. Free up any
kingpins. components that are frozen and
will not take lubrication.

Vibration and Shimmy 1. Wheel bearing seal damage and 1. Replace damaged parts as
leakage resulting in loss of necessary.
lubricant, corrosion, and excessive
wear.
2. Tires, wheels, or brake drums out Balance tires and wheels,
of balance. preferably with on-vehicle type
balancer, as this method balances
3C-4 FRONT AXLE AND SUSPENSION

DIAGNOSIS OF FRONT AXLE AND SUSPENSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Vibration and Shimmy 3. Bent wheel or out-of-round tire. Repair wheel and remount tire,
(cont.) Wheel nuts torqued unevenly. or replace.
Loose steering linkage Adjust, torque, and repair linkage
components. as necessary.
Wheel loose on hub. Inspect wheel boit holes for
damage. Replace wheel if
needed. Replace all wheel studs.
Driveline universal joints rough, or Repair driveline.
faulty. This condition may be
confused with steering vibration.
Engine misses or is out of balance. Correct miss in engine, or repair
This may also be confused with out-of-balance condition, clutch,
steering shimmy. pressure plate, or harmonic
balancer, etc.
Worn shock absorbers. Replace shock absorbers.

DIAGNOSIS OF FRONT-WHEEL BEARINGS

TAPERED ROLLER BEARING DIAGNOSIS 2. Classify the failure with the aid of the
iNustrations.
Consider the following factors when diagnosing 3. Determine the cause.
bearing condition: 4, Make all repairs following recommended
1. General condition of all parts during procedures.
disassembly and inspection.

GOOD BEARING BENT CAGE BENT CAGE

CAGE DAMAGE DUE TO IMPROPER CAGE DAMAGE DUE TO IMPROPER

HANDLING OR TOOL USAGE. HANDLING OR TOOL USAGE.

REPLACE BEARING. REPLACE BEARING.

 REAR SUSPENSION 3D-5

4. Shock Absorber
6. U-Bolts 16
8. Shackle
10. Spring
18. Rear Axle Housing

Figure 5. Rear Suspension Attachments

6. Brake flexible hose into bracket.

7. Hose clip (11) and steel tube nut (55) (figure 3).

Tighten
° Steel tube nut (55) to 15 N-m (11 Ib-ft} (figure
3).

8. Lower the vehicle and bleed the brakes as

described in HYDRAULIC FOUNDATION
BRAKES (SEC. 5A2).

6. U-Bolt Nuts and Bolts

10. Spring
18. Rear Axle Housing

Figure 7. U-bolt Removal or Installation

8
18. Rear Axle Housing
19. Jack
@e ‘ee

®
ge
Figure 6. Supporting Rear Axle

10 | °@
8. Shackle Nuts and Shackles
10. Spring
20. Bushing

Figure 8. Spring Shackle

3C-6 FRONT AXLE AND SUSPENSION

DIAGNOSIS OF FRONT-WHEEL BEARINGS (CONT.)

TAPERED ROLLER BEARING DIAGNOSIS (CONT.)

CRACKED INNER RACE

SMEARS FRETTAGE

RACE CRACKED DUE TO IMPROPER

SMEARING OF METAL DUE TO CORROSION SET UP BY SMALL
FIT, COCKING, OR POOR BEARING
SLIPPAGE, SLIPPAGE CAN BE RELATIVE MOVEMENT OF PARTS
SEATS. LUBRICATION.
CAUSED BY POOR FITS, WITH NO LUBRICATION.
LUBRICATION, OVERHEATING,
OVERLOADS OR HANDLING REPLACE BEARING, CLEAN RELATED
DAMAGE. PARTS. CHECK SEALS AND CHECK
FOR PROPER LUBRICATION.
REPLACE BEARINGS, CLEAN
RELATED PARTS AND CHECK FOR
PROPER FIT AND LUBRICATION.

REPLACE SHAFT iF DAMAGED.

HEAT DISCOLORATION

CD
HEAT DISCOLORATION CAN RANGE
FROM FAINT YELLOW TO DARK
BLUE RESULTING FROM OVERLOAD
OR INCORRECT LUBRICANT. my

EXCESSIVE HEAT CAN CAUSE STAIN DISCOLORATION

SOFTENING OF RACES OR
ROLLERS. DISCOLORATION CAN RANGE FROM
LIGHT BROWN TO BLACK CAUSED
BY INCORRECT LUBRICANT OR
TO CHECK FOR LOSS OF TEMPER MOISTURE.
ON RACES OR ROLLERS A SIMPLE
FILE
TEST MAY BE MADE. A FILE DRAWN RE-USE BEARINGS IF STAINS CNA
OVER A TEMPERED PART WILL BE REMOVED BY LIGHT POLISHING
GRAB OR IF NO EVIDENCE OF
AND CUT METAL, WHEREAS A FILE OVERHEATING IS OBSERVED.
DRAWN OVER A HARD PART WILL
GLIDE READILY WITH NO METAL CHECK SEALS AND RELATED PARTS
CUTTING. FOR DAMAGE.

REPLACE BEARINGS IF OVER

HEATING DAMAGE IS INDICATED.
CHECK SEALS AND OTHER PARTS.
 FRONT AXLE AND SUSPENSION 3C-7

DIAGNOSIS OF SHOCK ABSORBER if necessary.

5. Compare the compression and rebound
On-Vehicle Test resistance by stroking both shock absorbers as
in step 3. Replace both units if a definite
Shock absorbers are a sealed assembly and must
difference in either compression or rebound
be replaced if faulty.
resistance is felt.
1. Disconnect both lower shock mountings and
6. Inspect mounting brackets for looseness or
pull down on the shock absorber until it is fully
wear. Inspect rubber bushings and grommets
extended.
for wear or deterioration.
2. Inspect for leaks in the piston rod seal area.
Shock fluid is a thin hydraulic fluid, dark brown
Bench Test
in color, with a characteristic odor. A slight trace
of fluid seepage is permissible, as the seal is 1. The information given previously applies also to
designed to seep a slight amount of fluid to the bench test procedure. Bench testing the
provide for piston rod lubrication. shack absorbers may be desirable if there is still
If a great deal of oil is present, be certain that some doubt as to whether the shocks are worn.
the oil does not originate from some other In addition, the bench test allows a more
source (oil spray from engine, air compressor, thorough visual inspection.
etc.) before assuming that the shocks are 2. The shock absorbers must be tested in an
leaking. upright, vertical position. If tested in any other
3. Grip the lower end of the shock securely and position, air will enter the damper valve, causing
stroke up (compression siroke) and down the shock to appear weak.
(rebound stroke) several times. Rebound
resistance (extending the shock) should be NOTICE: Do not clamp on the reservoir tube,
greater than the compression resistance. If in the mounting threads, or distort the mounting
doubt, compare resistance of suspected shock eyes to prevent damage.
with a new one.
Resistance should be smooth and constant for 3. With the shock in an upright, vertical position,
each stroking rate. Replace shock if any binding clamp the bottom mount in a vise. Extend the
or unusual noises are present. shock fully.
4, Extend shock to the limit of its travel and 4. Follow “On-Vehicle Test,” steps 2 through 6 in
inspect for a bent damper rod. Replace the unit this section.

FRONT AXLE ON-VEHICLE SERVICE

INTRODUCTION Always straighten axles cold and never apply

heat. Also, they should never be repaired by
Preliminary axle inspection can be made while the welding, because heating or welding weakens the
axle is still mounted. Steering knuckles, kingpin material strength.
bearings, and thrust bearings can be replaced Do not weld any front axle components. The heat
without removing the front axle from the vehicle. from welding will weaken that portion of the
Check the axle for twist with alignment material.
instruments. If equipment is available, use X-ray in
section to check axle for minute fractures. FRONT AXLE REPLACEMENT
if the axle has been twisted or bent more than five
Refer to STEERING LINKAGE (SEC. 3B1), ABS
degrees (13 mm [1/2 in]) from the original shape,
the axle beam should be replaced. SYSTEM (SEC. 5A4), BRAKES (SEC. 5), or
When a bent condition exists, minute invisible “Steering Knuckle and Bearing Replacement” later
fractures may occur and cause failure under in this section, for removal of associated
ordinary operating conditions. components for axle removal. Raise the front of the
The axle can be straightened using the cold vehicle until the tires clear the floor.
method. This process must be performed by
[y] Important
personnel who are thoroughly familiar with such
operations and the tools involved. « Block the frame with safety stands.
 3C-8 FRONT AXLE AND SUSPENSION

shock absorber into its fully retracted

[es] Remove or Disconnect (Figures 1, 2, 3)
(collapsed) position. This will allow the shock to
* Support the axle with a floor jack. clear the axle assembly (figures 1 and 3).
1. Brake flexible hoses (1) (figure 1). Loosen the 5. U-bolt nuts (4) (figure 1).
nut (7) then remove the clip (6) (figure 2). 6. Front axle assembly (5) from the vehicle. Lower
2. Drag link (3), at the steering arm (figure 1). the axle and pull it out from under vehicle. Note
3. Stabilizer bar from bottom spring plate. the position of ali shims and spacers (figure 1).
4. Shock absorbers (2) at the lower stud. Push the

1. Brake Flexible Hose

2. Shock Absorber
3. Drag Link
4, U-Bolts Nut
5. Axle Assembly

Figure 1. Front Axie Assembly

Figure 2. Flexible Brake Hose

 FRONT AXLE AND SUSPENSION 3C-9

12
15 >
f 14 a
4 11
16
|
10 17
2

9
B
A. Upper Mount
4 . Lower Mount

oong
. Shock Absorber
. Upper Bushings
. Lower Bushings
10. Dish Washer
11. Flat Washer
. Center Washer
XY. 13. Spring Washer
14. Nut

O40
14 13
15.
16.
17.
Lock Nut
Frame Bracket
Lower Stud

Figure 3. Front Shock Absorber Attachment

H, H, L, Le
Clean 83 mm 120.4 mm 315 mm 860 mm
(3.3 in} (4.74 in) (12.4 in) (33.9 in)
* The axle in solvent. Remove all traces of old
grease and dirt.
18. Kingpin or Test Bar
Inspect (Figures 4, 5 and 6) 19. Cord
20. Center Bolt Holes
* The following parts for wear, damage, or other
abnormal conditions:
1. Fit the kingpin or test bar (18) into the kingpin
hole (figure 4).
2. Stretch a cord (19) across the centers of kingpin
or test bars.
3. Check to see if the cord is in line with the
centers of the center bolt holes (20) in the
spring seat when looked down from above the
cord.
4. Also, check to see if the kingpins or test bars
Figure 4. Front Axle Checking Fixture
(18) are in good vertical alignment as viewed
from the side (figure 5).
5. Check to see if the kingpin bores (21) are worn
(figure 8).

Measure

« Stretch a cord (19) and check the following

dimensions (figure 7).
3C-10 FRONT AXLE AND SUSPENSION

page 3C-1 of this section.

1. Position the axle assembly under the front

springs supported by a garage jack (figure 1).
2. Position any shims or spacers, which were
originally used or will be used, between the axle
and springs.
3. Raise the axie to the springs and install the
bumper stops, U-bolts, bottom plates, and U-
5. Axie bolt washers and nuts (figure 8).
18. Kingpin or
Test Bar fa] Tighten
C. Sight Line
* Front axle U-bolts to 127 N-m (94 Ib-ft).
Figure 5. Front Axle Alignment Check
4. Shock absorber bushings, washers, and shocks
onto the lower stud mounts (figure 3).

[QI Tighten

* Shock absorber nuts to 95 N-m (70 Ib-ft).

5. Stabilizer bar to bottom spring plate. Install the

bushings.

[QJ Tighten
¢ Stabilizer bar nuts and bolts to 94 N-m (69
ib- ft),

6. Drag link at the steering arm.

« Refer to STEERING LINKAGE (SEC. 3B1) in
this manual.
5, Axle 7. Lower the vehicle. Brake flexible hoses in a
21. Kingpin Bore neutral position.

Figure 6. Front Axle Kingpin Bore Inspection

[QJ Tighten
* Brake pipe nut to 15 N-m (11 lb-ft)
(figure 2).

24,3 (0.957) 8. Bleed the brake hydraulic system. Refer to

HYDRAULIC BRAKES (SEC. 5A) in this
manual.

Adjust
* Front end alignment. Refer to FRONT END
L, ALIGNMENT (SEC. 3A) in this manual.

11°45" STEERING KNUCKLE AND BEARING

19. Cord
REPLACEMENT
« Raise the vehicle until the tires clear the floor.
Figure 7. Checking Front Axle for Vertical Bow
Important
| Install or Connect (Figures 1, 3 and 8)
» Block securely with safety stands.
NOTICE: For steps 3, 4 and 7 see “NOTICE”on
 FRONT AXLE AND SUSPENSION 3C-11

[es] Remove or Disconnect (Figures 9 and 10)

Tools Required:
J-35710 Remover
. Tire and wheel as outlined in WHEELS AND
TIRES (SEC. 3E) in this manual.
. Hub and drum assembly as outlined in “Front
Hubs and Bearings On-Vehicle Service” in this
section.
. Brake backing plate. Refer to HYDRAULIC
FOUNDATION BRAKES (SEC. 5A2) in this
manual.
. Steering Linkage. Refer to STEERING
LINKAGE (SEC. 3B1) in this manual.
— Tie rod.
— Drag link (if servicing the left side knuckle).
. Bolts (32) and washers (33).
. Dust cap (34).
NO

. Nut (29), washers (30) and key boit (31).

- Remove the nut.
* Screw on Remover Tool J-35710 (figure 10).
* Tap end of the tool to loosen the key bolt.
- Remove the tool.
« Remove the key bolt (31).
. Kingpin (35). Drive the kingpin and plug out of
the knuckle with a brass drift and hammer.
. Remove the knuckle (37), thrust bearing (38),
and shim(s) (39).
10. Plug (36) and discard.
2. Shock Absorber Assembly
4, U-Bolts
22. Stabilizer Bar
23. Bumper Stops
24. Stabilizer Bracket
25. Shackle and Bolt
26. Spring Eye Bolt and Nut
27. Leaf Spring

Figure 8. Front Suspension Components

3C-12 FRONT AXLE AND SUSPENSION

Clean * Kingpin (35) for scoring or damage. Check the fit

of the kingpin in the axle (5). If the kingpin fits
+ All parts in solvent. Remove all traces of old loosely, replace the axle (figure 9).
grease and dirt. Be sure to get all grease and dirt Kingpin fit into the bushings can be checked in
out of the knuckle bushings (figure 9). the following manner: Clamp the knuckle in a vise
and insert the kingpin into the bushings.
Inspect (Figures 9, 11, 12, 13, 14, 15 and 16) Check for radial play by moving the kingpin in the
direction at a right angle to its axis, and then
* Knuckle (37) for cracks or damage. Pay special
move the kingpin endwise with your finger (figure
attention to the areas shown by arrows in figure 12).
11. Use X-ray inspection equipment, if available.
* Check tapered portion of the steering arms for
* Thrust bearing (39) for roughness of operation or abnormal contact in the following manner: Apply a
damage (figure 9). thin coat of dye.
* Key for damage (figure 9).
Check evenly for the tapered portion of the arm
and insert the arm into the tapered hole. Remove
the arm and check impression of contact obtained
40 on the taper. Correction or parts replacement is
32 necessary if the contact is uneven or if contact
39 g area is smaller than 3/4 of the entire length of the
\ O33 (SG taper (figure 13).
<= +34
Measure
35
0 C * Diameter of the kingpin. It must be within the
31 30 limits shown in figure 14.
* The clearance between the kingpin and the
= 22 Grn1a3 bushings must be as shown in figure 15.

Kingpin Bushing Replacement

DL, 38
If the kingpin to bushing clearance is too great, or
: 5 the kingpin or bushings are damaged, a new
kingpin kit must be installed.
Drive the old bushings out with a suitable driver
5. Axle 35. Kingpin (figure 16). Clean the holes.
29. Nut 36. Plug Press in new bushings, being careful to align the
30. Washer 37. Knuckle grease holes in the bushings and knuckle.
31. Key Bolt 38. Thrust Bearing Try the kingpin for proper fit in the bushings. If too
32. Bolt 39. Shim tight, the bushings must be reamed to allow a
33. Washer 40. Grease Fitting proper fit (figures 15 and 17).
34. Dust Cap 143. Bushing

Figure 9. Steering Knuckle and Attaching Parts

A. 35 mm (1.38 in}
B. 50 mm (1.97 in)
C. Inspect for cracks.

Figure 11. Steering Knuckle Inspection

31. Key Bolt 31 /
41. Tool J-35710

Figure 10. Removing Steering Knuckle Key Bolt

 FRONT AXLE AND SUSPENSION 3C-13

fF Diameter A
Figure 12. Checking Fit of Kingpin in Knuckle Standard 30 mm (1.181 in)
Limit 29.9mm_ (4.177 in)
Figure 14. Measuring Kingpin
42

l (2 }
~

>

37

“Ot I =

9
~.
37. Knuckle Diameter B minus
42. Steering Arm Diameter A
A. Contact area is longer than 3/4 of the Standard 0.06 mm = (0.0024 in)
entire length of the taper. Limit 0.15mm (0.0059 in)

Figure 13. Checking Fit of Steering Arm in Knuckle Figure 15. Kingpin and Bushings Clearance
o
Lathes |
Foy men
pecifoemes

()

Dimension A is 65 mm (2.5 in).

Dimension B is any suitable length.
Dimension C is 0.25 mm (0.010 in) less than the steering knuckie bore.
Dimension D is 0.25 mm (0.010 in) less than the bushing bore.

Figure 16. Knuckle Bushing Removal and Installation Tool

 3C-14 FRONT AXLE AND SUSPENSION

Thickness mm (in)
0.50(0,.020) 0.70(0.028)
0.55{0.022) 0.80(0.031)
0.60(0.024) 0.90(0.035)
0.65(0.026)

3. Remove the kingpin, knuckle, and thrust

bearing.

Assemble

A. Reamer « The selected shim(s) (figure 19). Grease all

37. Knuckle parts and install the knuckle, thrust bearing,
shims, and kingpin onto the axle. Align the
Figure 17. Reaming Steering Knuckle Bushings notch in the kingpin and key bolt hole in the
axle (figure 20).

foe] Install or Connect NOTICE: See “NOTICE” on page 3C-1 of this

section.
1. Lightly oil the axle bore, the kingpin, and the
knuckle bushings. [&Q] Tighten
2. Knuckle and thrust bearing onto the axle.
Temporarily install the kingpin. Be sure the + Install the key bolt from the rear of the axle.
roller thrust bearing is installed LH, and the bali Torque the key bolt nut to 32 N-m (24 Ib-ft)
thrust bearing is installed RH with the cover (figure 21).
side facing up as shown in figure 18.
4. Check the knuckle to assure that it turns freely.
Measure 5. Install the sealing plug in the bottom of the
knuckle kingpin hole. Use a suitabie bar and
« Raise the knuckle and measure the clearance
hammer (figure 22).
between the top of the axle and the knuckle
6. Install the upper kingpin seal, washers, and
(figure 19).
bolt.
« Note the dimension and select the shims that
Refer to STEERING LINKAGE (SEC. 3B1),
will give a clearance of 0.10 to 0.20 mm
HYDRAULIC FOUNDATION BRAKES (SEC. 5A2),
(0.004 to 0.008 in). Shims are available in the
WHEELS AND TIRES (SEC. 3£) and “Front Hubs
following thicknesses:
and Bearings On-Vehicle Service” in this section for
remaining component assembly.

44

5. Axle
37. Knuckle (Spindle)
39. Shim or Spacer
43. Thrust Bearing
44. Bearing Cover
45. Bearing Upper Side
46. Bearing Lower Side

Figure 18. Steering Knuckle Thrust Bearing Location

 FRONT AXLE AND SUSPENSION 3C-15

37

39
x

31. Key Bolt

37. Knuckle (Spindle) 35. Kingpin
39. Shim 37. Knuckle (Spindle)

Figure 19. Selecting Steering Knuckle Shim Figure 21. Keybolt Location and Position

47. Kingpin Notch

48. Key Bolt Hole

Figure 20. Aligning Kingpin and Keybolt Figure 22. Installing Steering Knuckle Lower
Sealing Plug
3C-16 FRONT AXLE AND SUSPENSION

FRONT SUSPENSION ON-VEHICLE SERVICE

FRONT SPRING REPLACEMENT * Spring front eye bolt.

* Shackle bolt.
Raise the vehicle until the tires clear the floor. » Shock absorber
Block the frame with safety stands. Support the + Bumper stop
front axle with a floor jack. « Rubber bushings

Remove or Disconnect Leaf Spring

(Figures 2, 3, 8 and 23)
[$] Disassemble (Figures 24 and 25)
1. Loosen the brake flexible hose tube nut. Pry the
clip off of the flexible hose (figure 2). * Apply a reference mark across the springs before
2. Remove the shock absorber (figure 3). disassembling the leaf spring assembly (figure
3. Remove the stabilizer bar (figure 8). 24).
4. Remove the U-bolts, bumper stop and stabilizer * Use a bench press for disassembly and
bracket (lower spring plate) (figure 8). reassembly (figure 25).
5. Spring rear shackle bolt (figure 23). ¢ Discard center bolt.
6. Front spring eye bolt (figure 23).
7. Remove the spring.

Inspect (Figures 8 and 23)

Check the following parts for wear, damage, or
other abnormal conditions:
+ Spring assembly.
« Clamps.
« Center bolt.
* U-bolts.

2/7. Spring
A. Reference Mark

Figure 24. Spring Leaf Reference Mark

27. Spring
25. Rear Shackle, Nut and Bolt C B. Adapter
26. Front Spring Eye Bolt and Nut C. Press
27. Spring
Figure 25. Assemble-Disassemble Leaf Spring
Figure 23. Spring Shackles and Eye Bolt
 FRONT AXLE AND SUSPENSION 3C-17

Inspect [oe] install or Connect (Figures 2, 3 and 8)

» Spring eye bolt (26) and lower shackle bolt (25) NOTICE: See “NOTICE” on page 3C-1 of this
for scoring or damage (figure 23). section for steps 4, 5, 6, 7 and 8.
« Spring leaf clamps for bending or cracks.
+ Spring leaves for cracks or breakage. 1. Place the spring on the axle with the
+ Spring eye bushings for wear or damage. identification mark “+, — , or 0” toward the front
facing up (figure 8).
Measure . Front eye bolt finger tight.

Gh
. Shackle bolt(s) finger tight.
- The clearance between spring eye pin and the . U-bolts, bumper stop, and stabilizer bracket(s).

&
bushing is 0.1—0.5 mm (0.004—0.02 in). » Raise the axle against the spring.
Assemble (Figures 8, 24 and 25) fa] Tighten
1. Leaf springs and clamps using a press (figure « Install the U-bolt nuts and torque them to 127
25). N-m (94 lb-ft).
- Be sure to line up the reference marks (figure
24). 5. Shock absorber (figure 3). See “Shock Absorber
- Apply grease to both faces of each leaf spring Replacement” in this section.
at assembly.
Tighten
NOTICE: See “NOTICE” on page 3C- 1 of this
section. * Shock absorber lower nuts to 95 N-m (70
ib-ft).
2. Center boit.
6. Lower the vehicle.
[A] Tighten
[RQ] Tighten
* Center bolt to 39 N-m (29 lb-ft).
« Spring eye bolts to 177 N-m (130 Ib-ft).
Spring Eye Bushing Replacement * Shackle bolts to 127 N-m (94 Ib-ft).
1. Bushing by driving out with a hammer and brass
drift J-35714 (figure 26). 7. Stabilizer bar (figure 8).

Tighten
* Stabilizer bar nuts and bolts to 30 N-m (22
Ib- ft).

8. Set the front wheels in a straight ahead

position. Install the brake flexible hose. Install
the clip. Connect the tube nut.

FQ] Tighten
« Tube nut to 15 N-m (11 lb-ft) (figure 2).
27. Spring
D. J-36714
SHOCK ABSORBER REPLACEMENT
Figure 26. Replacing Spring Bushing [es] Remove or Disconnect (Figures 3 and 8)

2. Inspect the shackle pin (bolt) for wear or 1. Safety nut and nut from top of shock absorber.
damage. Washer and bushing from top stud.
3, Measure the shackle pin (bolt) outside diameter. 2. Nut, two washers, and bushing from shock
The diameter is 24.7-25.0 mm (0.972—0.984 in). absorber bottom mount stud.
4. Drive the new bushing into the spring with the 3. Compress shock absorber and remove.
same tool that it was removed with. Remove remaining bushings and washers.
3C-18 FRONT AXLE AND SUSPENSION

Inspect (Figures 3 and 8) SHACKLE REPLACEMENT

* Shock absorber. Refer to “Diagnosis of Shock Raise the vehicle until the tires clear the floor.
Absorber” in this section. . Block the frame with safety stands. Support the
* Rubber bushings for cracks or deterioration. front axle with a floor jack.

| Install or Connect (Figures 3 and 8) [+9] Remove or Disconnect (Figures 1, 8 and 23)
NOTICE: See “NOTICE” on page 3C-1 of this 1. Washers and nuts (figure 23).
section for steps 4 and 5. 2. Drive bolts out, using a brass drift and hammer.
3. Shackle (25) (figure 23).
1. Washer and inner rubber bushing to the iower
bracket. Inspect (Figure 23)
2. Washer and bushing onto upper stud of shock
absorber. * Shackle (25) for cracks or damage.
» Upper and lower shackle bolts for scoring or
3. Compress and then expand shock absorber into
damage.
upper bracket.
4. install upper bushing, washer, and nut(s).
[oe] Install or Connect (Figures 8 and 23)
fa] Tighten 1. Shackle.
» Fixing nut to 20 N-m (14 lb-ft). 2. Upper and lower shackle bolts.
* Lock nut to 40 N-m (30 Ib-ft)
NOTICE: See “NOTICE” on page 3C-1 of this
section.
5. Install outer lower bushing, washer(s), and nut.

FQ] Tighten 3. Washers and nuts.

« Nut to 95 N-m (70 Ib-ft). [a] Tighten

* Shackle nuts and bolts to 127 N-m (94 lb-ft).

FRONT HUBS AND DISCS ON-VEHICLE SERVICE

Remove or Disconnect fy] important

(Figures 37, 38, 39 and 40)
* Do not drop the outer bearing (5) as it comes
1. Tire and wheel assembly, and caliper assembly off of the knuckle (spindle) (figure 37).
as outlined in WHEELS AND TIRES {SEC. 3E)
and HYDRALIC FOUNDATION BRAKES (SEC. 6. Remove dust shield (15).
§A2) in this manual. 7. Remove adapter (16).
2. Hub cap.
[S] Disassemble (Figure 37 and 41)
[] Important
1. Remove excess grease from bearing and race
« When removing hub cap, be careful not to area of nub.
scratch or distort the cap sealing face (figure 2. Drive the inner and outer bearing races out of
38). the hub.
The inner race, bearing, seal and spacer will
. Cotter pin from nut and knuckle (spindle). come out as the race is removed.
aw

4. Nut and washer from knuckle (spindle) (figure 3. Drive the outer race out from the opposite side.
39.)

5. Remove front hub and disk assembly. (figure

40).
 FRONT AXLE AND SUSPENSION 3C-19

. Hud Cap 9. Inner Bearing

—

. Cotter Pin 10. Disc

GH

. Nut 11. Inner Race

. Washer 12. Outer Race
oar

. Outer Bearing 13. Stud

. Hub and Disc Assembly 14. Hub
. Spacer 15. Dust Shield
On

. Oil Seal 16. Adapter

Figure 37. Front Hub, Disc and Related Parts

A. Wrench
1. Hub Cap 3. Nut
6. Hub and Disk Assembly 6. Hub and Disc Assembly

Figure 38. Removing Hub Cap Figure 39. Removing Front Hub Nut
3C-20 FRONT AXLE AND SUSPENSION

are loose or can be rotated in the bore, the hub

must be replaced. If the bearing cups are
cracked or pitted, they must be replaced.
. Bearings (5 and 9). Inspect the bearings for

Ro
excessive wear, chipped edges, and other
damage.
Refer to “Diagnosis of Front Whee! Bearings”,
previously covered in this section. Slowly roll
the rollers around the cone to detect any fat or
rough spots. Replace damaged parts.

Assemble

1. Lightly grease the bearing races. Using tools

J-8092, J-35712 and J-35713, seat them
completely into the hub (figure 42).
C. J-36429 2. Apply an approved wheel bearing grease into
the bearing rollers. The total amount of grease
Figure 40. Removing Front Hub that should be in the hub cavity is 160 grams
(5.6 9z) and in the hub cap 40 grams (1.4 02).
3. Install the inner bearing and the seal with the
hollow side of the seal facing the bearing.

14

D. Brass Bar
10. Disc
14. Hub

Figure 41. Removing Bearing Races

Clean E. Tool J-35712 (for inner Bearing)

J-35713 (for Outer Bearing)
* Hub, bearings, and races with non-flammable F. Tool Grip J-8092
solvent anc wipe dry. 11. Inner Race
12. Outer Race
Inspect (Figure 37)

{. Bearing races (11 and 12). Check the fit of the Figure 42. Installing Bearing Races
bearing cups in the hub (74). If the bearing cups
 FRONT AXLE AND SUSPENSION 3C-21

Disc Replacement 6. Install a new sensor rotor using a suitable

1. Remove the sensor rotor with a suitable installer.
remover. Be sure the sensor rotor is seated completely.
2. Remove the disc (10). Use an Allen wrench (G) 7. Assemble hub and disc.
to loosen the disc fixing bolts. (figure 43)
3. Separate hub and disc. NOTICE: See “NOTICE” on page 3C-1 of this
section.

Tighten

« Bolts 103 N-m (76 lb-ft).

Front Wheel Stud Replacement

[3] Important
* If any wheel experiences damage to a single
stud caused by a joose-running wheel, all the
studs should be replaced. A loose-running
wheel may cause only one stud to break, but
the other studs could have internally fatigued
G. Allen Wrench to the point of being damaged. Replacing only
10. Disc the broken stud and remounting the wheel
14. Hub may cause further damage and personal
injury. If the stud holes in the wheels become
Figure 43. Removing Disc larger in size or distorted, replace the wheel.

4. Inspect the disc excessive wear, warped condition 1. Remove wheel, hub, and disc as described
and cracks. earlier in this section.
5. Measure the disc thickness (figure 44). 2. Place hub on a suitable work surface and
« Disk diameter : 293 mm (NPR / W3500 / W4500) remove the studs, as required, using a hammer.
Standard 40.0 mm (1.57 in) 3. Inspect hub for warped condition, cracks, and
Limit 37.0 mm (1.46 in) enlarged stud holes.
* Disk diameter : 363 mm (NQR / W5500} 4. Place the hub on a wood workbench or a block
Standard 42.0 mm (1.65 in) of wood approx. 6" by 6" to protect the wheel
Limit 39.0 mm (1.54 in) stud ends and threads.
5. Insert a new wheel stud using a hammer.
Be sure the wheel stud is standed squarely and
seats completely.

NOTICE: See “NOTICE” on page 3C-1 of this

Ve
section.

10. Disc

Figure 44. Measuring Disc Thickness

3C-22 FRONT AXLE AND SUSPENSION

| Install or Connect 5. Apply grease into the hub cap and install it.
6. Return the caliper assembly to its original
1. Install adapter (16). position.

fQ] Tighten [RX] Tighten (Figure 46)

+ Adapter Fixing Bolt : 162 N-m (419 lb-ft) + Lock Pin Bolt 137 N-m (101 lb-ft).
2. Install dust shield (15).

Fa] Tighten

* Dust shield Fixing Bolt : 13 N-m (113 fb-in)

3. Install the spacer, hub, and disc assembly onto

the knuckle (spindle).
4. Install the outer bearing washer and nut onto
the knuckle (spindle).

Adjust (Figure 45)

« Adjust the wheel bearing as follows:

1. Tighten the nut until you are unable to manually
rotate the hub and disc assembly. L. Lock Pin Bolt
2. Loosen the nut. M. Caliper Assembly
3. Attach a spring balancer to one stud. Gradually
retighten the nut until the hub and disc Figure 46. Tightening Lock Pin Bolt
assembly bearing is adjusted to the specified
preload.
« Hub bearing preload.
New Hub Bearing 18 N (4 Ib)
Reused Hub Bearing 13 N (3 Ib)

K. Spring Balancer
13. Stud

Figure 45. Adjusting Front Wheel Bearing Preload

4. Install a cotter pin through the nut and knuckle

and bend it over.
+ If the notch in the nut does not line up with the
cotter pin hole in the knuckle, tighten the nut
until it does. Do not loosen the nut to line up a
notch and the knuckle hole.
 FRONT AXLE AND SUSPENSION 3C-23

SPECIFICATION

FRONT AXLE

Knuckle Spindle Diameter

Outer Bearing Race Seat 2... ese cceer eens e tense seneeene tree nsententeesseeerissensnesesneeseeneesnnees 35 mm (1.377 in)
Inner Bearing Race Seat... eceeeeceeceeseceneectenenceeeneerentenessssvssausnssecsuerseeteraesieeseseeewans 50 mm (1.968 in)
Kingpin Diameter
PLOCUCTION coccccccccceeeccccceucnccceccausereecuaveusuusmwasceseeeaeseecsenersersnnmeeeemeaeeeseeeeeeeensenemeseseaseneeeenaeenens 30 mm (1.181 in)
Service Limit .............cccceecccceeeenneeeceeneesesseetuanaeeeeeeseennenanees bececeneesuunaeeaeaeeeeeeeeeaneuneerseeeeesans 29.9 mm (1.177 in)
Kingpin to Knuckle Bushing Clearance
PrOCUCTION .......ccccccccecseesssccsseeeeeceeuecseseaceeteneresouensuneuauaeseeestsanseeenasseaseneresanecegeritrereeeesones 0.06 mm (0.0024 in)
Service Limit .........ccccccccccceccececeseeesseeeeecneneeeeaeeneerepeesceuaessueneaseneseesnneseeaaagegeeateeteemmegsen ons 0.15 mm (0.0059 in)
Knuckle to Axie Clearance
PLOGUCTION .....ccccccccccseseeceeeesseceeececeeceuunncesveneeeeuaerecunnsedeeueeeeeuatenanasgassaeeeeseneesinansseesueteeeanaes 0.10 mm (0.004 in)
Service Limit .........ccccccceecsessceccceeceneeesseccenereesnecneeeeeeeessaeesteaunensesneesenseeusaonaeceeserseteeaqenennees 0.2 mm (0.008 in)
Front Hub Bearing Preload
NeW Bearing .....ccccccccccsceceeereesseerseenessceeesaseeeesteeneeseeecensceecietereseeseecsuneeuetenesemsensaeeersceasnrasersesseneens 18 N (4 Ib)
REUSED Bearing ......ccecccccecseeeceseesrevstesnensesanenecneonnecsumensaacnesssenessseasgespreseesneacasansaconaceaeaesenaneneres 13 N (3 Ib)

SUSPENSION
Spring Eye Bolts and Shackle Bolts Diameter
PrOCUCTION .....ccccccccecccccecceusecseseecseccersanemsceeneeeeeseassecaacusecsaeseseesensneaseessneeseseaeneneeseeeueseneeaens 25.0 mm (0.984 in)
Service Limit ........ccccccccceceenecccnseceerseceeeeeeuseesceaueeeeereeecneuaadeeaenensaweeessaseagagarsenereeesanmanegeneeees 24.7 mm (0.972 in)
Spring Eye Pin to Bushing Clearance
PLOCUCTION .0.....ccscccccceeeceeeeeesereeeteeeceaneeeneenssneeeereeeneesertes pa enaanaeacuneaaaaacaeneaeaneeaeaeassnmenenmecaaes 0.1 mm (0.004 in)
Service LIMit ........cccceeesesesescceccceeeeuecesneceeceeceecuseesscsaueessaaeceusnaceassesesesaeseegamansennesstaaucaavaaaees 0.5 mm (0.020 in)

FASTENER TORQUES

AX1@ U-DOItS ..ccccccccccceeececceeecsseuscesecseecsencecneeeeereneesniranueneenesecienencessenenecemeseseennnsseseeeaseassene gees 127N-m (94 lb-ft)

Shock Absorber Lower Fixing Nuts...........::c:cecsessssercestecteees spuneesacseceuaeeu 95N-m_ suas seeeerseeeesseensaseneeeeenea (70 lb-ft)
Stabilizer Bar NUtS 0.0.0... .cccccceccccescceeeeeeee tee eeteee sete tere Hn EOE PRRE One fnEEUETE LEU ELE TER EE EaU Dane oE a aonaeeeeeene ea end 30N-m (22 Ib-ft)
Brake Pipe Nut........ecccccssssesesessensesenecnesseessesnenesnsetacerssteemessaeenanesaeeecanseanernnannnsaecassenancazsassnees 15N-m_ (11 Ib-ft)
King Pin Key Bolt ......0...ccccccsesseecsstceceeneenereuesessecarsnaesssneavecseaeseaeasereninencagecantianecerenecisennecsaens 32N-m_ (24 lb-ft)
Leaf Spring Center Bolt...........-. ddeavacsuasueteusaesesensasenensoganaccacousassoremetuesneaeeeseeeseseeeseneeuerterererenees 39N-m (29 lb-ft)
Leaf Spring Eye Bolts.........cccscecceneseeereetssnrecnsseeectuesesennees buvuqedeunananeneqaaeneaecsacaesaneessessaees 177 N-m (130 lb-ft)
Leaf Spring Shackle Bolts ..........ccccccececseccneesseeteetseetsnessenenssnesnesarerseenensesnenenersecesnsagreascaees 127N-m_ (94 lb-ft)
Shock Absorber Upper Fixing Nut...........ccccseeeeeenrceersecetecnsreeeauennessesneeteeseeconanrsaetags 20N-m_ (14 Ib-ft)
Upper LOck Nut... .cecceescceeerecerceneersnestsnireansceseeoesmnanecnsensererneneneraneatey 40 N-m_ (30 lb-ft)
Hub to Disc Bolts .....c.0..cccccecccscuesseseeseccceceeueetceeseacueeueseeseasnarsanerseetecinuannuscenenigneneatenensensanaeanae 103N-m_ (76 lb-ft)
Caliper LOCK Pin Bolts .......cccccecceseneeeeeersteaeteeeeeessereseneecssenasenacanennsnrnsearssareeanencessensnenanenengs 137 N-m (101 lb-ft)
3C-24 FRONT AXLE AND SUSPENSION

SPECIAL TOOLS

TOOL NO. TOOL NO.

ILLUSTRATION TOOL NAME ILLUSTRATION TOOL NAME

J-35710 J-35713
. ; :
King Pin Key Bolt Remover Front Hub Bearing Outer
Race Installer

J-35712
e= Front Hub Bearing Inner —* ~8082
Race Installer rip
 REAR SUSPENSION 3D-1

SECTION 3D

REAR SUSPENSION
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE

Description ........-.:csccssessssssssnsencsersesonsceneesssssensenscansarencstsuensoeonenssacuneneensausaeaseassnsenenenueasenentaneneratansosanneracsnsseseeaeanes 3D-1

Spring Maintemance.......s.sccsserecsseneccescsesnersessssenessnsssanenrsnsensssnsennansncntensentonsnaneerancesaneroneaccesaunenaeearaneceataunnenceney 3D-1
Diagnosis of Springs ........sscsesscceesssenesestsnsesscematenneenuennenssnenssnrsereenesonnronenseneansaanenattensecauenssnsssenesaussncanenaenasaees 3D-2
On-Vehicle ServiCe .....cscccscseecseneessesuerconsassoninessessensnersuuseauanmensatedousenees puneneanencenseneusedenecenamescauuaoneduanenuensuapnunnsens 3D-2
Spring Replacement ..........csccecseeesneensessrnseeeannssssenstecersunenseneeasenensanannensanecas cnueecaesensessnesanurvanstoueuanscansontaseens 3D-2
Spring Leaf Replacement..........cssssesecserssenssteseneseecsensnssurarsonsrersenensveneensensrasenenseaneananssarsateauecsaneautaeantaneanssasaes 3D-7
Spring Eye Bushing Replacement ........-..1sssocsssssscsssssessesennseneeseesssacensensennseneateatsaceutsanerseccarssneranenansaarasenes 3D-7
Shock Absorber Replacemenit........scssssssssenesescssseceneneesssneraceensensecsconusnessensrorsessseneneneanenssunazaeseausesnauaraunennes 3D-8
SPeCifiCAtiONS.......ecseseencscersneraeenrers paceannessususunenctucusesauenudssavasnsauegectdncctsunscdeuanansscuesansenroasarecassensesecsaensazennnensanae 3D-8
Fastener TOrQue@S.......-sssssecsssneseseressnssssesneeensssnrstsesstncsessssmnasaninsanssensansunasansaueeaentensnssesusas uacenessauenunnnnentanates 3D-8

DESCRIPTION

The rear suspension consists of two semi- SPRING MAINTENANCE

elliptical leaf springs. They have closed eyes at
each end with replaceable bushings. The front of Lubrication
the spring is attached to the vehicle frame with a Spring leaves are lubricated at the time of
bolt through a bracket. Shackle links connect the manufacturing and require no further lubrication
rear of the springs to frame brackets. unless the spring is disassembled. Metal spring eye
Auxiliary springs, bolted to the top of the main bushings require lubrication with chassis lubricant
springs, have no eyes and slide on the frame as described in MAINTENANCE AND
brackets. — . LUBRICATION (SEC. OB) in this manual.
Telescoping hydraulic shock absorbers are
mounted between the spring U-bolt support plate Tightening
and the vehicle frame. U-bolts must be kept tight at all times to hold the
axle and spring in place. Otherwise, the axle may
shift, causing misalignment; also, spring leaf failure
in the vicinity of the spring center bolt could result.
Refer to MAINTENANCE AND LUBRICATION
(SEC. OB) for tightening intervals.
 3D-2 REAR SUSPENSION

DIAGNOSIS OF SPRINGS

PROBLEM POSSIBLE CAUSE CORRECTION

Spring Noise 1. Loose U-bolts. 1. Tighten to specified torque.
2. Loose or worn eye bushings. 2. Replace the eye bushings.
3. Lack of lubrication. 3. Lubricate as required.
Spring Sag or Bottom 1. Broken spring leaf. 1. Replace the leaf or spring
assembly.
2. Severe operation or overloading. 2. Check the load capacity rating.
Spring Breakage 1. Loose U-bolts. 1. Tighten to specified torque.
2. Normait fatigue. 2. Replace the spring.
3. Overloading. 3. Check the load capacity rating

ON-VEHICLE SERVICE

SPRING REPLACEMENT Inspect

[+9] Remove or Disconnect (Figures 1-9) 1. Spring leaves for breaks or cracks.
* Raise the vehicle frame and support the frame 2. Front eye bolt bushing for wear.
with jack stands (2) (figure 1}.
t eos
1. The steel tube nut (55) from the brake flexible 5. Center bolt
hose (3). Pry the hose clip (11) off the flexible 6. Brackets.
hose (figure 3).
2. Nuts (12) and remove shocks from lower shock
absorber mounts (figure 4).
Measure (Figures
(Fig 9, 10 and 11 )
3. Support the rear axle housing (18) with a jack 1. Front eye bolt (9) figure (9). The diameter
(19) (figure 6). shouid be no less than 24.7 mm (0.973 in)
4. The U-bolt nuts and bolts (6) (figure 7). (figure 10).
5. The shackle nuts and shackles (8) (figures 2 2. Spring eye bushing clearance with inside
and 8). micrometer (23) (figure 11).
6. The front eye bolt (9) and spring (10) (figure 9). The difference between the dimension
measured in step 1 and the inside diameter of
the bushing should be no more than 0.5 mm
(0.02 in).

2. Jack Stands

Figure 1. Vehicle Supported on Stands

 REAR SUSPENSION 3D-3

3. Brake Flexible Hose

4. Shock Absorber Assembly
6. U-Boits
8. Shackle Assembly
9. Front Eye Bolt
10. Spring

Figure 2. Rear Suspension

2. The front eye bolt (9) with the head toward the
Install or Connect inside or centerline of the vehicle (figure 14).
(Figures 1, 3, 4, 7, 12, 13, 14 and 15)
Install nut finger tight.
NOTICE: See “NOTICE” on page 3D-1 of this 3. The shackle (8) bushing (20) and nuts into the
section for steps 3, 4, 6 and 8. rear of the spring (10) and the frame bracket
(figure 15). Install nuts finger tight.
1. New spring eye bushing(s) (22) if necessary.
Use a bushing tool J-35716 (24) that will not
[2] Tighten
damage the bushing or spring (10) (figure 12). « Front eye bolt (9) and shackle nuts (8) to 177
N-m (130 Ib-ft) (figures 14 and 15).
[3] Important

* Position the spring (10) with the camber mark 4. Support the rear axle with a floor jack and install
(25) toward the front (figure 13). the U-bolts. Oil the U-bolt threads.
3D-4 REAR SUSPENSION

[2] Tighten
+ U-bolt nuts to 177 N-m (130 lb-ft) (figure 7).

5. Shock absorber assembly (4) and attaching

parts to the lower shock absorber mount
(figures 2 and 4).

[Ql] Tighten

* Shock absorber nuts (12) to 95 N-m (70 Ib-ft) 3. Brake Flexible Hase
(figure 4). 11. Clip
* Shock absorber bolt (29) to 40 N-m (30 Ib-ft) 55. Steel Tube Nut
(figure 4).
Figure 3. Flexible Brake Hose Attachment

- - 5————

| 13 —»
14

29 :
ZL

15
ELL,
29 4. Shock Absorber
12. Nut
13. Mounting Stud
‘ 14. Rubber Bushings
15. Dish Washer
16. Flat Washer
17. Spring Washer |
- - 29. Bolt |
|

Figure 4. Rear Shock Absorber Mount

 FRONT AXLE AND SUSPENSION 3C-5

DIAGNOSIS OF FRONT-WHEEL BEARINGS (CONT.)

TAPERED ROLLER BEARING DIAGNOSIS (CONT.)

©) > GS © © GS
ABRASIVE STEPWEAR ETCHING
GALLING

PATTERN ON ROLLER ENDS BEARING SURFACES APPEAR GRAY

METAL SMEARS ON ROLLER ENDS
CAUSED BY FINE ABRASIVES. OR GRAYISH BLACK IN COLOR WITH
DUE TO OVERHEAT, LUBRICANT
RELATED ETCHING AWAY OF MATE-
FAILURE OR OVERLOAD.
CLEAN ALL PARTS AND HOUSINGS, RIAL USUALLY AT ROLLER SPACING.
REPLACE BEARING — CHECK SEALS CHECK SEALS AND BEARINGS AND
REPLACE IF LEAKING, ROUGH OR REPLACE BEARINGS—CHECK SEALS
AND CHECK FOR PROPER
NOISY. AND CHECK FOR PROPER
LUBRICATION.
LUBRICATION.

MISALIGNMENT INDENTATIONS FATIGUE SPALLING

OUTER RACE MISALIGNMENT DUE SURFACE DEPRESSIONS ON RACE FLAKING OF SURFACE METAL
TO FOREIGN OBJECT. AND ROLLERS CAUSED BY HARD RESULTING FROM FATIGUE.
PARTICLES OF FOREIGN MATERIAL.
CLEAN RELATED PARTS AND
REPLACE BEARING. MAKE SURE CLEAN ALL PARTS AND HOUSINGS, REPLACE BEARING — CLEAN ALL
RACES ARE PROPERLY SEATED. CHECK SEALS AND REPLACE RELATED PARTS.
BEARINGS IF ROUGH OR NOISY.

CAGE WEAR.
CU
ABRASIVE ROLLER WEAR
BRINELLING

WEAR AROUND OUTSIDE DIAMETER PATTERN ON RACES AND RELLERS

SURFACE INDENTATIONS IN
OF CAGE AND ROLLER POCKETS CAUSED BY FINE ABRASIVES.
RACEWAY CAUSED BY ROLLERS
EITHER UNDER IMPACT LOADING CAUSED BY ABRASIVE MATERIAL
AND INEFFICIENT LUBRICATION. CLEAN ALL PARTS AND HOUSINGS.
OR VIBRATION WHILE THE BEARING
CHECK SEALS AND REPLACE CHECK SEALS AND BEARINGS AND
IS NOT ROTATING.
BEARINGS. REPLACE IF LEAKING, ROUGH OR
NOISY.
REPLACE BEARING IF ROUGH OR
NOISY.
3D-6 REAR SUSPENSION

10. Spring
9. Front Eye Bolt 22. Spring Eye Bushing
10. Spring 24. Bushing Tool

Figure 9. Rear Spring Eye Bolt Figure 12. Replacing Spring Bushing

10. Spring
25, Camber Mark
25

10

9. Front Eye Bolt

21. Micrometer

Figure 10. Measuring Spring Bolt Diameter Figure 13. Rear Spring Position

22. Spring Eye Bushing 9. Front Eye Bolt

23. Inside Micrometer 10. Spring

Center , Spring
Line |! Front
23 of I
Truck ¥ 9

22 => f
i
I
I
|

Figure 11. Measuring Spring Eye Bushing Figure 14. Spring Eye Bolt Position
 REAR SUSPENSION 3D-7

10. Spring
27. Press Ram
28. Spring Center Bolt

10 20
8. Shackle and Nut Assembly
10. Spring
20. Bushing

Figure 15. Rear Spring Shackle

SPRING LEAF REPLACEMENT

Remove the spring as described in this section. Figure 17. Rear Spring in Press
inspect
Clean
1. Spring leaves for breaks or cracks.
* The Spring assembly. 2. Rebound clamps.
3. Center bolt holes in leaves for elongation.
[é] Disassemble

1. Mark the spring leaves (10) for reassembly Assemble

reference (figure 16). NOTICE: See “NOTICE” on page 3D-1 of this
2. Place the spring (10) in a bench press (27) and
section for steps 3 and 4.
slightly compress it. Remove the spring center
bolt (28) and clamps (figure 17). . Apply a coat of chassis lubricant to each leaf.
—

- Discard center bolt and replace with a new 2. Assemble the leaves according to the reference
one. mark.
3. Remove press pressure and move spring to + Compress the assembly in a press.
bench. 3. Install a new spring center bolt (28) and nut
(figure 17).
10. Spring
26. Reference Mark [] Tighten

« Spring center bolt nut to 98 N-m (72 lb-ft).

a FWBDODO)O-—Du-————4
0
4, Rebound clamps.
nee SS
_—_— an See
rr)
FR] Tighten
SI

cy _ + Rebound clamps to 20 N-m (14 lb-ft).

SPRING EYE BUSHING REPLACEMENT

Spring Eye Bushing Replacement is described

Figure 16. Marking Rear Spring under “Spring Replacement” in this section.
 3D-8 REAR SUSPENSION

SHOCK ABSORBER REPLACEMENT [oe] Install or Connect (Figures 2, 4 and 5)

| Remove or Disconnect (Figures 2, 4 and 5) 1. Assemble the rubber bushings (14) in the shock
The nuts and bolts attaching the upper and lower absorber eyes as shown in figures 2 and 4.
shock absorber mounts on the lower U-bolt plate 2. The spring washers (17) and shock absorbers
and on the frame side rails. (4) on the mounting studs (13) or bolts (figure
4).
inspect
NOTICE: See “NOTICE” on page 3D-1 of this
Refer to “Diagnosis of Shock Absorber’ in FRONT section.
AXLE AND SUSPENSION (SEC. 3C).
3. Nuts.

Tighten

* Shock absorber nuts to 95 N-m (70 Ib-ft).

SPECIFICATIONS
Spring Eye Bolt... cece cess sssesssscesecsesseseesesseeeuscesssaceaessiseessusacensssssnesseceeseessesnessesssssesessseuess 24.7 mm (0.973 in)
Spring Eye Bolt to Bushing Clearance .............ecsccessssuessseneessescseseunntosenconsenecsessssanaecacesuatsassesenseeesenas 0.5 mm (0.02 in)

FASTENER TORQUES

Front Spring Eye Bolt Nut... eecceeecseseeteseeseseaseuseeauecousssnsssesesaeseaueeseaeeseeeauseceescossentenens 177N-m_ (130 Ib-ft)

Shackle Nuts ..........::ccecessesesscseeessesoeseesesessesoaseseeseesaesecessessueseussseseusassessuseusosseassatessteauesteauneneusersees 177 N-m (130 lb-ft)
U-BOItS .0.. eee eee ceeesceeeneeeesensecsaneseessessansetesaneanensessesaeseescecseusareauessscoussseatacsssenseteganessseaesaeeaneseucssseas 177N-m (130 Ib-ft)
Shock Absorber Nut 2.0.0... sseccsecenescnseeeseaeseesnstsetsesecassessnsessesesenscsusssasennesssssnecstasateeeseseaussesecanensensss 95N-m_ (70 lb-ft)
Shock Absorber Bolt... eee eccecseessecceeessseteesenseeessescsecaseeesessaannngeeseansanecanneaasesausrseessseesaeestenseteesoes 40N-m (80 lb-ft)
Brake Steel Tube Nut ........ cc ccs sssssssssaneccesetccesessnesesenerscsseenseasseeseuessunsvenseseeeeuaseseusesrecessesanersenuees 15N-m_— (11 Ib-ft)
Spring Center Bolt... ecscccscesnescescsensssssersecsesssscassenesnsesseasesssaseecenasessaeenseeesenseaneaseaseateaeenseeeeess 98N-m (72 lb-ft)
Spring REDOUNA ClAMPS ..... sess ceeeanseseseeseetceesessssceacesaesesensessetsuscaanneseeaecesesesaeceeseatensestetseensensues 20N-m_ (14 lb-ft)
 WHEELS AND TIRES 3E-1

SECTION 3E

WHEELS AND TIRES

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

Wheels and RIMS ........0.cccsscossessssssstesseensensoceneserseseeressnecaeseeusenseenocsenssconsueauadsauevseurqunceunsseaeraaeenaassaseeneesrenenenses 3E- 2

DeSCiPtiOn .........scscesesncesessersenssseneensersreessaeenenneetnivneces suvsanseauvaneoetsonuaneesousuaessauasueanesansonsvansanaraasaceeaaseusne ness 3E- 2
Diagnosis of WheelS..........cscsecssseceressnsssneecacnenstenssorecssnenssenseutrsusursveranesenseseeseuasansenunssensuauneseasonsessenecesaeans 3E- 2
On-Vehicle Service: WheelS...........csscserscssersscoresses sonudsennensvenvaeeaedeueseedeanaedeeseeceaasouseatasescereasnogeamnearevenseas seer OE" 4
Lateral or Radial RUMOUt ...........ccsssscceeseesesuenseseeneessseessansauescavessuarawesseeseaeunseseesuensaneuenupannnnaenegsranetaseates 3E- 4
Wheel Studs and Nuts .........:cssssesscerssrssstssseeesneseneasnsevannessenusnorsensensensauencaeauaeseessaesseeseneanenenseaerensenscuneeudcaens 3E- 4
Wheel Replacement .........secssscssenssenssssesnnesecenseasuncoanenacneansenennsnsneesrsanusauuansucarsvensunsuaeneransueuseameaaranevansenesnen® 3E- 5
TireS ANd TUbe@S.......cccccccnscesccsessesseesuesorsesseesseeesseaesesuenaenennessensaceenaausuaustegetnaeeeacnusnnnussaeeanensneneggneneetecezaeniaaeeee 3E- 6
DeSCription ........scsersseeccsceesonsnensenseratceeaeae seesvednisenerunnecsenatessessesseees souseusnunsaausazncanususccarensaneveneransegneseasentansens 3E- 6
Diagnosis of Tires.............-. caeeenuvancousausaeseusarsuusenvevesensaseaunstoneogesoesersaurseenauenseneceesseseasanaseeaasensasensnensnasinanenecentons 3E- 8
Tire Weal ........ssscersccesssstenerseneneses cuesuneeseseadensensausaussuonaneaeesosneaseesosussanasauesanedouneoetdausoussenseavanscertaaguagedeanevenseane 3E- 9
On-Vehicle Service: Tires and TUDe@S.....:ccccccseccnnerses waeescenensessonseeaneeuuonunasseesasussearaceuduousooesnesseacaetaanseagentant 3E-11
How To Match Tires on the Rear Axle...........ccccssentcesecssesensssssesiimesscenssrneseeasennennenssoeenceneseessnavaanuaanensanens 3E-11
Tire Rotation ....c:esssccrssresenes uueuecaeageeesuaesseusarentensaesecensausonseassenssenteuensasieas cotesusueeaeessnesseesasetesnensanedsentaussanense 3E-11
Wheel and Tire Balancing ...........:ccesesscsserseessnserssersesessnsesscereneaeseeneseusaseesoesnnnneousonsenneausonsagenueesousumusninsess 3E-12
What Happens When Tires Get Hot............ccccssesreseensocnsnensansenecsnessrens saeeeseansetueseasersneneneuaceseescuesanvaaen sees 3E-13
Inflation Of TiS ........:cccecsccsesssscevrsesuesssesoserseesaneeoauacsceanesensecweceancustaneuvastusasnennsesasienceanennanseseeesescransuneseaneneenay 3E-13
Valve Core and Cap ........ccccccsestesmcsusecenssesesssssesenesenscensesunseenienseauenoneguscueviueetenstensonsnssnevensazansenanenancaaranay 3E-14
Tubes and Flaps........cciscseseecsersenneaseaneneseniniens senoananneaeevensessaedenavaresaneaeausuauaneuensaneanscansonttuonsansessscsensens 3E-14
Spare Tire.......ccssseccenees dsusauuensinuoesusaseeeeueseatenssneneeaeaseusenanusaseaensmuusgnisedrapsasseaseenaunsaseuss sraueesonvensusuvauatoeseantogtes 3E-17
Specifications.........cccseceoesensieneces puvcavarsrsouucs ureatesc
ses soesaeusoespedeeevsassannsa esaenran
caanesieeeqnecrtasonaeeneee es
onananensedaauaaonanies 3E-17
3E-2 WHEELS AND TIRES

WHEELS AND RIMS

DESCRIPTION

The vehicle is equipped with disc wheels. Disc

wheels have the wheel and rim as an integral unit
(figure 1).

. Wheei and Tire Assembly

Oh
. Front Wheel Nut
. Rear Inner Wheel Nut
. Rear Outer Wheel Nut
&

Figure 1. Wheels, Tire and Nuts

DIAGNOSIS OF WHEELS

PROBLEM POSSIBLE CAUSE CORRECTION

Wheel Hop (Vehicle Wheels

Vibration and Rough 1. Rocks and debris wedged between 1. Remove rocks and debris.
Steering) dual disc wheels.
2. Out-of-balance tire and/or hub and 2. Determine the out-of-balance
drum/rotor assembly. component and balance or
replace.
Improper positioning of the side 3. Reassemble with ring split
rings split. opposite (180 degrees) the valve
opening to improve balance.
Vehicle
Loose or worn driveline or suspension. Identify location of vibration carefully
as it may be transmitted through the
frame making a rear end vibration
appear to come from the front. Then
repair or replace loose or worn parts
(Refer to PROPELLER SHAFT
[SEC. 4B] for vehicle vibration.)
 WHEELS AND TIRES 3E-3

DIAGNOSIS OF WHEELS (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Wobble (Vehicle Vibrations Wheeis

and Rough Steering) 1. Bent or distorted disc from 1. Replace wheel.
overloading or improper handling.
2. Loose mountings, damaged studs, 2. Replace worn or damaged parts.
cap nuts, enlarged stud holes, Clean mounting surfaces.
worn or broken hub face, or foreign
material on mounting surfaces.

Vehicle
1. Improper alignment. 1. Have vehicle aligned.
2. Loose, worm or broken suspension Repair or replace.
parts.

Cracked or Broken Wheel Metal fatigue resulting from Replace wheel. Check position of
Discs (Cracks Develop in overloading. wheel on vehicle for working load
the Wheel Disc from specifications.
Handhole to Handhole,
from Handhole to Rim, or
from Handhole to Stud)

Damaged Stud Holes (stud Loose wheel mounting. Replace wheel and check for:
Holes Become Worn, * Installation of correct studs and
Elongated or Deformed, nuts.
Metal Builds up Around * Cracked or broken studs —
Stud Hole Edges, Cracks replace.
Develop from Stud Hole to * Worn hub face — replace.
Stud Hole) * Broken or cracked hub barrel —
replace.
« Clean mounting surfaces and
retorque cap nuts periodically.
» Rust streaks fanning out from stud
holes indicate that the cap nuts are
or have been loose.

Damaged Stud Threads Sliding wheel across studs during Replace stud following proper wheel
assembly. installation.

Loose Drum Improper drum bolt. Replace with proper length boit.

Loose Inner Wheel 1. Excessive stud standout from 1. Replace with proper length bolt.
mounting face of hub allowing
wheel nut to bottom out.
2. Improper torque. 2. Use recommended torque
procedure.

Broken Wheel Studs 1. Loose cap nuts. 1. Replace stud and follow proper
torque procedures.
2. Overloading. 2. Replace stud.
3E-4 WHEELS AND TIRES

DIAGNOSIS OF WHEELS (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Stripped Threads Excessive clamp load. Repiace studs —~ follow proper

torque procedure.

Rust Streaks from Stud Loose cap nuts. Check complete assembly, replace
Holes Correction damaged parts and follow proper
torque procedure

ON-VEHICLE SERVICE: WHEELS

LATERAL OR RADIAL RUNOUT to be true. Turn the wheel and make the
previous tests. If the tests are within the limits,
Do not use wheeis with bent rims. The continued the hub is good, but the wheel is sprung.
use of such wheels will cause tire wear and, if the 5. A dismounted wheel may be checked for side
wheel is mounted on the front of the vehicle, wobble by placing a straight-edge on the face or
difficulty in steering will result. Wheels that are hub of the wheel as shown in figure 3. Measure
thought to be distorted may be checked as follows, the distance from the straight-edge to the edge
referring to figure 2 for checking points: of the wheel rim. This should be checked at four
1. Raise the axle and safely support it. equally spaced locations. If the distance is the
2. Mount a dial indicator at the inside of the wheel same at all positions, the wheel is not distorted.
(2) as shown. Rotate the wheel and measure
the radial runout (out-of-round condition).
Runout should not exceed 2.3 mm (0.09 in).

33

33. Straight Edge

44. Measurements should be taken at four
equally spaced locations around the
hub of the wheel.
1. Wheel
2. Inside of Wheel
Figure 3. Wheel Checking Diagram
3. Crown of Rim

WHEEL STUDS AND NUTS

Figure 2. Method of Checking Distorted Wheels

3. Mount a dial indicator on the crown of the rim CAUTION: If any wheel experiences damage to a
(3) as shown. Rotate the wheel and measure single stud caused by a loose-running wheel, all
lateral runout (side wobble). Runout should not the studs should be replaced. A loose-running
exceed 2.3 mm (0.09 in). wheel may cause only one stud to break, but the
4. If doubt exists whether the wheel or hub is other studs could have internally fatigued to the
distorted, the hub may be checked as follows: point of being damaged. Replacing only the
Replace the existing wheel with a wheel known broken stud and remounting the wheel may cause
 WHEELS AND TIRES 3E-5

further damage and personal injury. If the stud following table. Snug all wheel nuts and then
holes in the wheels have become larger in size of tighten to the specified torque in the numerical
distorted, replace the wheel. sequence shown in figure 6.
improperly tightened wheel nuts could
When a damaged or broken stud is found, replace eventually allow the wheel to come off while the
all the studs. Internal stress cracks could result truck is moving, possibly causing loss of control
from the added strain in carrying the load of the and/or personal injury or damage.
broken stud. When the truck, wheel, or fasteners are new,
Stripped threads on the studs may be the result of have a technician tighten the wheel stud nuts
overtorquing the stud nuts or damage during wheel and/or rim clamp nuts with a torque wrench at 650
installation when placing the wheel over the studs. miles (1,000 km). This is necessary because the
Where a damaged thread is found, the stud clamping system used on the wheel must seat
should be replaced. before the fastener will hold a uniform clamp load
Broken studs are a result of operating with loose and remain fully tightened. Also have a technician
or over torqued stud nuts or improperly seated tighten the wheel stud nuts and/or rim clamp nuts
wheels. with a torque wrench after installing any wheel. in
addition, nut tightness on all wheels should be set
Freezing of a Nut with a torque wrench every 6,500 miles (10,400
This condition results from corrosion or galling of km).
the stud and nut assembly which can reach a point
where the removal of nuts is difficult. If this is a If a single or dual wheel and tire assembly is to
continuing problem, the threads of the stud should be removed and dismounted, the air should be let
be cleaned with a wire brush. To aid in avoiding this out by removing the valve core. This procedure
problem use cadmium plated stud nuts with must be done before removing the tire assembly
dichromate dip. from the vehicle.

Inspection and Maintenance of Wheels on Wheel Removal

Vehicle « Wheel studs and nuts on right side have
righthand threads, while wheel nuts on the left
Inspect side have lefthand threads.
* Loosen the stud nuts (figure 4).
» Examine the wheels at frequent intervals for safe * Raise the axle until the tires clear the floor.
operation.
- Particular care should be given to the front Front Wheel and Rear Outer Wheel
wheels. Check ail exposed areas often. Clean off Removal
dirt and look for cracks or other damage.
[| Remove or Disconnect
Avoid Abuse
Abuse may shorten the life of the wheel. Lack of 1. Stud nuts (outer wheel nuts for rear outer
care in changing a tire, heavy pounding on a wheel wheel).
rim, overloading or hitting curbs at high speeds, or 2. Wheel and tire assembly.
sharp angie may damage wheels.

Keep Stud Nuts Tight

The wheel stud nuts must be kept tight. Torque ali
stud nuts after the first use or any wheel change.
Inspect the wheels and check the wheel nuts during
service stops. Dirt streaks from stud nuts may
indicate looseness.

Balance Weight
Lead balance weights are available for all wheels.

WHEEL REPLACEMENT
CAUTION: Never use oil or grease on studs or
Figure 4. Left-and Right-Hand Wheel Nuts
nuts (figure 1). Use the torque specified for the
type of wheels on the vehicle, as shown in the
 j
3E-6 WHEELS AND TIRES

Rear Inner Wheel Removal

[+s] Remove or Disconnect (Fiqure 5)

66 “

1. Outer wheel nuts (66).

2. Outer wheel and tire.
3. Inner whee! nuts (55).

[® BR
4. Inner wheel and tire.
55
Front and Rear Wheels

| Install or Connect (Figure 5) 55. Inner Wheel Nut

66. Outer Wheel Nut
1. Wheel and tire assembly.
Figure 5. Inner and Outer Wheei Nuts
NOTICE: See “NOTICE” on page 3E-1 of this
section.
1 Rear Wheel For Flat
2. Stud nuts. giv Model
+ Stud nuts finger tight. Then torque stud nuts
in the sequence shown in figure 6.

fa] Tighten

* Stud Nuts to
Front: 440 N-m (325 lb-ft)
Rear : 440 N-m (325 ib-ft)

Figure 6. Wheel Nuts Tightening Sequence

TIRES AND TUBES

DESCRIPTION rim as shown in figure 7.

Tires on this vehicle have radial-ply construction, Overall Diameter

and are tube-type. These tires are designed for Overall diameter is twice the section height of a
highway and off-highway use. The proper size tire, tire (measured from opposite outer tread surfaces)
in addition to the correct inflation, should be including 24-hour inflation growth, plus the nominal
maintained for the load that the truck is designed to rim diameter.
carry. For additional information not covered in this
section, refer to the tire manufacturer's publication. Section Height
Section height is the distance from rim seat to
CAUTION: Do not mix different construction outer tread surface of a laden tire. (This
types of tires on the vehicle such as radial, bias, measurement does not include decorations,
and bias-belted tires, except in emergencies, markings or borders on tire.)
because vehicle handling could be affected and
may result in floss of control. Nominal Rim Diameter
Nominal rim diameter is measured from opposite
Definition of Terms rim seats.
The following terms refer to measuring a tire an
 WHEELS AND TIRES 3E-7

Bias Ply Tube-Type Tires

UV ,
Bias ply tube-type tires are standard on this
vehicle. Refer to figure 8 for the identification code
1 2 stamped on the outer wail of the tire. Refer to figure
9 for the “Tire Load and Inflation Table.”
6
| Radial Tubeless-Type Tires
5 Radial tires approved for use on ISUZU W4 truck
has tubeless-type construction. Refer to figure 8
4 3
and figure 9 for identification code and “Tire Load
and Inflation Table.”

7.50-16

Nominal Section |
Width in Inches Bead Diameter

205/60R— 17.5
“LC |
Nominal Section i Bead Diameter |
1. Overall Diameter Width in mm
2. Section Height
3. Rim Diameter [ Aspect ratio _
4. Overall Width
5. Section Width Height of tire
Aspect ratio (%) = ——_-4____
6. Rim Width Section width of tire

Figure 7. Measuring a Tire and Rim

Figure 8. Tire Identification
Overall Width
Overall width is the width of a new tire, including
24-hour inflation growth, and including protective TIRE LOAD AND INFLATION TABLE
side ribs, bars and decorations.
TIRES FOR VEHICLES IN HIGHWAY SERVICE
TIRE LOAD LIMITS AT VARIOUS COLD INFLATION PRESSURES
Section Width Tire Size Kpa |310 380 420 450 490 520 560 590
Section width is the width of a new tire (the Designation Psi |} 50 55 60 65 70 75 80 85 90
distance between outside of sidewalls) including Duai 2155 2260 2360
24-hour inflation growth and including normal 8R17.5-10 Single} (Ib) 2455 2575 2685
sidewalls, but not including protective side ribs, 195/65R16LT Dual | (Ib) 1885 2066
bars, or decorations. 205/60R17.5LT |Single| (Ib} 2249 2353
LT215/85R 16-10] Dual 2210 2320
Rim Width Single} (Ib) 2430 2550
Rim width is the specific rim width assigned to 226/70R 19.5-F | Dual 3245
each tire size designation to determine basic tire Single} (lb) 3450
dimensions. Dual 2140 2245 2345
7.50-16-10 Single} (Ib) 2440 2580 2670
Bias Ply Steel Cord Tires
Bias ply steel cord tires are not approved for use Figure 9. Tire Load and Infiation Table
on any Isuzu supplied disc wheel or demountable
rim.
3E-8 WHEELS AND TIRES

DIAGNOSIS OF TIRES

PROBLEM POSSIBLE CAUSE CORRECTION

Tire Slippage on Rim 1. improper storage or operating 1. Correct as required.

conditions.
2. Poor maintenance. 2. Follow proper maintenance
procedures.
3. Rust, corrosion on bead seating. 3. Correct as required.
4. Loss of pressure. 4. Follow proper maintenance
procedures.

Tire Mounting Difficulties 1. Mismatch tire and rim sizes. 1. Correct as required.
2. Defective or mismatched rings for 2. Correct as required.
rim use.
3. Overinflation of tires. 3. Follow recommended tire
pressure.
4. Corrosion and dirt. | 4. Correct as required.

Tires Show Excessive 1. Underinflated tires. 1. Properly inflate to recommended

Wear on Edges of Tread pressure.
Vehicle overioading. 2. Correct as required.
Pwn

High speed cornering. 3. Correct as required.

Incorrect toe-in setting. 4. Set to correct specifications.

Tires Show Excessive Tires overinflated. Properly inflate to recommended

Wear in Center of Tread pressure.

Excessive Tire Wear improper tire pressure. 1. Properly inflate to recommended

ooh

pressure.
2. Incorrect tire;wheel usage. 2. Install correct tire/wheel
combination.
Defective shock absorbers. Repair or replace.
&

Front end out of alignment. Align front end.

ae

oe

Loose, worn or damaged steering Inspect, repair or replace as

linkage, joints, suspension required.
components, bushings and bail
joints.

Dual Tires Rubbing Insufficient wheel spacing. Check tire and wheel sizes.
 WHEELS AND TIRES 3E-9

TIRE WEAR tires and a very light load on the inside tires, due to
centrifugal force. This unequal loading may have
Irregular Tire Wear two harmful results.
First, the rear tire on the inside of the curve may
Heel and Toe Wear — This is a saw-toothed effect
be relieved of so much load that it is no longer
where one end of each tread block is worn more
geared to the road and it slips, grinding off the
than the other. The end that wears is the one that
tread on the inside half of the tire. This type of tire
first grips the road when the brakes are applied.
shows much the same appearance of tread as tire
Heel and toe wear is less noticeable on rear tires
wear caused by negative camber.
than on front tires, because the driving action of the
Second, the transfer of weight may also overload
rear wheels creates a force which tends to wear the
the outside tires so much that they are laterally
opposite end of the tread blocks. The two forces,
distorted, resulting in too much wear on the outside
driving and braking, make for a more even wear of
half of the tire, causing a type of wear like that
the rear tires, whereas only the braking forces act
caused by too much positive camber.
on the front wheels, and the saw-toothed effect is
Cornering wear can be set apart from abnormal
more noticeabie.
A certain amount of heel and toe wear is normal.
camber wear by the rounding of the outside
shoulder or edge of the tire and by the roughening
To correct the problem, in addition to cautioning
of the tread surface which shows abrasion.
the driver on his driving habits, rotate the tires
Cornering wear often produces a fin or raised
regularly.
portion along the inside edge of each row in the
tread pattern. In some cases this fin stands out as a
Side Wear — This may be caused by incorrect
toe-in fin, and in others, it tapers into a row of tread
wheel camber, underinflation, hign-cambered
blocks to such an extent that the tire has a “step
roads, or by taking corners at too high a rate of
wear” look.
speed.
Driving more slowly on curves and turns will avoid
The first two causes are the most common.
grinding rubber off the tires. To offset normal
Camber wear can be readily identified because it
cornering wear as much as possible, tires should
happens only on one side of the treads, whereas
be rotated at regular intervals.
underinflation causes wear on bath sides. Camber
wear requires correction of the camber first and
Uneven Wear -- Uneven or spotty wear is due to
then interchanging tires. There is, of course, no
unequal caster or camber, bent suspension parts,
correction for high cambered roads. Cornering wear
out-of-balance wheels, brake drums out of round,
is discussed further on.
brakes out of adjustment or other mechanical
conditions.
Misalignment Wear — This wear is due to too
The correction in each case involves locating the
much toe-in or toe-out. In either case, tires will
mechanical defect and correcting it.
revolve with a side motion and scrape the tread
rubber off both.
Power and Speed —- Too much speed has always
If misalignment is severe, the rubber will be
been harmful to tires. Speed creates heat and
scraped off tires; if slight, only one will be affected.
excessive heat may damage tires.
The scraping action against the face of the tire
causes a small feather edge of rubber to appear on Stops and Starts — Quick stops and starts grind
one side of the tread and this feather edge is an
off tread in a hurry. This may cause flat spots which
indication of misalignment. To correct, adjust toe-in
continue to grow for the life of the tire.
or check the entire front end alignment.
Temperature — Less mileage can be expected
Cornering Wear —- When a vehicle makes a fast from a tire used in all warm weather driving as
turn, the weight is shifted from an even loading on
compared to ail cool weather driving, or from a tire
all wheels to an abnormal! overload on the outside
first put into service in warm weather.
3E-10 WHEELS AND TIRES

Tire Wear Due to Mechanical Problems

(Figure 10)
The following paragraphs include some wheel or
vehicle irregularities which may cause rapid or
uneven tread wear.

Toe-in — The wheels on the same axle are closer

together in the front than they are in the rear. When
toe-in is too much the tire wear shows feathered
edges on the outside edge of the skid design.

Toe-out — The wheels on the same axle are closer

together in the rear than they are in the front. Tire
wear shows feathered edges on the outside edge of
the skid design.

Camber — This shows the tilt of the wheel. Positive

camber is when wheels are closer together at the
point of road contact. Negative camber is when the
wheels are closer together at the top. Too much
camber results in greater wear on one side of the tire.

Caster — This is the backward tilt of the axle or

inclination of the kingpin at the top. Too little caster
causes the wheel to wander or weave— result, spotty
wear. Unequal caster causes the wheel to pull to one
side, resulting in more and uneven wear.

Sprung or Sagging Axle — Either of these

conditions causes uneven spreading of the load. A
sprung or sagging axle will cause the inside dual tire
to carry the greater load.

Sprung or Twisted Frame — Will cause rapid or

uneven tread wear.

Grabbing Brakes — Brakes out of adjustment and

out-of-round brake drums cause tire treads to wear
rapidly in spots. Out-of-round brake drums usually
wear out tires in a single spot. Improperly adjusted
brakes produce severai worn places.
Worn wheel bearings, loose radius rods and U-
bolts, unbalanced wheels, or wobbly wheels all
result in uneven and irregular tread wear.
At the first sign of uneven tire tread wear, check
and correct all mechanicai irregularities.

1. Toe-In
2. Camber
3. Sprung or Sagging Axle
4. Toe-Out

Figure 10. Mechanical Irregularities

 WHEELS AND TIRES 3E-11

ON-VEHICLE SERVICE: TIRES AND TUBES

HOW TO MATCH TIRES ON THE REAR Measuring the circumferences of the tires with a
AXLE steel tape after they are on the rims and inflated but
before they are applied to a vehicle is the most
The vehicle should be on a level floor, carrying an accurate method.
evenly rated capacity load. Be sure all tires are the Measuring in this manner takes into account any
new tires to be sure they will irregularities in wear. In checking tires already on a
same size. (Measure
be correctly matched.) vehicle, either a square (similar to but larger than a
1. Inflate all tires to the same recommended carpenter's square), a string gage, a large pair of
pressure. calipers, or a wooden straight-edge long enough to
2. Carefully measure the rolling circumference of lie across the treads of ail four tires, may be used
each tire with a steel tape. (figure 14).
3. Mark the size on each tire with chalk and
arrange them in order of size, largest to TIRE ROTATION
smallest.
It is a good practice to “break in” new tires on
4. Mount the two largest tires on one side of the
axle and mount the two smallest on the front wheels. “Breaking in” on an easy position
opposite side of the axle. increases the overall tire life.
The movement of the tires from front to various
5. The two tires mounted together on one side of
(1/4 rear wheel positions depends upon the type of unit
the axle must have diameters within 6 mm
in) of each other. being operated. It is necessary to use tires with
good nonskid tread design on drive wheels.

1. Steei Tape 4. Straight Edge

2. String Gage 5. Matching Stick
3. Square 6. Calipe

Figure 11. Types of Measurement

 3E-12 WHEELS AND TIRES

Two-Axle Truck
Tires should be rotated from front to rear wheels It is recommended, from the standpoints of tire
when tread depth is 3.2 mm (0.13 in) (figure 12). If wear and vehicle handling ease, to maintain proper
there is uneven front wheel tire wear, rotate tires balance of front wheel and tire assemblies on all
and check vehicle for mechanical irregularities models. All wheeis intended for use on the front of
(figure 10). When tires are moved to the rear, follow the vehicle, such as those switched during periodic
the recommendations in matching them with other tire rotation and those installed as new or repaired
tires. replacement equipment, should be accurately
balanced. This may be done by either of two types
of balancing systems which balance wheels either
Example:
on the vehicle or off. The “on-the-vehicle” type is
most desirable in that all rolling components (brake
drums, bearings, seals, etc.), are included in the
balancing procedure and thereby have any existing
unbalance corrected.

Static Balance
Static balance (sometimes called still balance) is
Front Rear the equal distribution of weight of the wheel and tire
assembly about the axis of rotation in such a
manner that the assembly will not rotate by itself,
regardless of its position. For example: A wheel
When tire tread pattern differs
with a chunk of dirt on the rim will always rotate by
between front and rear tires:
itself until the heavy side is at the bottom. Any
wheel with a heavy side like this is statically out-of-
baiance.Static unbalance of a wheel causes a
hopping or pounding action (up and down) which
frequently leads to wheel “flutter” and quite often
wheel “hap.”

Front Rear Dynamic Balance

Dynamic balance (sometimes called running
Figure 12. Tire Rotation Pattern balance) means that the wheel must be in static
balance, and also run smoothly at all speeds on an
axis which runs through the center line of the wheel
WHEEL AND TIRE BALANCING and tire and is straight-up-and-down to the axis of
rotation.
CAUTION: When balancing tires on the truck, To ensure successful, accurate balancing, the
follow the equipment manufacturer's instructions following precautions must be observed.
carefully. On trucks which do not have maximum Wheel and tire must be clean and free fram all
traction, drive wheel spin should be limited to 35 foreign matter. The tires should be in good
mph (56 km/h) as indicated on the speedometer. condition and properly mounted with the balance
This limit is necessary because the speedometer mark on the tire, if any, lined up with the valve.
only indicates one-half of the actual wheel speed Bent wheels that have run-out over 2.3 mm (0.09
when one drive wheel is spinning and the other in) should be replaced.
drive wheel is stopped. Inspect tire and wheel assembly to determine if
Unless care is taken in limiting the drive wheel an uncommon or out-of-round condition exists. Note
spin, the spinning wheel can reach excessive that this condition, if severe, cannot be “balanced
speeds, resulting in possible tire disintegration or out.” An assembly which has an out-of-round
differential failure, which could cause personal condition exceeding & mm (0.31 in) is not suitable
injury or extensive vehicle damage. for use on the front of the vehicle. Its use of the
On trucks which do have maximum traction, rear should be governed by its general condition
drive wheel spin should be limited to 70 mph (112 and whether the roundness defect seriously
km/h). On such trucks, do not attempt to balance a detracts from overall ride quality.
tire on a drive wheel with the other drive wheel on
the ground since the truck may drive through this
wheel.
 WHEELS AND TIRES 3E-13

WHAT HAPPENS WHEN TIRES GET HOT Operators carrying cargo which is explosive or
easily combustible should check tires at 50 mile (80
As a tire becomes heated, the air in the tire km) intervals and should also use a pressure
expands and the air pressure is raised. This is warning device.
normal unless the pressure buildup is excessive.
Buildups of over 138 kPa(20 psi) are excessive, INFLATION OF TIRES
indicating underinflation, overload, too much speed,
Inflate to the correct pressure when the tires are
too small a tire, or more often, a combination of
cool (figure 13). If the tires are always carrying less
these factors in Therefore, pressure buildups over
than the recommended maximum load, adjust the
138 kPa (20 psi) should be studied to determine
cause and proper corrective action. Normal air pressure downward to go along with the actual
pressure buildups (not over 138 kPa [20 psi) load carried.
Never “bleed” the tires to relieve pressure
reduce flexing. Thus, the amount of heat generated
allows the tire to reach a heat balance (the buildup.
Tire temperature will increase when the tire is in
temperature at which the rate of heating equals the
service and allows for the normal buildup in air
rate of cooling) at a lower temperature than if the
inflation pressure were maintained uniformly by pressure,
Tire temperature and air pressure will stay within
frequently bleeding out air. Tires should never be
limits that are not harmful to the tire when used
bled. When the pressure builds up excessively,
reduce the speed or the load instead. along with the recommendations for load and air
A tire operated for a considerable distance at pressure.
steady highway speeds, in a severely underinflated
or flat condition, becomes very hot due to internal
friction, and this heat transmits to the tire ins outer
surface. If, and when, the outer surface
temperature reaches the combustion point, the tire
bursts into flames. This usually occurs after the
vehicle has stopped. Such an event usually
involves a dual assembly where one of the tires is
flat and the other is extremely overloaded (also
underinflated even for normal load). In such cases,
either the tire which is severely underinflated or
completely flat, or the tire which is extremely
overloaded, could get too hot as to reach the point
of spontaneous combustion.

Prevention of Tire Fires

Regardless of the cause of a tire fire, the tire's
internal temperature is so high that even if the
flames are put out, repeated ignition may occur
until interna! temperature lowers enough. A fire
extinguisher usually will not have enough capacily
to control the fire until the burning tire can be
removed. Operators should carry special asbestos
44. Tread Contact With Road
blankets which, in case of fire, are useful in
preventing the fire from spreading to the vehicle 66. Proper Inflation
77. Underinflation
and cargo. If possible, a steady stream of water
88. Overinfiation
should be placed on the tire until it is cool enough
for removal.
The best protection against tire fires is to avoid Figure 13. Inflation of Tires
running on a flat tire, prevent underinflation through lf a high buildup of air pressure occurs, overload,
regular checking of inflation pressures, and avoid a underinflation, speed, or a combination of these is
buildup of grease or oil around the brake drum responsible. Use the size and type of tire that has
areas. the capacity to carry the load at a recommended
cold starting pressure.
 3E-14 WHEELS AND TIRES

The fabric, rubber, bead, contour, and size of VALVE CORE AND CAP
tires used on these vehicles are designed to obtain
maximum length of service under normal operating The valve core is a spring-loaded check valve in
conditions. THE TIRES ARE SET UP TO the valve stem, allowing inflation or deflation of the
OPERATE EFFICIENTLY ONLY ON A SPECIFIED tube or tire. This check valve, or core, is not
AMOUNT OF AIR. Unless the correct air pressure intended to hold the air during operation. The valve
is always maintained, the tires will not function as cap is provided to seal the air in the tube and tire.
they should. When the valve cap is tightened down on the stem,
An underinflated tire wears out faster than a the sealing washer inside the cap is pressed tightly
properly inflated tire. Also, an underinflated tire against the top of the stem, preventing air leakage.
affects steering and riding comfort. In addition, an it is important that valve caps be used at all times.
underinflated tire could slip on the rim, resulting in
losing the tire, tube, rim, and spacer. Overinflation TUBES AND FLAPS
may weaken the tire, causing a blowout.
For greater riding comfort, longer tire life, and to Tubes Chafed or Pinched by Fabric
reduce wear and tear on the truck chassis, tires Breaks
should be inflated for loads carried on tires as
Tubes may fail as a result of being chafed or
indicated in the “Tire Load and Inflation Table”
pinched by fabric breaks inside the tire. The
(figure 9). In no case should the combined front and
direction and shape of the tube injuries have rather
rear tire load exceed the maximum recommended
closely followed the pattern of the fabric breaks. A
load.
tire does not necessarily go flat right away when a
fabric break occurs on the inside of the tire because
Balanced Inflation
it may take some time for the injury to chafe
Balanced inflation may be described as: All tires completely through the tube.
on the same axle should always carry the same air
pressure. A difference in air pressure of the rear Tubes Damaged by Mismounted Flaps
tires and the front tires may be allowed within
The tube may become chafed by a fold at the
certain limitation; however, there should not be a
edge of the flap. In mounting tires requiring flaps, it
difference in pressures between the right and left
is recommended that the flaps be properly centered
tires on the same axle. A 34 kPa(5 psi)
between beads to prevent folds or wrinkles. Flaps
underinflated tire can lower the efficiency of most
which have once become twisted, creased, or
brakes. Balance tires for ease of steering, comfort
folded over at edges, should not be used again.
in riding, safety in driving, as well as for minimum
fuel use and maximum tire mileage.
Tubes and Casings Damaged by Foreign
materials in Casings
Pressure Loss
Any foreign material between the casing and tube
At periodic intervals, each tire should be gaged
will cause a chafing action. in time, one or both will
for pressure loss with an accurate gage before tires
become badly damaged and fail.
are brought to the correct operating pressure. The
Grit, pebbles, or other hard substances which
purpose of this check is to find out the exact
become embedded in the tube wall, will chafe the
pressure loss in each tire. In other words, if at any tube and become damaged.
time this check is made, and a pressure loss is
noted in any one of the tires, an inspection should
Tubes Stretched and Creased
be made of the tire showing the loss and the cause
of the loss corrected. This method should show a When a tube is larger than the inside of the
“danger signal” on the condition of the tires. The casing, it has become stretched and can become
pressure loss check should be made each time with creased. Creasing can also happen to a new tube
the same gage, so that any sign of inaccuracy in of proper size when incorrectly mounted. If the
the gage wiil be the same for all tires. crease occurs in the flexing area of the tire, the
resulting additional thickness of the tube where
folded causes a hinging action which cuts the tube
and often damages the fabric.
 WHEELS AND TIRES 3E-15

Creases Caused by Remounting Used Tube Installation

Tubes (Figure 15)
Tubes usually undergo some stretch or growth in 1. Insert the tube (12) in the tire and inflate it until
service. This is true of truck tubes because of the it is nearly rounded out.
high temperatures which develop. When a used 2. Using a brush or cloth swab, apply Ru-Glyde or
tube is mounted in a new, or nearly new tire, a equivalent to the tube base, to the rim side of
folded condition will usually result, and in time will the flap (10), and to the base of the tire beads
cause both tube and tire to become damaged. (9) (see arrows) (15). Do not allow the solution
to run down into the tire.
Tube Breaks Next to The Valve
Improper inflation procedure may cause a crack
or tear around the valve base at the edge of the
12——___,
bridge washer. Figure 14, view A, shows the
position of beads, flap and tube with 28-34 kPa
(4-5 psi) inflation pressure. The tube is fully
rounded out within the tire, but the pressure is not
enough to move the beads on wide base rims.
Depending upon tire size and condition of the rim,
i15 "
from 138-276 kpa(20-40 psi) pressure is required
to push the beads onto the tapered bead seats as
9. Bead Set
shown in figure 14, view B.
10. Flap
Forced by this high pressure, the tube can stretch
12. Tube
only in the rim area. Because the resistance to
13. Tire
stretch is greatest at the valve base, tension there
14. Rim
is often enough to crack the tube at the edge of the
15. Lubricate Areas Shown by Arrows
valve base.
Figure 15. Tube and Flap Installation

Do not use water-base lubricants for aluminum

wheel and tire assembly as rust and corrosion may
result.
3. Mount the tire (13) on the rim (14), making sure
that the valve is centered in the slot. Inflate with
minimum pressure to assure that the valve is in
proper position (centered in slot).
4, Replace the side ring and rim lock, where used,
and place the entire assembly in a safety cage.
Inflate the tire enough to be sure that the beads
are fully and properly seated.
5. Deflate tire COMPLETELY, by removing the
valve core. This is important to prevent tube
buckling.
6. Inflate the tire to the recommended pressure.
Used flaps may cause tube damage UNLESS
mounted with the size tire and rim originally
used,
When the tube and flap are not properly
| jubricated and mounted, they will be stretched thin
M N KK
CLLLLEP LILLE ia Vee in the tire bead and rim region (figure 16). This will
cause early damage.
9. Tapered Bead Set B Always clean rims thoroughly to remove rust.
10. Flap
11. Valve Base

Figure 14. Improper Tube Inflation

3E-16 WHEELS AND TIRES

As a precaution against flap damage, mark the

tire and rim size on the flap at the time of removal if
inspection shows that it is not damaged and can be
used again. When the flap is mounted again, this
marking protects against the danger of using the
flap with the wrong size tire rim.
New flaps and tubes should be used after tire or
rim repairs. Small wear spots and imperfections in
used tubes and flaps are hard to see.
14
Tube Recommendations
9. Bead Seats 1. Long life and high mileage received from
10. Flap 10 present day tires use up the useful service life
12. Tube of tubes.
14. Rim Therefore, when a casing is worn to the point of
16. Tube Base being unsafe, the tube generally is in the same
condition and should be replaced with a new
Figure 16. Tire Bead and Rim one.
2. If the valve cap is lost, clean the end of the
Certain precautions must be taken when valve before applying the air hose to prevent
mounting used flaps, or damage to the tire and tube dust and dirt from being blown into the tube.
will result. install a new cap.
New flaps can be used with any one of several 3. When the tubes are inflated for inspection, they
different tire and rim sizes as recommended. But should not be inflated to the point of
once used, the flap must be remounted in the same “ballooning.” When a tube is “bailooned,” it thins
size tire and on the same size rim from which it was out in the stretched area, making the tube too
removed. Aiways use a flap of a proper width to large in that area and resulting in foids or
prevent tube pinching. wrinkles when remounted.
 WHEELS AND TIRES 3E-17

SPARE TIRE
The spare tire is secured to the rear of the
chassis frame with a chain figure 24.

[=] Remove or Disconnect (Figure 24)

." Crs
1. Insert crank handie (11) into the rod cap (12)
and turn counterclockwise until the tire is on the
floor.
2. Remove the tire and disc wheel assembly (13).

[oe] Install or Connect (Figure 24)

1. Position tire and disc wheel assembly (13) on

the floor beneath the spare tire carrier.
2. Turn the crank handle and wind up the tire and
disc wheel until the disc tightens against the
bottom of the bracket.
3. Then pull out the crank handle from the rod cap
without reversing it.

A. Top View
11. Crank Handie
12. Rod Cap
13. Tire and Wheel Assembly

Figure 24. Spare Tire Assembly

SPECIFICATIONS

Front and Rear Wheel Nut [email protected] banneees ccsussesuseuseseuteneavststsaveneecsivstsnsavsaesees 440 N-m (325 Ib-ft)
MEMO
 REAR AXLE 4A1-1

SECTION 4

REAR AXLE AND PROPELLER SHAFT

CONTENTS

SUBJECT PAGE

Rear Axle c..ccccccccssssccocceccesceccesuseussnssonssossrssenseserssonnvassuansnceuspenoeccousauananaranenevaneseaazeesonscansaneceaeanseensnasnennentaneasenneansen 4A1

Propeller Shaft ........:scccsssssecececsserssesaeensesssceeossensssnsenssnnentssesansneanacanencneavens sanesedensensensnesausorenauansanunsonsosiaatssnanaeas 4B

SECTION 4A1

REAR AXLE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE
4A1- 1
General Description .........::ssssssessesssssescoeesensststeneusnnsrateansensansensensansssassaceanasaosnunacnnonsaneceenenccsancenceseneensnenneneas
4A1- 2
Diagnosis of the Rear Axle ........csscccssecssssrsssscssansenesssssneententnnseasessnsanecnsontenenansanesennennansacnanataneanenacascaneeaesinss
4A1- 2
Bent Housing Check .......sscssscscsscsesssesnscensenseseansanssssenssntscsasenennesseeecenssannncsunauenucusannnnenonnaseacenenonateaceasessnents
4A1- 3
On-Vehicle S@rviCe ....cccscsccsesenssncceststeeerssnsusunseneeseessnrenenacantnonnsonsenernssasnenuessearseanearansanenrsessensasatsenageunenenses
4A1- 3
Axle Shaft Replacement ..........cecsesssercssurveunecsemeasnnananensatennensucnnean aueneseaeusnecansonsusenseousaansancunecanereasaaees
4Ai- 4
Hub and Drum ASSeMDIy ........:essscsessensssnceersnseceneesetsesnannscnterennecenssanseesenenseanereneneonsuatauseasaniacersenesenanns
4A1- 7
Rear Axle Assembly Replacement ..........cscnssessencnererrensnencnees cesusasnesnanssuecenaesearusuusoeenssvensenas coneenensaevannans
4A1- 8
Differential Carrier .......cccccceesccscessssencserensseecsunenssessunensneansstennsenasnutonrentesnsqessnennunensesuessannrseuanenarsensneneenaes
9
Unit Repair of 292MM/320MM Differential Carrier ASS@MDLy .......-...-.:sssssesesersseessesnnecraeretserattenensittanens 4A1-
4A1-20
Specifications .........csseccseesecssseeessnssseacensescerencentsnimenanucatsarenvenseaerersenerscens sanaeseeauncaecsuccennevensnsseesensanenennaneeaeenens
4A1-20
Fastener TOrques....cssscsssssssssessssscssnssresesnsstssoneennenssesnmsocsnsaeensacsunnassnecaeanentaneavanenasneoneansasonenanennuensarneaysnyans
4A1-22
Special TOS ........ssscccessescsonsesnsecseneesssstscsnscneseanensnunsenanseronnsanorseacesanentanensnsncunsusnasaceansaroascanaanteaaenagnenansesessetes

GENERAL DESCRIPTION

The axle assembly is a single-speed, single- the differential side gears. The differential carrier
reduction type. The four-pinion differential assembly may be removed while the axle housing
assembly is mounted in a two-piece case. The axle is installed on the vehicle.
shafts are full-floating with the inner ends splined to
 4A1-2 REAR AXLE

DIAGNOSIS OF REAR AXLE

PROBLEM POSSIBLE CAUSE CORRECTION

Noise in Drive 1. Excessive pinion to bevel gear backlash. 1. Adjust.

2. Worn pinion and bevel gear. 2. Replace.
3. Worn pinion bearings. 3. Replace.
4, Loase pinion bearings. 4. Adjust.
5. Excessive pinion end play. ©. Adjust.
6. Worn differential bearings. 6. Replace.
7. Loose differential bearings. 7. Adjust.
8. Excessive bevel gear run-out. 8. Replace.
9. Low ail fevel. 9. Replenish.
' 10. Wrong or poor grade oil. 10. Replace.
11. Bent axle housing. 11. Replace.

Constant Noise 1. Flat spot on pinion or bevel gear teeth. 1. Replace.

2. Flat spot on bearing 2. Replace.
3. Warn pinion splines. 3. Replace.
4. Worn axle shaft dowel holes. 4. Replace.
5. Worn hub studs. 5. Replace.
6. Bent axle shaft. 6. Replace.

Noisy when Coasting _ 1. Axle noises heard on drive will usually be 1. Adjust or replace.
heard also on coasting, although not as
loud.
2. Pinion and bevel gear too tight (Audible 2. Adjust
when slowing down and disappears when
driving).

Intermittent Noise 1. Warped bevel gear. 1. Replace.

2. Loose differential case bolts. 2. Tighten

Noisy on Turns 1. Worn differential side gears and pinions. 1. Replace.

2. Worn differential spider. 2. Replace.
3. Worn axle shaft splines. 3. Replace.

Oil Leak at Rear Axle 1. Oil seals damaged, missing or worn. 1. Replace.
2. Rear axle housing. 2. Replace.

Oil Leak at Pinion 1. Oil seals damaged, missing or worn. 1. Replace.

Shaft 2. Pinion flange loose or damaged. 2. Tighten or replace.

BENT HOUSING CHECK outside tires. Turn the wheels to position the
chalk marks down.
1. Raise the axle housing and install jack stands 5. Measure across the tires at the chalk marks.
under the frame. Vehicle tires must be off the 6. Turn the wheels to position the chalk marks up.
_ _ floor. 7. Measure across the tires at the chalk marks.
2. Check the wheel bearing adjustment. Refer to The axle is bent if the “up” and “down”
“Wheel Bearing Adjustment” in FRONT AXLE measurements differ by more than 3 mm (1/8
AND SUSPENSION (SEC. 3C) in this manual. in). .
3. Check the wheel mountings. Refer to WHEELS 8. Turn the wheels to position the chalk marks
AND TIRES (SEC. 3E) in this manual. forward and level with the axle.
4. Chalk mark the tires on the outer wali of the 9. Measure across the tires at the chalk mark.
 REAR AXLE 4A1-3

10. Turn the wheels to position the chalk marks measurements differ by more than 3 mm (1/8
rearward and level with the axle. in).
11. Measure across the tires at the chalk marks.
The axle is bent if the “forward” and “rearward”

ON-VEHICLE SERVICE

AXLE SHAFT REPLACEMENT Measure

| Remove or Disconnect (Figures 1 and 2) » Axle shaft runout. Maximum allowed is 1.0 mm
(0.039 in).
1. Nuts (1) and washers (2) from the hub.
* Axle shaft flange runout. Maximum allowed is
0.05 mm (0.002 in).
NOTICE: Do not use a chisel or wedge to
loosen the shaft because this could damage [oq Install or Connect (Figure 1)
the hub or the shaft.
1. Axle shaft (3).
2. Axle shaft (3) (figure 2). * Lubricate the shaft splines.
« Align the shaft splines with the differential side
Inspect gear splines.
+ Inspect the axle shaft spline for wear, damage, or NOTICE: See “NOTICE” on page 4A1-1 of this
other abnormal conditions. section.
- Make necessary correction or parts replacement it
wear, damage, or any other abnormal conditions 2. Nuts (1) and washers (2).
are found through inspection.
+ Inspect the outer oil seal. Replace if necessary. fa] Tighten

« Nuts to 49 N-m (36 lb-ft).

. Nuts
—

. Washers
OnbAN

. Axle Shaft
. Outer Oil Seal g13(NPR) 1
| en
. Lock Washer —_—"
pore
a
ae

. Bearing Nut
. Hub and Drum Assembly
OMmMnN

. Outer Bearing Inner Race

. Inner Oil Seal
10. Inner Bearing
11. Hub and Drum
12. Oil Catcher
13. Wheel Pin

Figure 1. Rear Axle Assembly

 4A1-4 REAR AXLE

10. Inner oil seal (9) and inner bearing (10).

11. Hub from drum.

1. Nuts 14. Hub Bearing Nut Wrench

2. Washers
3. Axle Shaft Figure 4. Removing Bearing Nut

Figure 2. Removing the Axle Shaft

HUB AND DRUM ASSEMBLY

[+>] Remove or Disconnect (Figures 1, 3-5)

Tools Required:
J-35012 Rear Hub Bearing Nut Wrench
J-35013 Rear Hub Remover
1. Remove the drain plug from the axle case and
drain the oil (approximately 6 liters/13 pints).
2. Wheel and tire. Refer to WHEELS AND TIRES
(SEC. 3E) in this manual.
3. Axle shaft (3). Refer to “Axle Shaft
Replacement” earlier in this section.
4. Outer oil seal (4). Use screwdriver (figure 3). ~ 15. Hub
5. Lock washer (5) 16. Hub Remover

Figure 5. Removing Hub and Drum Assembly

Inspect

+ All parts for wear or damage. Replace parts as

necessary.

[oe] install or Connect (Figures 1, 5, 6, 7, 8 and 9)

Tools Required:
292 mm differential:
J-39114 Rear Hub Oil Seal Installer
4. Outer Oil Sael J-35008 Inner Bearing Installer
J-35019 Hub Outer Bearing Race Installer
Figure 3. Removing Outer Oil Seal 320 mm differential:
J-43413 Rear Hub Oil Seal Installer
6. Bearing nut (6) with hub bearing nut wrench J-43412 Inner Bearing Installer
(figure 4). J-35019 Hub Outer Bearing Race Installer
7. Hub and drum assembly (7) from the housing with
hub remover (figure 5). NOTICE: See “NOTICE” on page 4A1-1 of this
8. Oil catcher (12). section.
9. Outer bearing inner race (8) and outer bearing
outside race.
 REAR AXLE 4A1-5

ij. Wheel pin to drum.

[&] Tighten (NPR)

* Nuts to 392 N-m (289 Ib-ft).
« Stake nuts to prevent them from loosening.

2 Hub to drum.

[RJ Tighten
13 “LL
* Bolts to 13 Nem (113 Ibein)
15
3. Inner bearing (10) with inner bearing outer race
installer (17) and grip (18) (figure 6).
4. Inner oil seal (9) with oil seal installer (13) and
grip (18) (figure 7).
5. Oil catcher (12)
6. Outer bearing outer race with outer bearing
outer race installer and grip (figure 8).
7. Outer bearing inner race (8).
8. Hub and drum assembly (7).
13. Oil Seal installer
15. Hub
18. Grip

Figure 7. installing Inner Oil Seal

17. Inner Bearing Installer

18. Grip

Figure 6. Installing Inner Bearing

18. Grip
19. Outer Bearing Installer

Figure 8. installing Outer Bearing Outer Race

9. Bearing nut (6). Position the bearing nut so that

the side with the notched line (20) is turned
outward (figure 9). Align the center of the line
with the center of the groove in the axle case so
that the two threaded holes in the bearing nut
line up with the two holes in the lock washer.
4A1-6 REAR AXLE

20. Notched Line

Figure 9. Bearing Nut Alignment

FR] Tighten

Bearing nut (6) in three stages, as outlined

below;
* Stage 1: Tighten bearing nut to 147 N-m (108
lb-ft).
+ Stage 2: Fully loosen bearing nut.
* Stage 3: Tighten bearing nut to 78 N-m (58
lb-ft).

10. Lock washer (5).

11. Outer oil seal (4).
12. Axle shaft (3). Refer to “Axle Shaft
Replacement” earlier in this section.
13. Refill differential oil to specified level.
 REAR AXLE 4A1-7

REAR AXLE ASSEMBLY 8. Nuts and washers (27) and U-bolts (28).
REPLACEMENT 9. Axle housing (29).

| Remove or Disconnect (Figures 10 and 11) | Install or Connect (Figure 10)

- Raise the axle and install jack stands under the NOTICE: For steps 2, 3, 4, 6 see “NOTICE” on
frame. Vehicle wheels must be off the floor. page 4A1-1 of this section
Support the axle housing with a garage jack.
1. Wheels from the hubs. . Axle housing (29).

as
» Refer to WHEELS AND TIRES (SEC. 3E) in 2, U-bolts (28) and nuts and washers (27).
this manual. ,
2. Drain plug and gasket (22). fa] Tighten
- Provide a pan to catch the olf.
* Replace the plug and gasket after ail oil is
» U-bolt nuts to 177 N-m (130 lb-ft).
drained. . Shock absorbers (25).

oo
3. Axle shafts.
+ Refer to “Axle Shaft Replacement” earlier in [RI Tighten
this section.
4, Brake flexible hose (23). Loosen the nut (30) « Shock absorber nuts to 95 N-m (70 ib-ft).
and pry off the clip (31) before removing the
hose (figure 11). 4. Propeller shaft (25) to differential flange.
5. Load-Sensing Valve Bracket Bolt (24).
6. Propeller shaft (25). Refer to PROPELLER QJ Tighten
SHAFT (SEC. 4B) in this manual. : Propeller shaft nut to 103 N-m (76 Ib-ft).
7. Shock absorbers (26).

22. Drain Plug and Gasket

23. Brake Flexible Hose
24. Load-Sensing Valve Bracket Bolt
25. Propeller Shaft
26. Shock Absorber
27. U-Bolt Nut and Washer
28. U-Bolt
29. Axle Housing

Figure 10. Rear Axle Assembly

4A1-8 REAR AXLE

DIFFERENTIAL CARRIER
[es] Remove or Disconnect (Figure 12)

1. Propeller shaft (25). Refer to PROPELLER

SHAFT (SEC. 4B) in this manual.
2. Axle shaft (3). Refer to “Axle Shaft
Replacement” earlier in this section.
3. Differential Carrier (32).
30. Nut + Remove the mounting bolts.
31. Clip * Support and remove the differential carrier.

[><] install or Connect (Figure 12)

Figure 11. Removing Flexible Hose
NOTICE: See “NOTICE” on page 4A 1-1 of this
5. Load-Sensing Valve Bracket Bolt (24). section.
6. Brake flexible hose (23). Bleed air from the hoses
after assembly.
1. Apply liquid gasket to the joining faces of the
fA] Tighten axle case and carrier, and fixing bolts thread
portion.
* Brake hose nut to 15 N-m (11 Ib-ft). 2. Differential Carrier (32).

7. Axle Shaft. fa] Tighten

* Refer to “Axle Shaft Repiacement” earlier in » Differential carrier bolts to 59 N-m (43 Ib-ft).
this section.
8. Wheels to hubs. 3. Axle shaft (3). Refer to “Axie Shaft
* Refer to WHEELS AND TIRES (SEC. 3€) in this manual. Replacement” earlier in this section.
9. Axle Lubricant. 4. Propeller shaft (25). Refer to PROPELLER
« Refer to MAINTENANCE AND LUBRICATION SHAFT (SEC. 4B) in this manual.
(SEC. 0B) in this manual.

\ 25. Propeller Shaft

3. Axle Shaft
3 32. Differential Carrier

Figure 12. Differential Carrier Assembly

 REAR AXLE 4A1-9

UNIT REPAIR OF 292 MM / 320 MM DIFFERENTIAL CARRIER

ASSEMBLY
4. Side bearing outer races (4).
[o>] Remove or Disconnect (Figures 13 and 14)
[] important
* Mount the carrier housing in a repair stand.
* Keep the bearings separate. Do not
[3] Important interchange them.
« Scribe a reference mark to the right and left
side bearing caps to prevent interchanging 5. Differential cage assembly and ring gear (5).
(figure 14). 6. Drive pinion assembly (6).
+ Check and record the tooth contact pattern * Put reference marks on pinion assembly and
and backlash if the gear set is to be reused. differential cover before removal.
7. Shim (7)
1. Lock plates (1). 8. Pilot bearing retainer (8).
2. Bearing caps (2). 9. Pilot bearing (9).
3. Adjuster nuts (3).

This illustration is based on the 292 mm differential.

. Lock Plate
=

. Bearing Caps
nN

. Adjuster Nuts
BWHD

. Side Bearings Outer Race

. Differential Cage Assembly and Ring Gear
ODO

. Drive Pinion Assembly

DOO

. Shim
. Pilot Bearing Retainer
. Pilot Bearing
. Fixing Nut

Figure 13. Differential Carrier Subassembly

4A1-10 REAR AXLE

A. Referemce Mark
] Disassemble
11. Holding Fixture Base
12. Holding Fixture Differential (Figures 15, 16 and 17)
Tool Required:
J-35030 Differential Side Bearing and Rear
Hub Puller Pilot

fy] Important

* Prior to removal, scribe reference marks on

the ring gear and cage halves to ensure
correct reassembly (figure 17).

. Side bearings (13). Use puller pilot (23) and

Figure 14. Scribing Reference Marks to Bearing
remover (figure 16).
Caps
. Cage bolts (14). Replace the bolts with new

ht
ones.
. Differential cage B (15).

DOOR
. Lift differential cage A from ring gear (21).
. Washer (16).
. Side gear (17).
. Spider assembly (18).
OOnN

. Side gear (19).

. Washer (20).

16 17 QR is” 19 20
\
~ ) ‘.

13. Side Bearings < &

14. Cage Bolts
15. Differential Cage B 18. Spider Assembly 21. Ring Gear 21 29
16. Washer 19. Side Gear 22. Cage Half A
17. Side Gear 20. Washer

Figure 15. Differential Assembly

Se

EN
23. Puller Pilot
Figure 16. Removing Side Bearings Figure 17. Scribing Differential Cage
 REAR AXLE 4A1-11

Pinion Cage (Figures 18, 19, 20 and 21) 5. Pinion cage and seal (O-ring) (28).
Tools Required:
J-22912-01 Top Gear Shaft Bearing Clean
Separator
» All parts in a suitable solvent and blow dry. Do
J-35016 Drive Pinion Flange Bracket
not spin the bearings while blow drying with air.
. Pinion nut (24). Clamp the pinion in a soft jawed
vise using flange bracket (33) (figure 19). Inspect
Discard pinion nut.
. Flange (25). : Alt parts.
. Inner bearing inner race (31) from the pinion » Always replace drive pinion and ring gear as a
gear (32). Use bearing separator (figure 20). set.
. Oil seal (26) and outer bearing with race (27) « Replace any parts found damaged or worn.
and inner bearing outer race (30) from the Refer to “Tapered Roller Bearing Diagnosis” in
pinion cage and seal (O-ring) (28) by using the FRONT AXLE AND SUSPENSION (SEC. 3C) in
proper bar (36) through the two notches (35) this manual.
(figure 21).

24, Pinion Nut

25. Flange
26. Oil Seal
27. Outer Bearing with Race
28. Pinion Cage and Seal (O-ring)
29. Spacer
30. Inner Bearing Outer Race
31. Inner Bearing Inner Race
32. Pinion Gear

Figure 18. Pinion Cage Assembly

33. Flange Bracket 34. Bearing Separator

Figure 19. Removing Pinion Nut Figure 20. Removing Pinion Gear
4A1-12 REAR AXLE

6 I
35. Notch 18. Spider Assembly
36. Pry Bar B. Pinion

Figure 21. Removing Outer Bearing with Race Figure 22. Clearance Between Spider and Pinion

ahs
Measure (Figures 22, 23 and 24)
17
* Clearance between the spider assembly (18) and
the pinion (B) (figure 22).
292 mm differential
Standard: pt d2¢
0.07-0.13 mm (0.003-0.005 in)
Maximam allowed:
0.2 mm (0.008 in)
320 mm differential
15
Standard:
e+ id}
0.05-0.13 mm (0.0020-0.0051 in)
Maximam allowed:
0.2 mm (0.008 in)
- Clearance between the side gear (17: d.o) and
differential cage B (15: d,6) (figure 23).
292 mm differential 15. Differential Cage B
Standard: 17. Side Gear
0.05-0.11 mm (0.002-0.004 in)
Maximam allowed: Figure 23. Side Gear Clearance
0.25 mm (0.01 in)
320 mm differential
Standard:
0.13-0.20 mm (0.005-0.008 in)
Maximam allowed:
0.25 mm (0.01 in)
» Play in the splines between the side gears (17)
and axle shaft (C) (figure 24).
292 mm differential
Standard:
0.08-0.15 mm (0.003-0.006 in)
Maximam allowed:
0.3 mm (0.012 in) 17. Side Gear
320 mm differential C. Axle Shaft
Standard:
0.2 mm (0.08 in) Figure 24. Axle Shaft Ciearance
Maximam allowed:
0.5 mm (0.02 in)
 REAR AXLE 4A1-13

fe] Assemble

Pinion Cage (Figures 18, 25, 26, 27 and 28)

Tools Required:
292 mm differential:
J-35014 and J-8092 Oil Seal installer
J-35020 and J-8092 Inner Bearing Outer
Race/Outer Bearing Outer Race Instalier
J-35727 Inner Bearing Inner Race Installer

ww
31. Inner Bearing = ~——- 31
320 mm differential:
Inner Race
J-43411 and J-8092 Oil Seal Installer
40. Bearing Inner
J-43410 and J-8092 Inner Bearing Outer
Race Installer
Race/Outer Bearing Outer Race Installer
J-35727 Inner Bearing Inner Race Installer
Figure 27. installing Inner Bearing Inner Race
1. Pinion cage and seal (O-ring) (28).
2. Inner bearing with race (30) (figure 25). 6. Spacer (29).
3. Outer bearing with race (27) (figure 25). + Discard used spacer and install a new one.
4. Oil seal (26) (38) (figure 26). 7. Pinion Gear (32).
8. Flange (25).
- Discard used pinion nut and install a new one
at reassembly.

NOTICE: See “NOTICE” on page 4A1-1 of this

section.

9. Pinion nut (24).

Apply oil to seated surface of nut when
tightening.
37. Bearing Outer
Race Installer QR] Tighten
38. Grip
+ Pinion nut to 245 N-m (181 Ib-ft).

Figure 25. Installing Drive Pinion Bearing Races NOTICE: Do not reuse the pinion nut.

26. Oil Seal

27. Outer Bearing
39. Oil Seal Installer

Figure 26. Installing Rear Hub Oil Seal

5. Inner bearing inner race (31) (figure 27).

 4A1-14 REAR AXLE

[A] Adjust
Tool Required:
J-34913 0-25 lb. Tension Gage
* Clamp the pinion in a soft jawed vise.
* Hook spring tension gage at cage hole.
* Measure the pinion bearing preload (figure 28).
» Adjust bearing preload by tightening the flange
nut until specified preload is obtained.
« The flange nut should be within the specified
range when specified preload is obtained.
Flange Nut Torqe:
292 mm differential: 41. Tension Gauge
324-480 Nem (238-354 lb-ft)
320 mm differential: Figure 28. Measuring Pinion Bearing Preload with
441-598 Nem (325-441 Ibeft) Spring Tension Gage
Bearing Preioad:
292 mm differential:
New: 13-25 N (2.9-5.7 Ib)
Used: 6.5-12.5 N (1.5-2.9 Ib)
320 mm differential:
New: 26-38 N (6.0-8.6 Ib)
Used: 13-19 N (3.0-4.3 Ib)

Differential (Figures 15, 29, 30 and 31)

NOTICE: For steps 1 and 7, see “NOTICE” on

page 4A1-l of this section.

1. Cage half A (22) and ring gear (21).

« The ring gear should always be replaced with Figure 29. Ring Gear Bolt Sequence
the drive pinion as a matched set. Apply stud
lock to the bolts after treatment of the bolts 2. Washer (20).
with primer N. 3. Side gear (19).
4. Spider Assembly (18).
[QQ] Tighten §. Side gear (17).
6. Washer (16).
- Ring gear bolts to specified torqe in sequence 7. Differential cage B (15).
shown in figure 29. « Install differential cage B by aligning reference
292 mm differential: marks made during disassembly.
127 Nem (94 Ibeft) * If necessary, install cage bolts (14) from the
320 mm differential: ring gear side to prevent interference between
333 Nem (246 Ibeft) cage attaching bolts and drive pinion.
« Apply oil to thread portion of bolts before
installation.

[QJ Tighten
* Differential cage nuts to specified torqe.
292 mm differential:
69 Nem (51 Ibeft)
320 mm differential:
108 Nem (80 Ibeft)
 REAR AXLE 4A1-15

5. Side bearing outer race (4).

Measure * Be sure to keep the outer races with the
» Clearance between back face of side gear bearings they were with at disassembly.
and differential cage by inserting a feeler 6. Bearing caps (2) and adjuster nuts (3).
gage through the hole in the case. If the « Align the reference marks (E) applied at
clearance exceeds the limit, replace the thrust disassembly (figure 33).
washer or the side gear (figure 30). « Tighten the adjuster nuts so that they can be
292 mm differential: turned after installing and semi-tightening the
0.21-0.28 mm (0.008-0.011 in) bearing caps (figure 34).
320 mm differential:
0.10-0.38 mm (0.004-0.015 in) Measure

8. Side bearing (13) (figure 15) (figure 31). « Gheck ring gear runout (figure 35).
292 mm differential:
Standard:
0.05 mm (0.002 in)
Maximam runout:
0.2 mm (0.008 in)
320 mm differential:
Standard:
0.08 mm (0.003 in)
Maximam runout:
0.25 mm (0.010 in)

8. Pilot Bearing Retainer

10. Fixing Nut

Figure 32. Installing Pilot Bearing Retainer

42. Bearing Inner

Race Installer

Figure 31. Installing Side Bearing

| Install or Connect (Figures 13 and 32-40)

NOTICE: For steps 8 and 9, see “NOTICE” on

page 4A1-1 of this section. 2. Bearing Cap
E. Reference Marks
1. Mount the carrier housing in a repair stand.
2. Pilot bearing (9).
Figure 33. Installing Bearing Caps
3. Pilot bearing retainer (8) with the fixing nuts
(10) on the inboard side of the case (figure 32).
4. Differential cage assembly and ring gear (5).
4A1-16 REAR AXLE

inspect

« Ring Gear and Pinion Tooth Pattern (figure

36).
» New gears.
1) Apply a thin coat of red check to the faces of
7-8 teeth of the ring gear.
2) Turn the ring gear to get a contact pattern.
« The contact pattern is centered on the
gear tooth as shown in figure 36, with
IL, lengthwise contact clear of the toe.
« The length of the pattern in an unloaded
3. Adjuster Nut
condition is one half to two thirds of the
ring gear tooth on most models.
Figure 34. Tightening Adjuster Nuts

7. Shim (7) and drive pinion assembly (6). + Used gears.

1) Apply a thin coat of red check to the faces of
fy] Important the 7-8 teeth of the ring gear.
2) Turn the ring gear to get a contact pattern.
* Do not cover oil port when installing shim + Used gears usually do not display a
pack. square even contact pattern as new gears
Use reference marks applied on removal. do. Normally, gear contact is a “pocket” at
* Use new shim of the same thickness as the the toe-end with tails along the gear root.
old one is a new pinion and ring assembly are As the gear wears, the tail becomes more
used. dominant.
* Shims are available in the following * Adjust a used gear to show the same
thicknesses: 0.10 mm (0.0039 in), 0.12 mm contact pattern observed before
(0.0047 in), 0.14 mm (0.0055 in), 0.16 mm disassembly. A correct pattern is clear of
(0.0063 in), 0.18 mm (0.0071 in), 0.20 mm the toe and centered along the face length
(0.0079 in). of the tooth.

[QJ Tighten
* Pinion assembly bolts to specified torqe
292 mm differential:
M12: 69 Nem (61 Ibeft)
M14: 78 Nem (58 fbeft)
320 mm differential:
72 Nem (53 Ibeft)

21. Ring Gear

F. Dial Indicator

Figure 35. Ring Gear Runout

 REAR AXLE 4A1-17

3) Check the impression of contact obtained on + Backlash adjustment moves the contact
the ring gear teeth and make necessary pattern along the “face length” of the gear
adjustment as described in figure 36. tooth. Pinion position controls contact on the
“tooth depth” of the gear tooth.
Adjust « These adjustments are inter-related and must
be considered together. First adjust the
* Pinion depth and ring gear backlash. pinion, then the backlash.

Correct Pattern (New Gears) Incorrect Pattern

(Move Pinion Away From Ring Gear)

« Could vary in length. Pattern should cover * Pattern too far along tooth toward tooth
1/2 tooth or more (face width). heel.
« Pattern should be evenly centered between * Move ring gear toward pinion to decrease
tooth top land and root. backlash.
* Pattern should be clear of tooth toe.

Correct Pattern (Used Gears) incorrect Pattern

(Too Much Backlash)

* Pocket may be extended. * Pattern too far off tooth toe.

« Pattern along the face width could be ® Move ring gear away from pinion to in-
longer. crease backlash.

incorrect Pattern incorrect Pattern

(Move Pinion Toward Ring Gear) (Not Enough Backlash)

« Pattern too close or off tooth root. ¢ Pattern too close to tooth top iand and off
e Move pinion away from ring gear. center.
© Move pinion toward ring gear.

Figure 36. Pinion Depth and Ring Gear Tooth Patterns

4A1-18 REAR AXLE

Pinion Adjustment 2) Check the side bearing preload drag with a

* Pinion position is controlled by the pinion spring gage (figure 39).
bearing cage shim pack. « NSK Bearing
* Remove shims if pattern is at the top land of New : 0.58 — 1.33 kg (1.3 — 2.9 Ib)
ring gear tooth. Used : 0.29 ~ 0.66 kg (0.7 — 1.4 Ib)
« Add shims if pattern is too close to the root of « Koyo Bearing
ring gear tooth. New : 1.17 — 1.83 kg (2.6 — 4.0 Ib)
* Check ring gear backlash after each shim Used : 0.59 - 0.91 kg (1.3 - 2.0 Ib)
pack change (figure 37).

Ring Gear Backlash (figure 37)

¢ Obtain a dial indicator set.
1) Loosen the adjuster nuts (3) (figure 13).
2) Tighten the adjuster nuts (3) to zero
backlash, then loosen by one notch.
3) Tighten the adjuster nuts (3) to contact the
bearing cup, and tighten three more
notches.
4) Check backlash with dial indicator at four
positions equaily spaced.
292 mm differential:
0.18-0.23 mm (0.007-0.009 in)
320 mm differential:
0.19-0.29 mm (0.007-0.011 in)
* To add backlash, loosen the adjuster nut
on cage half A and tighten the adjuster nut 3. Adjuster Nut
on cage half B the same amount.
» To remove backlash, loosen the adjuster Figure 38. Side Bearing Preload Adjustment
nut on cage half B and tighten the adjuster
nut on cage half A the same amount.

F. Dial Indicator ~
Figure 39. Checking Side Bearing Preload Drag
Figure 37. Checking Ring Gear Backiash

Adjust
+ Side bearing preload.
1) Tighten the adjuster nut on the ring gear
side 2 more notches to give a proper
bearing preload when correct backlash and
tooth contact are obtained (figure 38).
 REAR AXLE 4A1-19

8. Fully tighten bearing caps (figure 40).

[RI Tighten

» Bearing cap bolts to specified torqe.

* Recheck ring gear backlash after tightening
the bearing cap bolts.
292 mm differential:
108 Nem (80 Ib-ft)
320 mm differential:
157 Nem (116 Ibeft)
9. Lock plates (1) (figure 13).

Tighten

* Lock plates to specified torge. 3. Adjuster Nut

292 mm differential: 21. Ring Gear
29 Nem (22 lb-ft) 43. Bearing Cap Bolts
320 mm differential:
13 Nem (9 Ibeft) Figure 40. Tightening Bearing Cap Bolts
4A1-20 REAR AXLE

SPECIFICATIONS
NPR
TYPO ..eeeeescseneeeeeeeceeneeereeeneecaaneeteessssaenaeenennessinenaeeeesedenesuddereeseersescasaassesessasensnasseaeesseeeseeneas Banjo—Full Floating
Gear TyYPe .... eee cccceecescssceesscsseeneusceuscsenaceeepnacessseedeeaecadscurseaesecnseseneenpaeeseecaanecessenesesessensesecesesenaeesenee Hypoid
Ring Gear Pitch Diameter .............. ccc ceeccescessnesensnsenssesnsssecsseceesscmesecassagegneaquausacanneacesesaaeeneusaees 292 mm (11.5 in)
Ring Gear Backlash 2.0... ceessessseeecesssrseeneseevesseaaeosaeecesascesseeaeseneeeuscnneneneeeneees 0.18-0.23 mm (0.007-0.009 in)
Pinion Bearing Preload Adjustment Method 0.0.0.0... eeseececsessesensttesesenseseesssersessesessseneseeeseneseeseceeesaneens Spacer
Preload at Cage Bolt Hole
(Pitch Circle Diameter 155 mm / 6.10 il)... cee esseceeeeeeeesaeeeeeeeees New : 13-25 N (2.9—5.7 Ib)
Used: 6.5-12.5 N (1.5—2.9 Ib)
Flange Bolt Hoje Pitch Diameter... eecescsesesceneceeeennenenssunnessatsesuacuecnssueesesusonsasenegateseenees 100 mm (3.94 in)
Side Bearing Preload Adjustment Method ............cceeeeeeereees sonecesomscneaaeaaeuceeaunoeaeencenecenageeanenenes Adjusting Nut
Preload at Ring Gear Fixing Bolt
(Pitch Circle Diameter 240 mm/9.45 in) NSK Bearing ......... New : 0.58—1.33 kg (1.3-2.9 Ib)
Used: 0.29--0.66 kg (0.7—1.4 Ib)
Koyo Bearing ........ New : 1.17-1.83 kg (2.6—4.0 Ib)
Used: 0.59-0.91 kg (1.3-2.0 Ib)
Allowance for Sid@ Bearing ............cccccccsssecensecesenececcensenestnnesessunseuseseeneeses 0.007-0.014 mm (0.0003—0.0006 in)
Differential Type 2... csseesseeseeseesneeecnuweessensecseseeesusamueossaneseserseeseususaseeeesteseaessaaaenedeeetecaeeaaenaterseses Four Pinion
Axle Shaft Type .0...... cece c ccc eecsecsncnnecsneceneesonsaneeeeneneeereeeecoeecereseceseeteeesesneseeseeetenes Integral Shaft and Drive Flange
Oil Capacity 22... eee eee eeeeeteeesecererseeeeeneueaseneaueeasasesesencacegeeeesecneneeeneaengaaeessateresseaenenameneeetas 9.7 liter (10.3 qts)

FASTENER TORQUES

Axle Shaft NUtS ...........cccceecccseeceesanseeeeneeeecenecenaamaeenoneeeeneeeesnnnaaesneeesneseeeeuaneaaaaneaneeseneceuuaaeasaneees 49 N-m (36 Ib-ft)

Wheel pin to Drum Nuts... eee eee ceesseessensenenenseoeeoneaeasosseesesaneaueceseseomecseeeeaseameaseeesteseeeeess 392 N-m (289 Ib-ft)
Hub tO Drum Bolts .........cccesessceneesseeneceeneseecaeeaeanaesnesnesneanaauanaanseveneceenaanegnasaueseneneuseassaeoaaentenes 13 Nem (113 Ibsin)
Bearing Lock Nutt ............ cece eesessssensencaemeaanennameeteemeeseoerorsanees 147 N-m (108 Ib-ft}»0 (Zero)>78 N-m (58 lb-ft)
U-bolt Nuts ..........ccceeeeeeeeeneeeereneneaesessoraveeseunee wedeeeeeccunnaaaseenseeeneeeeaaceceueeeteeeecesecnentaneeneateenesen 177 N-m (130 Ib-ft)
Shock Absorber Nuts .........c.ccccecssessensseseeceseeeaenaeneaeeseeeerseenaaeaaaueneensecssasagagnaaatesesesaeasaaananeereetens 95 N-m (70 lb-ft)
Propeller Shaft Nuts ...........eeccecessenseseesersentessnaeeeeesseessseaeneaeeeseeseueuseseneesoussanssetesscserseanaenaatens 103 N-m (76 Ib-ft)
Brake Hose Nut ..........cc:cessscccceeeceenecancenaaeteeenessessmasenanagagenseeteaancasaoameegeneersessedsoaseseneeeeesenaenoagaees 15 N-m (11 ib-ft)
Differential Carrier Bolts ........0...ccceceeccecseescoesecteterteeeceanennecauaeesseeesesamecseaeecseseeeseas¢ensseanaeereneneeeaed 59 N-m (43 {b-ft)
PiniOn Nut ....cc..ccccccccccessenseceeecesseaaeeeeeesnenecsceseeecesensacsaeeesesssacseenaeeesessercententenseereneees 324-480 N-m (238-354 Ib-ft)
Ring Gear Bolts .......c cc ceccccseeseeeseeeesseeeeeseeueessaneuececesasnaeueesiaessenseceensaseersecseaseeuevsseuseeeeneenees 127 N-m (94 lb-ft)
Differential Cage NUt ........ cc eceeceeceecreseeneccusenensnaedaasansaaseeneasuuuaeaeuuasedanaeaunenenaeeuasaueuaeaeaeeneseenees 69 N-m (51 lb-ft)
Pinion Assembly BoltS ............... cc. ccc ceesecnsesseecaneoneeeeseaennmaaeaeeeeeeenseesesereeenseereneteserserseetenses M12: 69 N-m (51 Ib-ft)
M14: 78 N-m (58 lb-ft)
Bearing Cap Bolts .........cecessecreceeeeseseneereneesseesmnaneseseensesneenpeeteresee bovevereceveteueenteetensenenenaeeoeses 108 N-m (80 Ib-ft)
LOCK PlALCS ooo eee ccc ccceccueseeeeessnessceneeeeeeereesaaneseeeneeeensecdaneneaaaeesaeeeeedsseenepesetepeesoumneasaaeeeeenenensnnaea 29 N-m (22 Ib-ft)

NQR
TYPO oeececccseessecerceneeseseeesesseessssesaeceaseceessneessseeueesssessasenseeegesnseecnsesaeseaeesueeseesnnesenaeesseesarenaes Banjo—Full Floating
Gear TYPO... ceecccecseeceseeeteneeeeeeceseessesuecesnsneaeeenueaseseeassceseessesseeseeneeesepeareesneeespnecgesesenasenecsuaeqneneecnaneensen Hypoid
Ring Gear Pitch Diameter .............:eccccceescessecsssosneecsneeessceneecsnansesenscessusecassenecaeeensensseseenteneaeeas 320 mm (12.6 in)
Ring Gear Backlash .2..... cc cececeesecsecssecsseesaseecsesseeeenscansisensesseesatenimegsennecneenees 0.19-0.29 mm (0.007-0.011 in)
Pinion Bearing Preload Adjustment Method ............ccccecerresseesneneessneesenenesaceseseesencnesssaserenenesnenerennecens Spacer
Preload at Cage Bolt Hole
(Pitch Circle Diameter 155 Mm / 6.10 iN)... eee teeta eeesesetnteeeeees New : 26-38 N (6.0—8.6 Ib)
Used: 138~19 N (3.0—4.3 Ib)
Flange Bolt Hole Pitch Diameter ............ccsescccsecsenecetneesneeceseeceanescentenecaeesnaeeeeneeetneeeetenesnenags 100 mm (3.94 in)
 REAR AXLE 4A1-21

Side Bearing Preload Adjustment Method 000... 0... ceceeeeceeceeenetereteeeseraeseaeuerseeescsmecaneaesessonenaaas Adjusting Nut
Preload at Ring Gear Fixing Bolt
(Pitch Circle Diameter 240 mm /9.45in) NSK Bearing ......... New : 0.58-1.33 kg (1.3-2.9 Ib)
Used: 0.29-0.66 kg (0.7—1.4 Ib)
Koyo Bearing ........ New : 1.17~-1.83 kg (2.6—4.0 Ib)
Used: 0.59-0.91 kg (1.32.0 Ib)
Allowance for Side Bearing ............::.cccccccceessecsneeeceeeesseeeecesecenersnneaeneneatens 0.007-0.014 mm (0.0003-0.0006 in)
Differential Type .............cccccccceectscnnecerererterscaeneseneeeneninnneneneeermdadeeneeseseeenensaenaseaeseseeenaueneueeenseeeeueuas Four Pinion
Axle Shaft Type ......... eee eecseeeceesenccneeeeeeseeeeesuaseeseuesssseecuuaenecsesauaeseuseessanuereaeenes integral Shaft and Drive Flange
Oil Capacity oo... ceceeeeceseeecseeceeeesesneneeeeeeeesneecenerseseeseneveneneenssasesuuesgussesseeensenuesesseascnewersnees 9.7 liter (10.3 qts)

FASTENER TORQUES
Axle Shaft NutS 0.0.0.0... ccccsccsssssccescsnenscssacnameaacnasanseacesscesauscenseneceesseeeneteeereneeesmeuseeneeteeneneneneeten 49 N-m (36 Ib-ft)
Hub to Drum BoltS ........cccccceccecceeeceeseeseeecotecesureenesenetuderseesaeanecaeaneaaeaneaeaneeasaaaasaeaessieaeeeeaamens 13 N-m (113 Ib-in)
Bearing Lock Nut ......... cece seeessueeescerenserneeeeseeesensensnnneesenenen 147 N-m (108 Ib-ft)-30 (Zero)—»78 N-m (58 Ib-ft)
U-bolt NUtS ...0ccsccceccecsceccessessneseeecensessenencauseeeeesseneeecesenensesnneaeersonceqeeqiaertereeneersneeenieneteeennen 177 N-m (130 lb-ft)
Shock Absorber Nuts ........ccccccccccccccececeseeceseeeeeseeeeerensuetestaeeterreeectigmceneaccegeneeeeenteseenstieeenteesenes 95 N-m (70 Ib-it)
Propeller Shaft Nuts 00.0.0... ceecccsssesesusssennesneetenteneseeseeecsecsneesuscnsrsseesaeeesssseasesseetsessessraeaes 103 N-m (76 lb-ft)
Brake Hose Nut ........cccccccccecceccseeeceuseeseseneeeseaeseeeuuaessceeenesnecaseuaenegssensseeseenoaaauienees deeeeeesauanaeenees 15 N-m (11 lb-ft)
Differential Carrier Bolts ......0.......: cesses seeeee ree eaneeeeees be saeeeeeseceseeaaaesuanassesancesaaeaegaeestenseesusageanenees 59 N-m (43 Ib-ft)
Pinion Nut .....0....-.ceeeeeeee peaceuseececeneusauceereseneesecuceaueseneecesonaetecsersectnaenesatenerententcga 441-598 N-m (325-441 lb-ft)
Ring Gear Bolts ..........:cceccceseesesesseseseeneesseecenseceressersesesesteseausaeessaeseaneaeseaeeseaesneaesessegneniaesy 333 N-m (246 lb-ft)
Differential Cage Nut 0... cece eesssneessosseremeecssuseeeauueneeseeuseecseesnesesaeesereassanensenneesesnananaenaes 69 N-m (51 Ib-ft)
Pinion Assembly Bolts ..........0:.:cecssesseessseeccesenseneesasausssasesenenseeseeneaeseesegensuassensneesccenaeererassnnaaaes 72 N-m (48 Ib-ft)
Bearing Cap Bolts .........cceeceeceseseesssussssenecssueessnsesecseueeseseneessnsssessonaensuenseesnnaseseeesseeneerenenss 157 N-m (116 lb-ft)
LOCK PlateS ..........ccccceccececcneneeeeeeeeeeevereesnoneeeseweseusuueenssmuaeaeeneeees bhedceneeesteaeapeaenereesnecserganeetoneseseaeed 13 N-m (9 lb-ft)
4A1-22 REAR AXLE

SPECIAL TOOLS

TOOL NO. TOOL NO.

ILLUSTRATION TOOL NAME ILLUSTRATION TOOL NAME

eo
J-35012 L a J-35016
=e Rear Hub Bearing E/ Drive Pinion Flange
Nut Wrench _— Bracket
e 7 ee

Ve J-35013 4 \ J-22912-01
eX Rear Hub Remover SLE eons Top Gear Shaft Bearing
~ Separator

2 —
(oy J-39114 Ce J-35014
Y Rear Hub Oil Seal \ Pinion Cage Oil Seal
installer installer

(“o\y J-43413 (7 J-43411

Rear Hub Oil Seal Ce: Pinion Cage Oil Seal
installer Installer

J-35008 “e J-35020
inner Bearing Installer Drive Pinion Inner / Outer
Race Installer

<> J-35019 J-43410

Ae Hub Outer Bearing Drive Pinion Inner / Outer
Outer Race Installer Race Installer

J-43412 J-35727
NE Wy Hub Inner Bearing Inner Bearing inner Race
Outer Race Installer Installer

J-3289-20 J-34913
Holding Fixture Base Tension Gage

J-35715
Differential Carrier
Holding Fixture
a J-35021
Differential Side Bearing
Installer

J-35030 J-8092
Differential Side Bearing Grip
and Rear Hub Puller Pilot
 PROPELLER SHAFT 4B-1

SECTION 4B

PROPELLER SHAFT
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

De@SCriptiOn .........csssssssrcscsscsssenssesenseersnsastonsonensensnneeassnenneerssasies benausarentuvatusransecensuseoasspecnieusesesnenaeseaussensetssssass 4B- 1

Propeller Shaft .......cccssssscssesssessscssscsesmueorsansceesesssneseseseneaceneresnsanersassscnseesonsonssnecascucneasensnsersauaeseeevesecueess 4B- 1
Center Bearing .........secsesscesssecssesnseusecsnseuseneesesaneseestensessecoensnsensesnonenssaneensenneassesaenssnestensenestetsenaeateaneataas 4B- 3
Universal JOINS .......ccsscscscssscsssesercesenseasnsnesesersonsonnessonsecsueanenteacuansanonsceersgantantsesesensoreneaesonapennssamereneeaaencanenns 4B- 3
Driveline Vibration Diagnosis (Road TeSt) ..........ccssscrseessesssosunnecenseresnnensenensnsatenassensnecssensntaeenuauasensecsenins 4B- 3
Diagnosis of the Propeller Shaft .......sssccssncsssnsesnssserscarssnstsronneessnracscnnenssonseanuoueasises senneanrensassenussennaneasoneese 4B- 4
On-Vehicle Service .......ccsscssessesersessesuessessscsneccnsnseesssnescceesansaraeausatesunennecennesensesuaesueaasessneerscesenunecanuvasenseoenese® 4B- 5
Driveline Angle AGjUStMENE .........cssseussesssesenteesenssersssntersceentenscanseneeenerterseasenetonseossanrcensensuaensuranenaenentas 4B- 5
Propeller Shaft Balancing ........cccsssessseesceecsensseerssessnenteseesesseenensenrsuenesnereersetirenuetsansansessrenaseensarssncauensses 4B- 6
Propeller Shaft Replacement ...........cc:ssccscsssecessnsecesenseessesenseeaseenaneenenssensnensenranaseansnseasansceuneauecensnusenenescens 4B- 7
Universal Joint Replacement .......ccssssscscsssssnsescecesersscesensniaenscoseneceutenenanteseneunsensaseneenseranatseuencarsenteetenenans 4B- 7
Center Bearing Replacement .........:ccssrsecscensssescsenennecnssersasnenenneceenunescesansesatensensevausreotesenutersorenenenerenseeas 4B- 9
Lubrication .........-.00 suavuneearsagnesuatasauauseaneanoasesneneceeseceraesesenensanczersedueusarausnauoersauedenerioeenaerssorsequenuseenseseceuananens 4B-10
Specifications ..........cccssssesssecscsconseceeseoeensnneenseneneesseeceetseensentmeansvareanussquueesavenestoannennenensestansertusereansvarsesenenonaas 4B-11
Fastener TOrques........csccsssssssssesssssessersesnanenssrssecesessssenenseneconscnanssanaesesennenesssnonsadeneetnusossuennuceuaecsnavenuaaseaasevedss 4B-11

DESCRIPTION
PROPELLER SHAFT Vibration can be caused by an out-of-phase
propeller shaft.
Torque is transmitted from the transmission to the The shaft will absorb the vibration from the
rear axle through Propeller shaft (Long wheel base speeding up and slowing down each time the
truck has two propeller shafts) (3 and 5), the center universal joint rotates. The vibration would be the
bearing (4) and the universal joint (2) assemblies same as a person snapping a rope and watching
(figure 1). The propeller shaft is a balanced- the “wave” reaction flow to the other end. When a
tubetype design. A slip joint is used at the forward propeller shaft is working in phase, it would be
end of the rear shaft. similar to two persons snapping a rope at the same
time and watching the “waves” meet and cancel
Phasing each other out. This would be the same as the
universal joints on a propeller shaft. The total
All propeller shafts are designed and built with the cancellation produces a smooth flow of power to
yoke lugs (ears) in line with each other (figure 2). the wheels. For this reason, it is very important to
This condition produces the smoothest running
mark the propeller shafts when disassembling to
shaft position and is called phasing.
assure proper reassembly alignment.
4B-2 PROPELLER SHAFT

1. Transmission Yoke Flange

2. Universal Joint
3. Front Propeller Shaft
4, Center Bearing Assembly
5. Rear Propeller Shaft

Figure 1. Propeller shaft Assembly

1. Correct Phasing
2. Incorrect Phasing

Figure 2. Propelier Shaft Phased

 PROPELLER SHAFT 4B-3

CENTER BEARING
The center bearing (4) is used to support the
center portion of the driveline when two propeller
shafts are used (figure 1). The bearing is a ball type
and is mounted in a rubber cushion that is attached
to a frame crossmember.

UNIVERSAL JOINTS 2. Universal Joint

(spider)
Universal joints are mounted to a flanged yoke on 6. Outside Bearing
each end. Diameter
The flanged yoke is attached to the component by
studs or bolt and nut assemblies. The center Figure 3. U-Joint and Bearing Arm
bearing yoke is attached by a special staked nut. U-
joints are identified by the outside bearing diameter
(6) of the spider (inner cross) (figure 3).

DRIVELINE VIBRATION DIAGNOSIS (ROAD TEST)

There are four major component groups that places — in the steering wheel or in the seat
usually cause, or are related to vibration. When a bottom.
technician is road-testing a vehicle for vibration, he This can be very helpful in locating the vibration
must remember these four major component to the front or rear of the vehicle.
groups:
1. Engine and mounts. Coast Test
2. Clutch and transmission. Take the vehicle past the vibration speed, shift
3. Tires, wheels and brake drums. into neutral, and coast back through the vibration
4. Propshaft and U-Joints. range. On this test, two kinds of vibration normally
Before road-testing a vehicle, be sure to check occur - a shaking or a buzzing. A shaking vibration
the following: is usually tires, wheels or brake drum/disc
1. Propshaft is in-phase. assembly. A buzzing vibration is usually a driveline
2. All fasteners are tight, like U-joints, tires, and problem.
engine mounts. An additional check may be performed to assure
3. Air pressure in the tires. that the vibration is caused by the driveline.
4. Load conditions. Remove the axle shafts from the drive axle. With
service brakes applied, operate the engine with the
Road Test transmission in gear and the clutch engaged at the
The technician should road-test the vehicle speed where the vibration occurred on the road
himself so he knows exactly what the complaint is. test. If the vibration is the same, you can be
Record the speed and rpm where the vibration is reasonably sure that the source of the vibration is
at its worst. The vibration is likely to be in two the driveline.
4B-4 PROPELLER SHAFT

DIAGNOSIS OF THE PROPELLER SHAFT

PROBLEM POSSIBLE CAUSE CORRECTION

Universal Joint Center bearing Replace center bearing.
PON>
Noise Worn universal joint bearings. Replace.

PON
improper lubrication. Lubricate as directed.
Loose flange bolts. Tighten to “Specifications”.
Ping, Snap, or Click Loose bushing bolts on rear springs. Tighten bolts to specified torque.
ws

hR—
in Driveline Out of phrase companion flange. Remove companion flange, turn 180°
NO

from its original position, iubricate

splines and install.
Tighten bolts to specified torque.
Roughness or Bent or dented propeller shaft. 1.Replace propeller shaft.
Vibration
PoN>

Undercoating on propelier shaft. 2. Clean propeller shaft.

Tire unbalance. 3. Balance or replace as required.
Tight universal joints. 4. Impact yokes with a shaft hammer to
free up. If unable to free up or if joint
feels rough when rotated, replace.
Worn universal joints. 5. Replace.
Oo

Burrs or gouges on companion 6. Rework or replace the companion

flange. Check snap ring locating flange.
surfaces on flange yoke.
7. Propeller shaft, parking brake drum 7. Check for missing balance weight on
or companion flange unbalanced. propelier shaft.
8. Incorrect rear joint angle. The angle 8. Check and correct trim height at curb
is usually too large when it is a weight. Check and correct joint angle.
factor.
9. Excessive looseness at slip spline. 9. Replace necessary parts.
10. Distorted or damaged yokes or 10. Install new yokes and flanges.
flanges.
11. Yokes out of phase. 11. Remove companion flange, turn 180°
from its original position, lubricate
splines and install. Tighten bolts to
specified torque.

Scraping Noise Companion flange, or en yoke rubbing on Remove interference.

rear axle or center bearing.

Roughness Above Tires unbalanced or worn. Balance or replace as required.

56 km/h (35 mph)
Felt and/or Heard

Squeak 1. Lack of lubricant. 1. Lubricate joints and splines. Also check

for worn or brinelled parts.
2. Center bearing. 2. Replace or lubricate.

Whine or Whistle Center support bearing. Place vehicle on hoist or with rear wheeis
free to rotate and diagnosis for source of
noise, replace.

Shudder on 1. Loose or missing bolts at center 1. Replace or tighten bolts to specified

Acceleration (Low bearing or flanges. torque.
Speed) 2. Incorrectly set front joint angle. 2. Shim under transmission support
mount to change front joint angle.
3. Worn universal joint. 3. Replace.
 PROPELLER SHAFT 4B-5

ON-VEHICLE SERVICE

DRIVELINE ANGLE ADJUSTMENT Checking Driveline angles (Figure 4)

Correct driveline angles are necessary to prevent 1. Remember to check driveline angles both with
torsional vibration. There must be at least a 1/2 the vehicle unloaded and loaded.
degree change in adjacent components of the 2. To determine driveline angles, a split-level
propeller shaft angles to promote longer universal protractor or an inclinometer is required. When
joint life. angles are read from the 0 degree mark, record
Adjustment of the angles of the driveline and use the angle shown on the protractor.
components can be done by the use of spacers or When angles are read from either of the 90
shims at the center bearings. Also, the angles can degree marks (vertically), do not record the
be adjusted by raising or lowering the front or rear angle shown on the protractor since 90 degrees
of the transmission by adding or removing shims, marks must be understood to be the same as 0-
plates, washers, etc. The following procedure degrees on the horizontal plane. Thus, if a
covers checking and adjusting driveline angles on vertical reading is 85 degrees, the angle being
vehicles. measured is 5 degrees.

B—LEVELLING PROPELLER SHAFT YOKE D— CHECKING REAR AXLE PINION ANGLE

Figure 4. Checking Driveline Angles

4B-6 PROPELLER SHAFT

3. All angles should be read within 1/4 degree (15 it will cause early wear and possible seizure of
minutes) and they should be measured with the the journal to the needle bearings in the journal
protractor held on a clean, flat surface. cap.
4. Inflate all tires to the pressure at which they are The operating angle of a propeller shaft should
normally operated. Park the vehicle on a not be the same as the component it is attached to
surface which is as level as possible both from (Example: transmission angle 3 degrees 45
the front-to-rear and from side-to-side. minutes, propeller shaft angle 3 degrees 45
5. The vehicle must be in its normal operating minutes).
position. Do not attempt to level the vehicle by The operating angle must be greater than 0
jacking up the front or rear axle to obtain a level degrees and 30 minutes.
condition. Position safety blocks at the wheels.
6. Check and record the angle on the engine and PROPELLER SHAFT BALANCING
main transmission. This reading can be taken at
the rear of the transmission on the output An unbalanced propeller shaft and U-joint
flange. assembly will likely be caused by one or more of
Record this reading on a sketch. the following conditions:
7. Move the protractor to the 0 degree reading and . Missing balance weights.

Ohm
check the driveline angie between transmission . Bent, dented, or damaged tubing.
and axle (Example: 4 degrees 40 minutes . Worn slip spline (inboard type).
down). - Foreign material on propeller shaft tubing or
8. Check the axle yoke angle with a protractor & end yokes,
(Example: angle up 2 degrees 30 minutes). . Improperly installed propeller shaft and U-joint
an

9. With all the above angles recorded, these assembly.

values are checked to obtain the journal cross Clean all foreign material from the shaft and end
operating angles of each propeller shaft set to yokes. Visually inspect the assembly and if
determine if they are operating to within a 3 necessary, remove it from the vehicle and repair as
degrees maximum of each other. If the required.
operating angles or journals exceed 3 degrees,

7. Nuts from Parking Brake

8. Center Bearing Support
9. Nuts to Forward Shaft Flange
10. Nuts to Rear Axle Flange

Figure 5. Propeller Shaft Components

 PROPELLER SHAFT 4B-7

Do not attempt to replace missing balance = Install or Connect (Figures 2 and 5)

weights or to straighten a bent tube without the
proper tools. + Support the propeller shaft sections in the
It is recommended that such repairs be referred installed position.
to service outlets that specialize in such work. * Check the propeller shaft flanges for the correct
“in-phase” alignment (figure 2).
PROPELLER SHAFT REPLACEMENT 1. Transmission flange yoke (7) to parking brake
flange.
| Remove or Disconnect (Figure 5) 2. Center bearing support(8) to the frame’s cross
frame.
+ Biock the wheels.
« Support the propeller shaft. Adjust
1. Center bearing support from the cross frame(8).
2. Transmission flange yoke (7) from parking « Alignment of center bearing support.
brake flange.
3. Flange connection at rear of center support (9). 3. Flange connection at rear of center support (9).
4. Flange connections at differential (10). 4. Flange connections at differential (10).

Inspect (Figures 6 and 7) NOTICE: See “NOTICE” on page 4B-1 of this

section.
¢ Shaft runout 0.5 mm (0.020 in) (figure 6).
+ Spline wear 0.5 mm (0.020 in) (figure 7). Tighten
» Flange bolts and/or nuts to 102 N-m (75 Ib-ft).
¢ Center bearing bracket bolts to 40 N-m (30
ib-ft).

UNIVERSAL JOINT REPLACEMENT

[eo] Remove or Disconnect (Figures 8, 9 and 10)
« Reference mark the propshaft for correct
alignment (figure 8).
1. Propeller shaft as described earlier in this
1. Dial Indicator section.
2. Propeller Shaft
<= Front 9
Figure 6. Checking Shaft Runout

0.5mm
0.20 in
mommemnee
| | eilfeomemacee

1. Alignment Marks
2. Propeller Shaft

Figure 8. Propeller Shaft Alignment Marks

1. Yoke
2. Shaft Spline
3. Wear Limit Measurement

Figure 7. Spline Wear Limit

4B-8 PROPELLER SHAFT

5. Spider (14) from flange yoke (15).

inspect

* All parts. Replace as necessary.

[oe] install or Connect (Figures 8, 9, 11 and 12)

1. Flange yoke (15) to propeller shaft.

* Align reference marks (figure 8).
2. Spider (cross) (14).
3. Needle roller bearings and cap (13). Install the
spider to the flange yoke. Using the spider as a
guide, install the needle roller bearings into the
hole in the arm of the flange yoke by tapping
with a soft hammer (figure 11).
4. Snap ring (12).
5. Lubrication fitting (11). Install the lube fitting at
12 an angle of approximately 30 degrees to the
spider. The parts should be installed so that all
lube fittings are pointed upward (figure 12).
6. Propeller shaft as described earlier in this
11. Lubrication Fitting section.
12. Snap Rings
13. Needle Roller
Bearings and Cap
14. Spider
15. Flange Yoke

Figure 9. Universal Joint

2. Lubrication fitting (11).

3. Snap rings (12).

NOTICE: Use care to prevent bearings from

dropping on the floor as damage may result.

Figure 10. Removing Bearings from Yoke

4. Needle roller bearings and cap (13). Tap one

end of the yoke with a soft hammer to force the
bearing out of the yoke (figure 10). Strike Figure 12. Installing Lube Fittings
opposite side of the yoke to force the opposite
bearing out. Remove the other bearings in the
same manner.
 PROPELLER SHAFT 4B-9

CENTER BEARING REPLACEMENT

15. Nut and Washer

16. Coupling Driver
17. Cushion Rubber
18. Center Bearing
19. Dust Cover

ae

Figure 13. Center Bearing Components

2. Cushion rubber (17). Apply 13 g (0.8 oz) of

[-] Remove or Disconnect (Figure 13) bearing grease to the lip of the dust cover and
1. Propeller shaft as described earlier in this center bearing.
3. Dust cover (19).
section.
. Flange nut and washer (15). 4. Coupling driver (16).
5. Washer (15).
GP

. Coupling driver (16).

. Cushion rubber (17).
&

. Center bearing (18). A. Washer

om

+ If the bearing will not slide off the shaft, it will

be necessary to use a bench press.
6. Oil seal (19).

Inspect
+ All parts. Replace as necessary.

| Install or Connect (Figures 13-16)

1. Center bearing assembly onto the propeller

shaft using a bench press.

17. Rubber Figure 15. Installing Spring Washer

18. Center Bearing
NOTICE: See “NOTICE” on page 4B-1 of this
section.

6. Flange nut (15).

[A] Tighten
+ Flange Nut to 440 N-m (325 Ib-ft) (figure 16)

Figure 14. Install Rubber

4B-10 PROPELLER SHAFT

joint should be rotated while applying lubricant

under pressure to relieve any air lock inside the
joint which would prevent lubricant from
reaching the bearing area.

Figure 16. Installing Flange Nut

7. Propeller shaft as described earlier in this

section.

LUBRICATION

Universal Joints 1. Grease Fitting

Universal joints are drilled and provided with a 2. Be sure grease seeps out of ali these areas
lubrication fitting through which the fubricant travels
to all four bearing caps, direct to the needle bearing Figure 17. U-Joint Lubrication
(figure 17). Needle bearings are protected against
lubricant leakage and the entrance of foreign matter
Sliding Spline Sections
by seals.
Apply grease gun pressure to the lubrication
1. Lubricate with a chassis lubricant. Refer to
fitting until lubricant appears at the pressure relief
MAINTENANCE AND LUBRICATION (SEC.
hole as shown in figure 18. At this point, apply
OB).
pressure until grease appears at the sleeve yoke
2. When greasing the joint, A flow of grease at all
seal as shown in figure 18.
four trunnion seals must be visible to ensure
Universal joints and slip yoke splines should be
lubrication of the U-joint. If grease does not
lubricated at periods specified in MAINTENANCE
appear at all four trunnion seals, the universal
AND LUBRICATION (SEC. 0B) in this manual.

1. Lube
2. Grease Fitting
3. Sleeve Yoke Seal
,3

) 2
On

Figure 18. Spline Lubrication

 PROPELLER SHAFT 4B-11

SPECIFICATIONS

Prop Shaft RUMOUt ......... ccc eeeneeeeeceeeereeeeeeseeeeasesrsseaeerssseussancaseetecasetseneesenenarcarceraareneeeey 0.5 mm (0.02 in)

Spline Weal ....c.e cece scesesseeneseteceenecsaesenenecaseneneeraccecenterseseeeesoasssenenecnenessataeceareceesanrasunneenatias 0.5 mm (0.02 in)
Center Bearing Grease ...........:ccceceeseereceseeetecenteees vccesecceeaucecaucsceceecensnnesseneceesnessencecereseseneeaieesneens 13 g (0.8 oz)

FASTENER TORQUES

Flange Bolts and/or NUtS ..........cccccssesseserecesererneeeseaeraneuseeseresecsesannesnaecaneerteetesrarneneereecses 102 N-m ( 75 Ib-ft)

Center Bearing Bracket Bolts .0..........cccsecscescssserseeeetesteereeenesenesnarnenteseeeeenseeennarerateecneetietts 40 N-m ( 30 ib-ft)
Flange NUt ......cecceeecseecesseseeeesersecsenssseceesnecseeveernseseecseneecestecnasserterecereanenseneny be tedeceeeeeeenreeenes 440 N-m (325 Ib-ft)
MEMO
 HYDRAULIC BRAKES 5A-1

SECTION5

BRAKES
CONTENTS
SUBJECT PAGE

Hydraulic Brakes ........sccssssesesssseesessessseessesseeensanensnensensntsesentncenaneansnesessesnnoneneneanenensnantsensinensteseeneasuneasactwunessanerges 5A

Vacuum Booster Brake System ........ccssesssssssessenessestsensensoncentnusssnsonsarsnesnnesennsneneseesesnentsees aeuenenessesuventauseantense 5A1
Hydraulic Booster Brake System ........cssscsecsessesssseerssseesennesssesnsssersennenenanesaneneatensineceennnacenenuansstecsonacanenoonsannses 5A2
Hydraulic Foundation Brakes..........-..-ssecossessnssesnessssenssnsensaessanssssesenenannensanenesseatansasessnuesanecnrstsaasarictsensnacensans 5A3
Anti - lock Brake System (ABS)............cssssssssscnsnsserseessteesmnencnseesresuuecasteaentnonessoatscaeaneneenueecanenssersaneuasantecsaneaaenags 5A4
Parking Brakes.........::csssssssssessssssesssserensscersnersssssnenaunssnusesconsocssenvennssossarstscnenesnseaesesnanancensnersacanannacauatesoenseeusatanens 5C

SECTION 5A

HYDRAULIC BRAKES
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

IMtPOGUCTION ....cccssececsccessccsseonscsssrsenssentesssenssenensassanecsneursasontauensssnaneguuseensonsurssoeesedeneusnesaecsassarsausaneseneanessesersunsnonsnes 5A- 2

DeSCTiption .......ssscsssssecssseccenesssseossssesssssnecsnsessnnanessaseneanensessetecevasensasissantansoueneassensnneersuassesrarsenareccvarsnnecset sents A" 2
Hydraulic Brake FIUIG.........+.csssssessesssenssessenssssesnaserenssasssrreneuencentensententsansinnatineaneasonisavanssansoarsecansaness eaveneene 5A- 2
Brake System Diagnosis.............::ssssssssssssseseessseesenmmssnsennnonessssessnnneneensneensansansaansensnereneunnsentsatacsnnsceesnennanenaan® 5A- 2
Road Testing Brakes .......c.cssusssscssssssnssssssseessensuesssssmuecsnsectssnsarscesentensassnanienserestonsenonasseguacansaransuenectanaseneatas 5A- 2
Brake System Diagnosis Chait.........ssseccseesseneacsssneccsenensentsnnssssnsnneneesseasennneseaneesneacaeritanenueatsecgensegunensans 5A- 3
Brake Lining Diagnosis Chatt..........s:scssssssssesessestssusenacsusanssnsesssncsnesnenuncsssananentensennacansneesninecscanensausenecnents 5A- 7
Brake Drum Diagnosis Chart ........:ccsccsecsseseccessesnsnensunsescssunsnsessenesisenensseassees auesseaueneeeseeeeesesoenanonsuesccausagee 5A- 8
Front Disc Brake Diagnosis Chatt.........csssensossssnssscesneeruneesnscssssercasrsnessnscoatsensssaunenseniaescutacsvarauauanannentces 5A- 9
Inspection and Repair ..........scsscssesessssnereessassemsnnsansensessnserneenarscanassetentianssunsesaasansncenneranioassecasnascuesnianscussenees 5A-10
System Inspection ........ssscssscsscseccsssseeeesesenansssseensessesaeesscnsenerercennesavennasseneunneescanuantenesoscasenaaszenennantss conerevoene AH 40
Contamination of Brake SySt@m........cscccssssseneeseeeeeeeneanesensnnrsenesensensensensenssensatatseneaseasiansonunaanantvanunansenes 5A-10
Flushing Brake System ..........:cessseessessseses devscnsueprressensausausaasaecsacavstsenseausonsessousaesnsensenesnatensueansacgnevensuneaeas 5A-10
Bleeding BrakeS.cccccscescessssessrsssscssccecsssessscersssssussusscecsocascerseeaccnsssensennocsvaneassessusasessecanenencrerneserensreenenseceeennsense AA TO
Load-Sensing Proportioning Valve (LSPV) Adjustment ........--.scsersseseeersteereeessnsaestennascennasaneneesorecensens 5A-12
Brake LimeS.....ccscsssessesescecssscrsnsseeesonsonessatseensnesecasorsocesonsaatenanssesneneeesesnensscseasoastesnensenunsaennusenaneseananuaneaagats ween DAW14
B5A-15
Brake Fluid RES@rvoOir .......:scsccccssscssesnsnneserscsnsssesscsssensensnenanansrenersusensnsaneseusnsneesnanereasenensenseceeumnenarevennacanengess
pvedansseadansanesaneasnecgnrousavenaonesaedenensoenseesaesey 5A-16
Load-Sensing Proportioning Valve (LSPV) ......:.:ssssssssersenerseses
5A-17
Master Cylinder ........-s:-ssssscssssscrassessecncsneenssnsessnasstatnasansnansecnesscananneassossensvensecamsasanssuensennunrsesnenasensncearenseneesanes
peaneecopesenneenaes canseennnraneessaunecenesusscouueesens nennaves 5A-19
Brake Pressure Metering Valve .......csccsccssscssnessseessnnnscnueronesenees
gree 5A-20
Specifications.........esecececnsecn sesuqussucecunensau¢eanesuauenensescsansesstasunesausansseusunesnentanunnunsuegtensamerrerereneerceauenunenstessnu
Fastener TOrques ...........-:scssesssssecensesensssenesennenrensneretaceseuneaueusennaestersasnaneasseasauaasoseasaneanauenansesgencaniuessunquaenssgas 5A-20
5A-20
Special TOOIS........ssesssesssesessnssssssensessneonsessssnensnssneenncenessaceatenatsnsersrensvessueescanensasnnscensanaaensauatsacanananseraanunnaurasenanees
 5A-2 HYDRAULIC BRAKES

CAUTION: When servicing wheel brake parts, do cause serious bodily harm. A water-dampened
not create dust by grinding or sanding brake cloth or water-based solution should be used to
linings or by cleaning wheel brake parts with a dry remove any dust on brake parts. Equipment is
brush or with compressed air. Many wheel brake commercially available to perform this washing
parts contain asbestos fibers which can become function. These wet methods will prevent
airborne if dust is created during servicing. asbestos fibers from becoming airborne.
Breathing dust containing asbestos fibers may

INTRODUCTION

DESCRIPTION HYDRAULIC BRAKE FLUID

The system uses hydraulic foundation brakes with Brake fluid is a specially blended liquid which
two wheel cylinders in each brake. The brake provides a means of transmitting hydraulic pressure
booster is a vacuum-ioaded servo-type similar to between the booster and the wheel cylinders. Brake
automotive applications. fluid is one of the most important parts of the
The vehicle is equipped with a Load-Sensing hydraulic system. Do not reuse drained brake fluid.
Proportioning Valve (LSPV) that redistributes Refer to MAINTENANCE AND LUBRICATION
hydraulic pressure/braking force to the front and (SEC. 0B) in this manual for description of brake
rear axle based on the vehicle load. fluid.

BRAKE SYSTEM DIAGNOSIS

ROAD TESTING BRAKES External Conditions That Affect Brake

Performance
Brakes should be tested on a dry, clean, * Tires—Tires having unequal contact and grip on
reasonably smooth and level roadway. A true test the road will cause unequal braking. Tires must
of brake performance cannot be made if the be equally inflated and tread pattern of the right
roadway is wei, greasy or covered with loose dirt so and left tires must be approximately equal.
that tires do not grab the road equally. Testing will * Vehicle Loading—When the vehicle has unequal
also be adversely affected if the roadway is loading, the most heavily loaded wheels require
crowned so as to throw the weight of the vehicle more braking power than others. A heavily loaded
toward the wheels on one side or if the roadway is vehicle requires more braking effort.
so rough that the wheels tend to bounce. + Front Wheel Bearing —A loose front wheel
Test the brakes at different speeds with both light bearing permits the drum and whee! to tilt and
and heavy pedai pressure; however, avoid locking have spotty contact with the brake linings causing
the wheels and sliding the tires on the roadway. erratic brake action.
Locked wheels and sliding tires do not indicate « Front End Alignment—Misalignment of the front
brake efficiency since heavily braked, but turning end will cause the brakes to pull to one side.
wheels will stop the vehicle in less distance than
locked wheels. More tire-to-road friction is present
with a heavily braked turning tire than with a sliding
tire.
 HYDRAULIC BRAKES 5A-3

BRAKE SYSTEM DIAGNOSIS CHART

PROBLEM POSSIBLE CAUSE CORRECTION

No Brakes 1. Restricted tubing or hose. 1. Replace defective parts.

2. Brakes out of adjustment. 2. Adjust.
3. No fluid.

Insufficient Brakes 1. Pedal improperly adjusted. 1. Adjust.

2. Worn linings or drums. 2. Replace as necessary.
3. Plugged, crimped, restricted lines. . Repair or replace.

Slow Brake 1. Pedal binding. 1. Lubricate pivot pin, clean-check for

Application foreign objects.
2. Wheel cylinder piston sticking. 2. Repair the wheel cylinder.
3. Restriction in the lines. 3. Remove the restriction or replace the
line.
4. Worn linings or drums. 4. Replace as necessary.

Uneven Braking 1. Damaged hydraulic lines. 1. Repair or replace.

(Front or Rear Brakes) 2. No brake fluid at the master cylinder. 2. Check for plugged, kinked or damaged
not Working) hose to the reservoir.

Wet Weather: 1. Linings too sensitive to water. 1. Replace in axle sets.

Brakes Grab or won't | 2. Dirty brakes. 2. Clean out.
Hold 3. Bent mounting plate — opening. 3. Replace.
4, Scored drums. 4. Machine in pairs. Replace if necessary.

Brakes Squeak 1. Mounting plate bent or shoes twisted.| 1. Replace damaged parts.
2. Metallic particles or dust imbedded in| 2. Replace the linings in axle sets.
the lining.
3. Lining rivets loose or lining not held 3. Replace the rivets and/or tighten the
tightly against the shoe at the ends. lining by riveting.
4. Drums distorted tapered, or not 4. Machine or replace drums.
square.
5. Incorrect lining. 5. Replace the linings in axle sets.
6. Mixed size linings. 6. Use all standard or oversize linings in a
brake.
7. Weak or broken return spring. 7. Replace the return spring.
8. Loose wheel bearings. 8. Tighten to the proper setting.
9. Loose mounting plate, drum, wheel 9. Tighten.
cylinder.
10. Linings located wrong on the shoes. | 10. Install the linings correctly.
11. Linings worn out. 11. Reline the brakes.
12. Linings glazed. 12. Replace.
13, Cracked or threaded drums. 13. Replace in axie pairs.

Brakes Chatter 1. Incorrect lining to drum clearance. | 1. Adjust to specification.

2. Loose mounting plate. _ 2. Tighten securely.
3. Grease, fluid, road dust on the lining. | 3. Clean or reline.
4, Weak or broken return spring. 4. Replace the return spring.
5. Loose wheel bearings. 5, Readjust.
6. Drums out-of-round. 6. Machine the drums in axle sets.
7. Cocked or distorted shoes. 7. Straighten or replace.
5A-4 HYDRAULIC BRAKES

BRAKE SYSTEM DIAGNOSIS CHART (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Brakes Chatter 8. Distorted, tapered, or barrel-shaped 8. Machine drums in pairs. Replace if

(Cont.) drums. necessary.
9. Incorrect lining material. 9. Reline with correct linings.
10. Linings worn out. 10. Reline the brake.
11. Linings loose on the shoes. 11. Rerivet the linings to the shoes,
Replace if necessary. Check for
damaged or distorted shoes.
12. Foreign material imbedded in the 12. Replace the linings in axie sets.
linings.
13. Cracked or threaded drums. 13. Replace in axle pairs.

Shoe Click 1. Return springs weak. 1. Replace the spring.

2. Shoe bent. 2. Straighten or replace.

Noise and Chatter | 1. Bent, damaged or incorrect shoes. 1. Replace with the correct shoes and
Squealing, clicking, or | lining. Always replace in axle sets.
scraping sound upon; 2. Worn out lining. 2. Replace the shoes and lining in axle
brake application sets.
' 3. Foreign material embedded in the 3. Replace the shoes and lining in axle
lining. sets.
4. Broken shoe return spring. 4. Replace the return spring.
5. Cracked or threaded drums (lathe 5. Replace the drums in axle sets.
marks).
6. Mixed size linings. 6. Use all standard or oversize linings in a
brake.

Pulls to One Side 1. Grease or fluid soaked lining. 1. Replace in axle sets.
2. Loose wheel bearings, loose (or 2. Adjust the wheel bearing, tighten (or
distorted) mounting plate on the rear replace) the mounting plate to the axle
or front axle or loose spring bolts. and tighten the spring bolts.
3. Linings not of the recommended kind. | 3. Install recommended linings.
Install the shoes correctly.
4. Tires not properly or evenly inflated 4. Inflate the tires to recommended
or unequal wear of tread. pressures. Rearrange the tires so that
Different tread non-skid design. a pair of non-skid tread surfaces of
similar design and equal wear will be
installed on the front wheeis, and
another pair with like tread will be
installed on the rear wheels.
5. Water, mud, etc., in the brakes. 5. Remove any foreign material from all
of the brake parts and inside of the
drums.
6. Wheel cylinder sticking. 6. Repair or replace the wheel cylinder.
7. Weak or broken shoe return spring. 7. Gheck the spring—replace distorted,
open coiled, or cracked spring.
8. Out-of-round drums or different sized | 8. Refinish or replace the drums in axle
drums on the same axle. pairs.
 HYDRAULIC BRAKES 5A-5

BRAKE SYSTEM DIAGNOSIS CHART (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Pulls to One Side 9. Brake dragging. 9. Check for loose lining. Adjust.
(Cont.) (Refer to “(DRAGGING BRAKES”.)
10. Weak chassis springs, loose U-bolts, | 10. Replace the spring, tighten the
loose steering gear, etc. U~bolts, adjust the steering gear, etc.
11. Loose steering. . Repair and adjust.
12. Unequal camber. 12. Adjust to “Specifications”.
13. Restricted brake line or hose. . Check for soft hose or damaged lines.
Replace as necessary.
14, Wheel cylinder size different on 14. Replace with the correct cylinders.
opposite sides.
16. Loose kingpin. 15. Replace the kingpins or bushing.
16, Distorted, damaged, or scored drum. 16. Refinish the drums in axle pairs.
Replace if necessary.
17. Front end alignment. 17. Align the front end.
18. Excessively worn lining. 18. Replace in axle sets.
19. Mixed size linings. 19. Use all standard or oversize linings in a
brake.
20. Water/wet linings. 20. Apply the brakes a few times while
moving at a slow speed to dry the
linings.

One Wheei Locks 1. Gummy lining. 1. Repiace in axle sets.

2. Tire tread slick. 2. Match up tire treads from side to side.
3. Brake adjustment not correct. 3. Adjust the brakes.
4. Restricted brake line or hoses. 4, Check for soft hoses or damaged lines.
Replace as necessary.
5. Incorrect linings. 5. Replace. Linings must be the same on
the axle.
6. Grease or fluid soaked lining. 6. Replace in axle sets.
7. Foreign material in the brakes. 7. Remove the material.
8. Mixed size linings. 8. Use all standard or oversize linings.

Light Pedal Pressure-| 1. Brake adjustment not correct. 1. Adjust the brakes.
Brakes too Severe 2. Loose mounting plate on the front 2. Tighten the plates.
(Grabby Brakes) axle.
3. A small amount of grease or fluid on 3. Replace the linings.
the lining.
4, Incorrect lining. 4. install factory specified linings.
5. Wheel bearings loose. | §, Adjust the wheel bearings.
6. Lining loose on the shoe. 6. Replace the lining or the shoe and
lining.
7. Excessive dust and dirt in the drum. 7. Clean and sand the drums and linings.
8, Out-of-round drum. 8. Turn the drums in pairs or repiace.

Low Pedal or Pedal 1. Excessive clearance between the 1. Adjust the brakes.
Goes to Floor linings and drum.
2. Pedal stop not adjusted, or missing. 2. Adjust or install the pedal stop.
3. Weak brake hose. 3. Replace with new hose.
4, Leaking wheel cylinder. 4, Clean and rebuild.
5A-6 HYDRAULIC BRAKES

BRAKE SYSTEM DIAGNOSIS CHART (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Low Pedal or Pedal . Air in the hydraulic system. . Bleed the hydraulic system.

oo
Goes to Floor (Cont.) . Improper brake fluid (low boiling . Flush the system and refill with
point). recommended brake fluid.
. Low fluid level. . Fill the reservoir with brake fluid; check
for leaks and bleed system.
. Bent or distorted brake shoes. . Replace in axle sets.

cooO
. Leaks at hydraulic line connections. . Check for hydraulic leaks and repair.

Slow Brake Release . Foot pedal binding. . Lubricate the pivot pin; clean-check for
foreign objects.
. Restriction in the line. . Remove the restriction or replace line.

G NO
. Weak shoe return spring. . Replace the spring.

Poor Assist or Loss . Low brake fluid level. . Fill the reservoir to the proper level.
of Assist Bleed the system.
. Air in the hydraulic system. . Locate the source of the air leak and
repair. Bleed the system.
. Weak brake hose. . Replace.
. Loss of vacuum. (NPR) . Inspect for vacuum leaks or
malfunctioning pump. Repair or
replace as necessary.
. No brake fluid at the master cylinder. . Check for plugged, kinked, or
damaged hose to the reservoir.

Brake Fade . Incorrect lining. . Replace with recommended lining.

meh

ab

. Poor lining contact. . Grind the lining to the proper radius;

adjust.
. Thin drum. . Replace the drum.
©
®

. Dragging brakes. . Adjust.

mb

wb

. All conditions listed under “PULLS . All corrections listed under “PULLS TO
TO ONE SIDE”. ONE SIDE”.

Ali Brakes Drag when . Pedal does not return to stop. . Lubricate the pedal linkage; adjust the
Adjustment is Known pedal.
to be Correct . Improper fluid. . Replace rubber parts and fill with the
recommended brake fluid.
3. Use of incorrect rubber parts. . Install the proper parts.

One Wheel Drags . Weak or broken shoe return spring. . Replace the return spring.
. Brake shoe to drum clearance too . Adjust to specification.
nm

small.
. Loose wheel bearings. . Adjust or replace the wheel bearings.
. Wheel cylinder piston cups swollen . Rebuild the cylinders. Flush the
and distorted or piston stuck. hydraulic system and fiil with
recommended fluid.
. Pistons sticking in the wheel cylinder. . Clean or replace the pistons; clean the
cylinder bore.
. Drum out-of-round. . Machine the drum.
. Restricted brake line or hose. . Check for soft hoses or damaged lines.
Replace as necessary.
 HYDRAULIC BRAKES 5A-7

BRAKE SYSTEM DIAGNOSIS CHART (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

One Wheel Drags . Distorted shoe. . Replace.

@
@
(Cont.) . Defective lining. . Replace with the recommended lining.

Oo
oo
. Loose or bent mounting plate. . Tighten the fasteners; replace the
—_
plate.

Dragging Brakes 1. improper fluid. . Flush the hydraulic system and fill with
recommended brake fluid, and replace
rubber components.
2, Brake pedal adjustment incorrect. 2. Adjust the pedal.
3. Incorrect shoe return spring. 3. Replace the shoe return spring.
4, Brake pedal linkage interference or 4. Free the linkage and lubricate.
binding.
5. Incorrect lining. 5, Replace the linings.
6. All conditions listed under “ONE 6. All corrections under “ONE WHEEL
WHEEL DRAGS”. DRAGS”.

BRAKE LINING DIAGNOSIS CHART

PROBLEM POSSIBLE CAUSE CORRECTION

Poor Contact at the 1. Bell-mouthed drum. 1-5. Repair or replace as required.

Center of Shoe 2. Distorted mounting plate.
3. Bent brake shoe.
4, Undersize linings.
5. Loose wheel bearing.

Unequal Wear on the | 1. Brake linings not a balanced set. 1-2. Repair or replace as required.
Shoes in the Same 2. Sticking wheel cylinder piston.
Brake

Material at the Center | 1. Undersize linings. 1-2. Repair or replace as required.

of the Shoe 2. Oversize drum.
Excessively Thin

Lining Tapered 1. Bell-mouthed drum. 1-3. Repair or replace as required.

across the Width 2. Bent shoe.
3. Distorted mounting plate.

Lining Worn at One Bent mounting plate. Repair or replace as required.

End

Linings Glazed 1. Grease on lining. 1-2. Repair or replace as required.

2. Wrong type lining for service
involved.

Rivets Tear Loose 1. Improper set rivet. 1-3. Repair or replace as required.
2. Improper setting of the rivet.
3. Enlarged rivet holes in the shoe.
5A-8 HYDRAULIC BRAKES

BRAKE LINING DIAGNOSIS CHART (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Unequal Wear . Weak shoe return spring. . Repair or replace as required.

ON=
Opposite Brakes, . Obstructed hydraulic line.
Same Axle . Stuck wheel cylinder piston.
& . Brake drum surface in poor condition.
. Loose wheel bearing.
om

Linings at Scored . Scored drum. Repair or replace as required.

_t,

. Abrasive material between the lining

and drum.

Cracks at Bolt Holes . Overtightening bolts. . Repair or replace as required.

or Rivet Holes . Wrong type rivets or bolts.
& GAD

. Rivets not properly set.

Mn

. Dirt or rust on the shoe table.

. Too thick a shim under the lining.
. Wrong size lining.

Elongation of the Bolt . Loose rivets or bolts. . Repair or replace as required.

oooh,

Holes or Rivet Holes . Wrong size rivets.

Wear on the Edge of 1. Wrong width lining. 1-4. Repair or replace as required.
the Lining 2. Holes improperly drilled.
3. Loose wheel bearing.
4, Bent shoe.

Groove on the Edge 1. Lining too wide. 4-2. Repair or replace as required.
of the Lining 2. Worn drum.

BRAKE DRUM DIAGNOSIS CHART

PROBLEM POSSIBLE CAUSE CORRECTION

Brake Drum Heat 1. Out-of-round brake drum. 1-3. Repair or replace as required.
Checked in Spots 2. Eccentric mounting of the drum.
3. Loose wheel bearing.

Drum Uniformly Heat | 1. Improper friction materials. 1-3. Repair or replace as required.
Checked 2. Overworked brake.
3. Driver abuse.

Excessive Scoring of | 1. improper friction materials. 1-5. Repair or replace as required.

the Drum 2. Overworked brake.
3. Abrasive material between the lining
and drum.
. Soft drum.
nb

. Bent or warped shoe.

Excessive Drum . Driver abuse. Repair or replace as required.

BOM =

Cracks . Weak drum.

. Wrong friction material.
. Overworked brake.
 HYDRAULIC BRAKES 5A-9

FRONT DISC BRAKE DIAGNOSIS CHART

PROBLEM POSSIBLE CAUSE CORRECTION

Brake Pull 1. Brake pads hardened. 1. Replace.

2. Brake pads worn excessively. 2. Replace.
3. Brake rotor worn or scored. 3. Grind or replace.
4. Disc brake caliper malfunctioning. 4. Clean or replace.

Brake Roughness-or . Rotor excessive lateral runout. . Check per instructions.

ea
Chatter (Pulsates) If not within specifications, replace or
machine the rotor.
. Rotor parallelism not within . Check per instructions.
specifications. lf not within specifications, replace or
machine the rotor.
. Pad reversed (steel against iron). . Replace brake pad and machine rotor
to within specicications.

Excessive Pedal . Excessively worn pad. . Check and replace pads om sets.
Effort . Piston in caliper stuck or sluggish. . Remove caliper and rebuild.
. Fading brakes due to incorrect pad. . Remove and replace with original
equipment pad or equivalent.
. Grease on the brake pads. . Replace or clean.

Brake Drag . Piston in disc brake caliper sticking. . Replace piston seals.
. Brake pads sticking in caliper. . Clean.
. Rotor warped excessively. . Grind or replace.

Grabbing or Uneven . Corroded caliper assembly. . Glean and lubricate.

Braking Action (All
conditions listed
under “Pulls”)

Brake Noisy . Brake pad worn. . Replace.

=
BOM —

. Brake pads hardened. . Replace.

BRON

. Brake pads ni poor contact with rotor. . Correct.

. Brake disc(s) warped, worn or . Grind replace.
damaged.
. Disc brake anti-squeak shims . Replace.
on
oi

fatigued.
. Front hub bearings loose or preload . Adjust or replace.
is incorrect.
. Brake disc rusted. . Grind or replace.

Poor Brake Action . Disc brake caliper faulty. . Clean or replace.

mNbON—

. Water or oil on brake pads. . Clean or replace.

Gh

. Brake pads in poor contact with rotor. . Correct.

. Brake pads worn. . Replace.
mb

. Brake disc rusted. . Grind or replace.

5A-10 HYDRAULIC BRAKES

INSPECTION AND REPAIR

SYSTEM INSPECTION system. Usage of other fluids may contribute

to contamination and possible failure of rubber
* Maintain proper level of brake fluid in reservoir. components in the system.
Refer to MAINTENANCE AND LUBRICATION
(SEC. OB) in this manual for the recommended 3. Replace all rubber parts of the system,
fluid and checking intervals. including brake hoses and seals.
« Check the brake lining for wear. Reline the brakes 4. Refill the system with recommended fluid.
before the lining is worn sufficiently to permit the 5. Bleed the system.
rivets to damage the brake drums.
Keep the pedal pivot and roller pins lubricated to FLUSHING BRAKE SYSTEM
assure free movement and rapid release of the
brakes. DO NOT over-lubricate. NOTICE: Do not use alcohol for flushing the
* Inspect the entire brake system regularly for fluid system or cleaning assemblies where alcohol
and vacuum leakage. Correct the leakage could be trapped and subsequently contaminate
immediately. the brake fluid.
+ Be sure the brake shoes or pads are free on their Contaminated fluid may then cause eventual
mounting and that the shoe return spring is not failure of rubber components in the system.
weak, distorted, or broken. Also check that the
mounting is not sprung, cracked or loose on the It is recommended that the entire hydraulic
axle or steering knuckle. system be thoroughly flushed with clean brake fluid
* Observe the BRAKE warning light and make whenever new parts are installed in the hydraulic
checks and repairs as indicated. system.
Flushing is also recommended if there is any
CONTAMINATION OF BRAKE SYSTEM doubt as to the grade of fluid in the system or if
fluid has been used which contains even the
if the brake fluid becomes contaminated, it will smallest trace of mineral oil. Flush the system
lose some of its original qualities and cause rubber whenever there is any question of contamination.
parts to deteriorate. Flushing is performed at each bleeder valve in
Use only hydraulic brake fluid recommended in turn, and in the same manner as the bleeding
MAINTENANCE AND LUBRICATION (SEC. 0B) in operation, except that the bleeder valve is opened
this manual. When other than recommended fluid 1-1/2 turns and fluid is forced through the lines and
has been used, drain and flush the entire hydraulic bleeder valves until it emerges in color.
system, using only new, clean brake fluid as a Approximately two or three quarts of fluid is
cleaning agent. Disassemble, clean, and inspect required to flush the hydraulic system thoroughly.
the hydraulic units. Check reservoir fluid level after flushing at each
Replace all rubber parts. Refill the system with valve anc replenish if required. When flushing is
recommended fluid, from a sealed container. completed at all bleeder valves, make certain the
Flush the brake system until ail old fluid is reservoir is filled to the proper level.
removed when performing major brake work. Old
fluid should be bled from the system and replaced BLEEDING BRAKES
with clean brake fluid if any of the hydraulic system
parts are corroded or the fluid is discolored or dirty. Use only hydraulic brake fluid recommended in
lf any of the rubber parts of the hydraulic system MAINTENANCE AND LUBRICATION (SEC. OB) of
are soft or swollen, old fluid should be removed and this manual when replacing fluid lost during
the hydraulic system should be flushed with clean bleeding procedures.
brake fluid. Do not reuse old brake fluid at any time. The presence of air in the system is a result of low
in the event that improper fluid has entered the fluid in the reservoir, or of some part of the system
system, it wili be necessary to service the system having been disconnected. Bleeder valves are
as follows: provided on the wheel cylinders.
1. Drain the entire system
2. Thoroughly flush the system clean with brake
fluid.

NOTICE: Use only brake fluid when flushing a

 HYDRAULIC BRAKES 5A-11

Bleeding Sequence
It may be necessary to bleed the hydraulic system
at all four wheeis if air has been introduced through
low fluid level or by disconnecting the brake lines.
If a brake line is disconnected at the wheel cylinder,
then that wheel cylinder only needs to be bled. If
brake lines are disconnected at any fitting located
between the master cylinder and wheel cylinders,
then all the wheel cylinders served by the
disconnected line must be bled.
Bleeding of the brake hydraulic circuit should be
performed in the following sequence:
+ Right rear whee|-LSPV-Right front wheel—Leit
front wheel Figure 2. Brake Bleeding Setup
* Right rear wheel--LSPV—Left front wheel-Right
front wheel 5. Pump the brake pedal twa or three times and
then hold down.
Bieeding Procedure 6. Open the bleeder screw about one-half turn and
When bleeding, disconnect the fuse {60A) for fully depress the brake pedal (figure 3).
ABS hydraulic unit. Observe flow from the hose.
The vehicle engine must be running to bleed the
brakes. Apply the parking brake and block the
vehicle wheels.
Fluid in the reservoir must be checked after
bleeding it at each valve (bleeder screw) and
replenished if required. Brake pedal should be
pumped up and down slowly and should be on the
downstroke as the valve is closed.
1. Fill the reservoir with recommended brake fiuid
and keep at least one-half full of fluid during the
bleeding operation (figure 1).

Figure 3. Bleeding Brakes

7. Glose the bleeder screw as soon as bubbles

stop and the fluid flows in a solid stream.
Release the brake pedal after closing the
bleeder screw.
8. Repeat at the same bleeder until bubbles stop.
9. Repeat at the other bleeder screws in the
proper sequence.
10. Replace the bleeder cap.
11. When the bleeding is complete on each wheel,
Figure 1. Brake Fluid Reservoir check the level of brake fluid in the reservoir
and replenish as necessary.
2. Bleed in the sequence recommended
previously.
3. Remove the bleeder screw valve cap.
4. With the proper size box end wrench over the
bleeder screw, attach a hose over the screw
and allow the end to hang in a glass jar
containing enough brake fluid to cover the end
of the hose (figure 2).
5A-12 HYDRAULIC BRAKES

LOAD-SENSING PROPORTIONING VALVE

(LSPV) ADJUSTMENT
This adjustment should be performed with the
battery voltage applied to the vaive.

1. Adjust the specified rear axle weight by loading

the rear body as necessary.

Rear Axle Weight

GVWR 12,000 Ib 1,200kg (2,650 Ib)
GVWR 14,500 Ib 1,500kg (3,310 Ib)
GVWR 17,950 Ib 1,400kg (3,090 Ib)

Connect the wiring with miniature lamp (1) and

RD

a battery (2) between valve bracket (3) and

linkage (4) with each end of wiring cliped. This Figure 5. Load-Sensing Proportioning Valve
wiring is necessary to find the moment at which Adjustment-1
piston within the valve assembly is brought into
connect with the linkage. . Depress the linkage (4) near the valve assembly
slightly downward with finger (test pressure :4.9-
7.8N (1.1-1.7lb)) and check to see if the
miniature lamp (1) goes out.

Lamp goes out : OK Adjustment is completed.

Lamp remains on: NG

Repeat adjustment operation outlined

under paragraph 3.
Excessive force is exerted on linkage
by piston (8) within the valve assembly.

Figure 4. Miniature Lamp Wiring

Note:
As the linkage is coated with insulation material,
turn the clip (5) with 2 or 3 turns to break
insulation.
. Loosen the nut (6) and raise the valve assembly
(7) all the way. Then lower the valve assembly
gradualily and tighten the nut (6) when
miniature lamp (1) turns on, If the miniature
lamp (1) goes out as the nut (6) is tightened,
lower the valve assembly (7) slightly with the
nut loosened, then retighten the nut (6).
 HYDRAULIC BRAKES 5A-13

5. Inspection of brake fluid pressure (Reference

value)

1) Adjust the rear axle weight as specified

under the paragraph 1.
2) Install the pressure gauge on bleeder
screws on the front and rear brakes.
3) Depress the brake pedal and take reading
of the pressure gauges. The brake fluid
pressure is normal if the pressure of fluid
within the rear wheel cylinders is within
the range of 5,0314588kpa (729+97psi)
when pressure of fluid within the front
wheel cylinders reaches 7,850kpa
(1,138psi).

[y] important
Figure 6. Load-Sensing Proportioning Vaive The brake pedal should be depressed gradually
Adjustment-2 until specified pressure is reached without
pumping or adjusting foot pressure.
Note:
Adjustment can also be made by means of nuts
(9) and (10) on shackle at rear axle case side.
However, shackle nut is not normally used for
adjustment as it is for making fine adjustment.

(9)

(10)

Figure 6-1. Load-Sensing Proportioning Valve

Adjustment-3
 5A-14 HYDRAULIC BRAKES

BRAKE LINES 2. Clip (15).

3. Pull the hose end from the frame bracket (17).
Brake system units are interconnected by flexible 4. Special eye bolt (12) at the banjo end (11).
hose and special steel tubing. Flexible hose is used
between the cab and frame connections, between foe] Install or Connect (Figure 9)
the frame and front wheel cylinders and between
1. Special eye boit (12) at banjo end (11).
the frame and rear axle brake line.
2. Hose end to frame bracket (17).
When the hydraulic tines have been disconnected
3. Clip (15).
for any reason, the brake system must be bled,
4, Union Nut (16).
after connecting the lines. Refer to “Bleeding
Brakes” in this section.
Brake Hose Inspection
The flexible hydraulic brake hose should be
CAUTION: Never use copper tubing for hydraulic
inspected at least twice a year. The brake hose
brake lines because copper is subject to fatigue,
assembly should be checked for road hazard
cracking, and corrosion which could result in
damage, for cracks and chafing of the outer cover,
brake failure.
and for leaks and blisters. A light and mirror may be
needed for adequate inspection. If any of the above
Flexible Hose conditions are observed on the brake hose, it will
At the front wheel brakes, the hose is threaded be necessary to replace it.
into a frame junction and a banjo-type fitting is used
at the wheel cylinder elbow. The banjo end and the Metal Tubing
frame end must be indexed properly to be installed.
When necessary to replace metal brake line,
The line at the rear axle is similar in installation.
always use special meta! tubing which is designed
Use new copper gaskets at the banjo ends at
to withstand high pressure and to resist corrosion.
installation.
Ordinary copper tubing is not satisfactory for use as
[-9] Remove or Disconnect (Figure 9) hydraulic brake lines. When replacing tubing,
always use the same size as that removed.
» Clean the fittings (14) and connection. Refer to the parts book for preformed lines and
1. Union nut (16). bulk brake line.

Vacuum Hose

MEE Oil Pipe

Gee Flexible Hose
==] Vacuum Pipe
Ze Rubber Hose

ge Check Valve

A. Vacuum Pump F. Metering Valve J. Front Wheel Cylinder

B. Servo Unit G. 5-Way Connector K. Rear Wheel Cylinder
C. Fluid Tank H. 3-Way Connector L. Solenoid for Exhaust Brake
D. Vacuum Tank |. Load Sensing Proportioning M. Power Chamber
E. Electric Vacuum Pump N.Exhaust Brake Valve
(GVWR 6,577 kg/14,500 Ib model only)

Figure 8. Brake Line Diagram

 HYDRAULIC BRAKES 5A-15

15
Vacuum Pump (for GVWR 6,577 kg
1 P 13 14 16 (14,500 Ib) Model)
1. Turn the starter switch to “ON” position (not to
start the engine}, and depress the brake pedal
several times.
2. Check the vacuum pump operation at the same
time as vacuurn warning buzzer sounds.
* Refer to CAB AND CHASSIS ELECTRICALS
(SEC.8).
11. Banjo End
12. Special Eye Bolt Brake Line Supporting Components
13. Copper Gasket lt is important that all brake tine supports, clips,
14. Fitting retainers, grommets, junctions, and supporting
15. Clip brackets be maintained to prevent unnecessary
16. Union Nut vibrations and eventual loosening or separation of
17. Frame Bracket the connections. Clamps are used on the same
hoses at.the connections with metal lines and
Figure 9. Brake Hose components. All clamps and brackets (when used)
must be in place and tightened securely in position.
CAUTION: Never use copper tubing for hydraulic
Check for missing or deteriorated grommets or
brake lines because copper is subject to fatigue,
ioom material. Replace as necessary. Bent,
cracking, and corrosion which could result in
damaged, or missing components should be
brake failure.
repaired or replaced.
Brake lines must have a minimum of 6 mm (7/4
BRAKE FLUID RESERVOIR
in) clearance between lines.
[+s] Remove or Disconnect
Tube Flaring
in order to ensure a proper flare, a special flaring
tool must be used. When using the tool, instructions fy] Important
furnished by the too! manufacturer should always
» Use only DOT 3 brake fluid in this reservoir.
be followed. Always inspect newly formed flares for
Refer to MAINTENANCE AND LUBRICATION
cracks or malfunctions which might cause leaks.
(SEC. OB) in this manual for hydraulic brake
Double Lap Flaring Kit J-23530 with Tube Cutter
fluid recommendations. Refer to “Bleeding
J-23533-01 and Metric Adapter J-34912 provides all
Brakes” previously in this section for bleeding
the necessary components to double lap flare
the hydraulic brake system.
hydraulic brake line. After flaring,blow out the brake
« Block the vehicle wheels and apply the
lines with compressed air before installing on
parking brake.
vehicle.
« Disconnect the battery ground cable.
* Lift up the access cover to the combination
NOTICE: Double lap flaring tool must be used, as
brake fluid/clutch fluid reservoir.
single flaring tools cannot produce a flare strong
enough to hold the necessary pressure.
{. Attaching bolts.
2. Hose clamps and hoses.
Replacement
3. Electrical connector.
1. Clean dirt, grease, and other foreign material off
4, Reservoir assembly.
the line fittings at both ends.
2. Procure the recommended steel tubing and fe] Disassemble
fitting nuts to the correct size. (Outside diameter
of the tubing is used to specify size.) ° Cap.
3. Cut the tubing to length. Correct length may be « Filter holder.
determined by measuring the old pipe using a « Filter.
cord and adding 3 mm (1/8 in) for each double » Baffle.
flare. ¢ Dust cover.
4. Install the fitting before starting second flare.
5. Bend the tubing to match the old pipe using a inspect
tubing bender. A recommended clearance of
19 mm (3/4 in) should be maintained to all « Filter.
« Reservoir tank.
moving or vibrating parts when installed.
 5A-16 HYDRAULIC BRAKES

— If the tank is damaged or the electrical 1. LSPV assembly (24).

switch is not operating, the assembly must 2. Bolt (23).
be replaced.
Fa] Tighten
[ae] Assemble

Dust cover. * Bolt to 20 N-m (14 lb-ft)

Baffle.
« Filter. 3. Bolt (22).
Fitter holder.
« Cap. [2] Tighten

* Bolt to 20 N-m (14 lb-ft)

[oe] Install or Connect

1. Clamp hose bands to reservoir. 4. Brake pipe (21).

2. Electrical connector.
3. Retaining bolts. [RQ] Tighten
4. Battery ground cable. « Brake pipe to 15 N-m (11 Ib-ft)
5. Fill the reservoir. Note the warning on the
reservoir cap. Fill to MAX on the tank. Adjust
Inspect * LSPV Refer to “Load-Sensing Proportioning Valve
Adjustment’ in this section.
« Run the engine and bleed the brakes.
« Check for leaks.
« Remove the wheel blocks and check brake
application.

LOAD-SENSING PROPORTIONING VALVE

(LSPV)
[+9] Remove or Disconnect (Figure 10)

1. Brake pipe (21).

2. Bolt (22).
3. Bolt (23).
4. LSPV assembly (24).

[><] Install or Connect (Figure 10)

NOTICE: For steps 2, 3, and 4, see “NOTICE”

on page 5A-1 of this section.

21.Brake Pipe ; wee ee —

22.Bolt
23.Bolt
24. LSPV Assembly

Figure 10. LSPV Assembly

 HYDRAULIC BRAKES 5A-17

MASTER CYLINDER . Plug and O-ring (5).

* Install master cylinder on J-41431 support
feo] Remove or Disconnect (Figure 11) plate or equivalent, fix the support plate in a
vice, and loosen plug using a J-41432 wrench
Tool Required: or equivalent.
J-41431 Brake Master Cylinder Support
Plate or Equivalent . Secondary cup (6).
J-41432 Brake Master Cylinder Wrench or 10. Bushing (7).
Equivalent 11. Primary cup (8).
. Meter cluster and switch connectors. Refer to 12. Supporter (9).
INSTRUMENT PANEL (SEC.10D). 13. Plug and O-ring (10).
. Brake hoses and brake pipes. * Install master cylinder on J-41431 support
plate or equivalent, fix the support plate in a
NOTICE: If brake fluid spillage occurs, wipe it vice, and loosen plug using a J-41432 wrench
up immediately. ar equivalent.
. Nuts mounting cylinder body to servo.
. Holder plate (1). 14. Supporter (11).
on hm
sO

. Hose joint (2). 15. Secondary piston assembly (12).

. O-ring (3). 16. Primary cup (13).
. Primary piston assembly (4). 17. Bushing (714).
« Pull out the piston by hand so that it may not 18. Secondary cup (15).
be damaged.

Holder Plate . Supporter

ONOaArwh>

Hose Joint 10. Plug and O-ring

O-ring 11. Supporter
Primary Piston Assembly 12. Secondary Piston Assembly
Plug and O-ring 13. Primary Cup
Secondary Cup 14. Bushing
Bushing 15. Secondary Cup
Primary Cup

Figure 11. Master Cylinder Assembly

 5A-18 HYDRAULIC BRAKES

NOTICE: If plug tightened to specified torque

Inspect
is found floating from cylinder body, plug
¢ All parts for wear, distortion or other conditions should be disassembled again and checked
and replace as needed. for abnormal parts fitting. Then reassemble.
- Return port for clogging. If necessary, clean the
port with a wire tag and blow away foreign matter
with compressed air.

[oe] Install or Connect (Figure 11)

NOTICE: For steps 6, 12, and 16, see “NOTICE”

on page 5A-1 of this section.

[] important

* Prior to installing the primary and secondary

pistons, lubricate the piston cups with clean
brake fluid. When installing the parts, take
care not to cause damage to the lipped
portion of the piston cup.

1. Secondary cup (15) and bushing (14) to

secondary piston assembly (16) (Figure 12).
* Combine secondary cup and bushing with Figure 13. Installing Primary Cup
secondary piston as indicated by allows, and 3. Supporter (9), primary cup (8) and bushing (7)
push the assembly in until bushing comes into to primary piston assembly (4) (Figure 14).
contact with cylinder body step. + Combined the parts of primary piston as
indicated by allows. Then push the assembly
in until bushing comes into contact with the
step in cylinder body.
« Pull out primary piston alone taking care not
to be let bushing get out of the step.

(a
Figure 12. Installing Secondary Cup

2. Primary cup (13), supporter (11), plug and

O-ring (10).(Figure 13)
* Combine primary cup and supporter with plug
as indicated by allows.
Figure 14. Installing Primary Cup
* Install master cyliner body on J-41431 support
plate or equivalent, fix in a vice, and tighten
plug to specified torque using a J-41432
wrench or equivalent.

By Tighten
* Plug to 44 N-m (33 Ib-ft).
 HYDRAULIC BRAKES 5A-19

4. Secondary cup (6), plug and O-ring (4).

[-] Remove or Disconnect (Figure 16)
(Figure 15).
* Combine secondary cup with plug as 1. Brake pipe assembly (40).
indicated by allow. 2. Brake pipe (41) from metering valve (39).
« Install master cylinder body on J-41431 3. Bolt (42).
support plate or equivalent, fix in a vice, and 4, Metering valve (39).
tighten piug to specified torque using a J-
41432 wrench or equivalent.
foe] install or Connect (Figure 16)
[2] Tighten 1. Metering valve (39).
- Plug to 44 N-m (33 Ib-ft). 2. Bolt (42).

Tighten

« Metering vaive to 8 N-m (69 Ib-in)

3. Brake pipe (41).

[QJ Tighten
» Brake pipe to 15 N-m (11 Ib-ft)

4. Brake pipe assembly (40).

J Tighten
pare
=> cn cal

« Brake pipe to 15 N-m (11 lb-ft)

5. Bleed the system.

* The brake system must be bled, after
Figure 15. Installing Secondary Cup connecting the lines. Refer to “Bleeding
Brakes” previously in this section.

5. Primary piston assembly (4).

6. O-ring (3).
. Hose joint (2)
OON

. Holder plate (1).

. Master cylinder assembly to servo.

[RJ Tighten

« Nuts to 14 N-m (122 Ib-in).

10. Brake pipes and hoses.

11. Meter cluster and switch connectors. Refer to
INSTRUMENT PANEL (SEC.10D).
12. Bleed the brake system.

BRAKE PRESSURE METERING VALVE

After the preceding measures have been installed

37. Master Cylinder
on the vehicle and a reasonable service life cannot
39. Metering valve
be achieved, there is a brake pressure metering 40. Brake Pipe Assembly
valve available. The brake pressure metering valve
41. Brake Pipe
momentarily delays load on front brakes to
42. Bolt
distribute brake load for improved service life. The
metering valve is relatively simple to install and has
shown improved disc brake life in severe Figure 16. Brake Metering Valve
applications.
5A-20 HYDRAULIC BRAKES

SPECIFICATIONS

FASTENER TORQUES

LSPV Nut... ee eeeteneeeeeecnenntoee beaneneesneuasceseuaeeesaroaeeceeeatensesaesoesecnsuatesnaaeceeansuseesesteanensenaes 18 N-m ( 13 lb-ft)

LSPV Shackle Bracket Bolt ..........cccce sccetsteeeessesseenesensessneneeesondeesenunsnuseeeseesensaeceieeseeeetsecenenaes 20 N.m( 14 Ib-ft)
LSPV Bracket Bolt... ccccececcseeeeeceeeeeeeeeeeeeeeeeneedseedenseetssassuaessieesagsesssettsnessieseesaveseeesesenaes 20 N-m( 14 Ib-ft)
Brake Pipe 0 LSPV oc cesesessssneesensescensneceeceseseeeesesaerensesseneedernserstegmenseasertereenepaeeneeesenseeeees 15N-m ( 11 Ib-ft)
Master Cylinder Plug ...............c:.:cceeeseeeseceseseneenenneesaneameceaseneneceneceneeesccameseseaesuceuacenaneeueensaeeeeees 44N-m( 33 lb-ft)
Master Cylinder Nut o........... ceca cee ceeeesonecnenesneeensenaeeseceeeceeeneeneoueeeeenencecensaesaenasceneneeeaucesonsuseenas 14 N-m (122 Ib-in)
Reservoir Hose Clamp Bolt .............ccccuccececececescseseessnesessuerserussesarsnsnctseesessesensesessesesensaeaseenseeas 3N-m ( 26 Ib-in)
Brake Pipe .........e cc ccseeecenceeeceesensenenaneecontuaneuseneereenenceoatectessucnseeasesseecenuanesanaaeeetteeceeenuseceeseeeeens 15.N-m( 11 lb-ft)
Metering Valve Bolt ................::ccceceecesseneescesensecseneeeeceseuseessaceetersescnnanaeeceeeesssusesuaaeeensessseeanansens 8 N-m ( 69 lb-in)

SPECIAL TOOLS

TOOL NO. TOOL NO.

ILLUSTRATION TOOL NAME ILLUSTRATION TOOL NAME

J-41431 J-23530
Master Cylinder Support Double Lap Flaring kit
Plate

J-41432 J-23533-01
Master Cylinder Wrench Tube Cutter
 VACUUM BOOSTER BRAKE SYSTEM 5A1-1

SECTION 5A1

VACUUM BOOSTER BRAKE SYSTEM

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
On-Vehicle Service .......cccessesesseesnsesssnecsnsneesensenseerseeesaneusouesausecnessausaentasausuaasusussnunseusesueusoasauseausuansansunseeneaunasees 5A1-1
Vacuum Booster (Servo) Replacement..........ceccsssesessensssssssssrssorsenusovsserseusnsnagreantesseaetsgearsaueensanentanstseseeas 5A1-1
Brake Pedal Replacement. ..........:cesssse sauseneaaenaonsaonsutenesnedcodesseenedevaoueauaedaurcduecautasaussausesaeaneasuaensaenanonsensanae 5A1-4
Brake Pedal AdjuStMent.........cc:sscssssnsssesscssrseesersennteneeeeesnennesnsnsneecausenneanasesnesnecanaaneasaoesaenmaseneneuenentennesenes 5A1-4
Specifications.........cscscecsecesesesessensensenencersereensenreeeneerssnsenserseneneesieoseanesecssetsnseaeieanseneeeniesennunreaiearsenenseenens 5A1-6
Fastener TOrQues........ccesscsessccssscsssseneneesneserserserseesesotstsnesensuensnsensossannuenstassensonaussnausnenesanesnenneneeneaaeneauscerenent 5A1-6

ON-VEHICLE SERVICE
VACUUM BOOSTER (SERVO)
REPLACEMENT Inspect

Vacuum booster cannot be over hauled.

| Remove or Disconnect (Figure 2)
If it is found faulty, replace its assembly with a
« Block the vehicle wheels and apply the parking new one.
brake.
* Battery ground cable. Push Rod Length Adjustment (Figure 1)
1. Steering wheel. Refer to STEERING WHEEL * Apply 66kPa (19.7 inHg) of negative pressure to
REPLACEMENT (SEC.3B4). the master vac assembly.
2. Remove steering column tilt control bolt. Refer » Use a scale to measure the push rod length (push
to STEERING COLUMN REPLACEMENT rod to flange face clearance).
(SEC.3B4). Push Rod Length “L” to 18.2 mm (0.717 in).
3. Instrument panel assembly and ventilation duct. « if the push rod length is not equal to the
Refer to INSTRUMENT PANEL (SEC.10D). specification, it must be adjusted.
5, Master cylinder hydraulic lines at master ~ Loosen the lock nut.
cylinder (1). Turn the screw boit in the appropriate
6. Vacuum hose at servo unit (2). direction to adjust the push rod length.
7. Brake pedal assembly with master cylinder and -~- Tighten the lock nut.
servo unit.
7. Clevis pin (3).
8. Four servo unit mounting nuts (4) at pedal
bracket (6).
9. Master cylinder (1) with servo unit (2).
10. Four nuts retaining master cylinder (5) to servo
unit (2).
5A1-2 VACUUM BOOSTER BRAKE SYSTEM

Screw Bor A”

Lock Nut pEy

Figure 1. Push Rod Length Adjustment

x Install or Connect (Figure 2)

NOTICE: For Steps 2, 3, 5 and 9, see “NOTICE”

on page 5A1-1 of this section.

1. Servo unit (2).

2. Master cylinder assembly (1).

FQ] Tighten

* Nuts (5) to 14 N-m (122 Ib-in).

3. Four servo unit mounting nuts (4) to pedal

bracket (6).
 VACUUM BOOSTER BRAKE SYSTEM 5A1-3

1. Master Cylinder
2. Servo Unit
3. Clevis Pin
4. Servo Unit Mounting Nuts
5. Master Cylinder Mounting Nuts
6. Brake Pedal Bracket
7. Bracket Mounting Bolts

Figure 2. Vacuum Booster (Servo) Components

Tighten 8. Instrument panel assembly and ventilation duct.

g Refer to INSTRUMENT PANEL (SEC.10D).
« Nuts (5) to 14 N-m (122 Ib-in). 9. Remove steering column lock control bolt.
Refer to STEERING COLUMN REPLACEMENT
4. Connect servo unit clevis to brake pedal, and (SEC.3B4).
install clevis pin (3).
5. Brake pedal assembly with master cylinder and Tighten
servo unit. - Lower nut to 14 N-m (122 Ib-in).
« Upper nut to 16 N-m (12 Ib-ft).
Tighten » Lock lever bolt to 54 N-m (40 Ib-ft).
- Bolts to 42 N-m (32 lb-ft).
10. Battery ground cable.
6. Vacuum hose at servo unit (2). 11. Bleed the system.
7. Master cylinder hydraulic lines at master 12. Release the parking brake and remove the
wheel blocks.
cylinder (1).
 5A1-4 VACUUM BOOSTER BRAKE SYSTEM

BRAKE PEDAL REPLACEMENT

[+] Remove or Disconnect (Figure 3)

* Block the vehicle wheels and apply the parking

brake.
* Battery ground cable.
1. Brake pedal bracket with master cylinder and
servo. Refer to VACUUM BOOSTER (SERVO)
REPLACEMENT of this section.
. Clevis pin.
GM

. Servo with master cylinder.

. Return spring (1).
Bm

. Pedal shaft (2) from brake pedal assembly.

Om

6. Brake Pedal (3).

Inspect

* Bushings, return spring and bolt for wear or

damage.
* Replace all parts found defective.
1. Return Spring
[oe] Install or Connect (Figure 3)
2. Pedal Shaft
1. Pedal shaft (2) to brake pedal assembly. 3. Brake Pedal

NOTICE: See “NOTICE” on page 5A1-1 of this Figure 3. Brake Pedal Assembly
section.
2. Return spring (1).
BRAKE PEDAL ADJUSTMENT
3. Servo with master cylinder. Adjust (Figures 4 and 5)
[2] Tighten NOTICE: For steps 4 and 5 seen “NOTICE” on
page 5A7-1 of this section.
* Nut to 14 N-m (122 Ib-in).
. Loosen the jam nut at the stop lamp switch.
tk

. Clevis pin.
2. Loosen the jam nut on the vacuum servo push
oman

. Battery ground cable.

rod (figures 4 and 5).
. Bleed the system.
3. Turn the push rod until the distance from the
. Release the parking brake and remove the
centre of clevis pin hole to mounting surface of
wheel blocks.
the brake pedal bracket should be set at
109+1mm (4.29+0.04 in).
When fixed under this condition, there is no
need to adjust the brake pedal height and free
play.
4. Tighten the push rod jam nut.

fa] Tighten

+ Jam nut to 20 N-m (14 lb-ft).

5. Stop lamp switch so that the end of the switch

threaded portion contacts the brake pedal, then
back-off the switch 2 turn.

[RJ Tighten

* Stop lamp switch lock nut to 20 N-m (14 Ib-ft)

6. Check brake pedal operation to be sure it’s

operating properly.
 VACUUM BOOSTER BRAKE SYSTEM 5A1-5

Measurement (Figure 2)
A
+ Brake pedal normal play is between 4—7 mm
(0.16—0.27 in) (reference).
* Brake pedal height “A” is 167mm (6.58 in)
(reference).
» Brake pedal travel “B” is between 180+5mm MYT
~ pe Gy
(7.09+0.2 in) (reference).

jamal

[oo

) A, .ecccone .10941mm (4.29+0.04in)

ME in rype j ;
nn FF Figure 5. Pedal Height and Travel Adjustment
- Adeli 1 gd Se fy
VN whi ON y
_e oY

\ ' |
1 \ \ a

S Aa

i. 7 “s
= ~
uA \ \
d \ Ko)
<x

OSS es,

A. Pedal Height
(Reference) ..........++ 167mm (6.58 in)
B. Pedai Travel
(Reference) ............. 180+5mm (7.09+0.2 in)

Figure 4. Pedal Height and Travel Measurement

5A1-6 VACUUM BOOSTER BRAKE SYSTEM

SPECIFICATIONS
SOrVO Unit TyPe .0.... ec cescesecseeecsesenssseensssnsevstensuecenseceassaeesssencessnaeussserssssnssuvavseseaeevssseectsanevsesecaneeaseess Tandem

Servo Unit Diaphragm Diameter

GVWR 12,000 and 14,500 Ib MOdelS .0.......ceceesssceseecseseeesseneecssevensesuecenss 230 mm + 254 mm (9 in + 10 in)

Push Rod Length.............cecceccesesesensvnsenssseseesene veveteeeseaveseaauuensaersestensessaeuenesseuseeeserseensugeeesenss 18.2 mm (0.71 in)

FASTENER TORQUES

Master Cylinder Mounting Nuts 00.00.0000... cessseecsensereessseeececsueseesssesusaresseeaeeneusevassaneaeecseseees 14. N-m (122 Ib-in)
Master Vac Mounting Nuts .0......00..0 ccc ccccecesscnseesssasecessseeecessuacuessseuueeessstaessessucsesecsauesesneseeenees 27 N-m( 20 Ib-ft)
Push Rod Lock NUt ..... ic e ccc cnseeeeseeeeesseaneeescnenanescnaseessstecessenaeees Seaveteectuaecetonseeecaeeeeeeseaaes 19N-m ( 14 Ib-ft)
Push Rod Jam Nut... ec cseeeeessneneeseeaaesensssseusestsusesessneeeeessnatess cosdeanaeeeaeeteaesnaeseetenteenaes 20 N-m ( 14 Ib-ft)
Stop Lamp Switch LOCK Nut ......... cc cssccccesessssceeeceeeesccsensaesereessseenenns bad naneaeteaeeetenaneecseetenseneaes 20 N-m ( 14 Ib-ft)
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-1

SECTION 5A2

HYDRAULIC BOOSTER BRAKE SYSTEM

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage couid result.

CONTENTS

SUBJECT PAGE

General DeSCHiption.......ccscssscessesercesetsneneerennensasaseeracensniuerenensuenvenenenuverscasseecaensnencsecesaeneeatanersenesusntaeatananyy 5A2- 1

Booster ASSOMDIy ..........-.-sseccssesssenensssesssesenssssssesnsesenseneananceesseentensnesisensaussuseusenstnecsestatensauansnanunannaneetaensegss 5A2- 1
Fluid and Fluid Handling..........cscscssescssnsessnsssssesneanstescnerscsenseseneesseoussucsusuunversuesnsvessssnsesseesenntensneraensseaenanees 5A2- 1
Flushing The Hydraulic Booster SyStem..........sreccssssscnassseeessnsorssesssanetsisseerensenseeneaencnenecguacunscansnans 5A2- 2
System Outline... ssccssssessseressesensecesceeserenssseesteneestsensassmsenuessneensonssnsansareseconsaeensonenennerserseanseatsseeceansanensansenes 5A2- 3
Hydraulic Booster Troubleshooting..........---ssesssesesssserseneserenesssserestensraessunnesacensassareneenssseneunasaesauanuanaaeeneens 5A2- 4
NOteSS cc.ccccccccccscsesesssnecesessrevscescnsesocensnrensursoeseousauecssecennunanseanescusaausavcaseosessuenoanrsecessuensaueranensunenauerauaceusdunsgnessers 5A2- 6
Supply Parts ReplaceMentt.........ccssscscsseseseseeenensesssusseusnsenssssnentssesseransateaceissnenennensnsnnnanenenneauracanvenenceseeasees 5A2- 6
On-Vehicle Se@rviCe ........c:cccccccessensesscsoscecssonrensssteceserserauanenuenseusnerescenessdsneussarananentnganesuausnusauetausesscsuneoromentennaees 5A2- 8
Accumulator and O-Ring Replacement ........c..sssssssesssesessnesereasssenmusaunarsesatorsensnsaesennsenensnecasasaanannusanys 5A2- 8
Hydraulic Booster Replacement.........ccsssissseressssssseneenrsnencsasanencnnnrsncnsensatensennanenaceseeneens: sauanuaouatensesseaevenss 5A2- 8
Clevis and Lock Nut Replacement ..........cssscsscessssearsenenseeseesenssusesrencsnasesnmensnarnensneessnseniantsansnenaatensanaees 5A2-13
Guard Replacement .......scscsssscsssssssessscssensensensansesecessnmuasunnsestesrsansseensaseseeseerscreracenenerasessaeasssuannanennanacanuentent 5A2-13
Brake Pedal Replacement .............csssesemeeneersnessesterenernrsentssssreraregeneens suseaeesannenessnesgeaesansavcensuentaeuenseasens 5A2-14
Brake Pedal AdjUuStmenit...........sccssecssesrcsssssnsseeesenesseneatsantarsnssrocouiensenenssesesenennarnaneereneneaescateuinaeouneeraueeutates 5A2-14
Specifications..........cssssecssscoesssescssecceerenenseensneewussassasssrsssatenesensessetsneassasnanenensteotsacentsenansaunancauaresansaageenteseansensass 5A2-16
Fastener TOrques........sscssssssssssesssssscerescsnssesenssanensecssenssnoseatensenscsnterenseensnesensansercasarscananenranauaveratansens eeseneneees 5A2-16

GENERAL DESCRIPTION
BOOSTER ASSEMBLY the piston to a balanced position. As the piston
The hydraulic booster is a device that applies moves, it pushes the cylinder rod and applies
force to the master cylinder when the brake pedal is pressure to the master cylinder.
applied. The fluid flowing through the booster head A relief valve inside the pump limits the pressure
is controlled by brake pedal movement. to 11,770 kPa (1670 psi). This pressure level
Fluid from the hydraulic brake booster and power provides good braking without damaging the brake
steering pump enters the booster at the inlet port, pipes or hoses. When actuated, the relief valve
flows through the control valve and seat, leaves allows fluid to bypass the piston.
through the outlet port and flow switch, and returns
to the hydraulic brake booster pump. FLUID AND FLUID HANDLING
The hydraulic booster cylinder rod attaches to a This system uses no special fluids. However, care
piston that connects with the spool valve. This must be taken to use the correct fluids. The master
assembly moves when brake pedal pressure is cylinder and brake system uses brake fluid, while
applied. The spool valve restricts fluid flow and the hydraulic brake booster pump uses power
builds pressure on one side of the piston. The steering fluid.
pressure overcomes the return spring and moves
 5A2-2 HYDRAULIC BOOSTER BRAKE SYSTEM

SUBSTANDARD OR CONTAMINATED FLUID

NOTICE: Hydraulic brake systems use two distinct

and incompatible fluids. Power steering fluid is
used in the hydraulic booster brake system. Brake
fluid is used in the master cylinder and brake
pipes to the wheels. Be extremely careful when
selecting brake system fluids or seal damage can
result. Refer to SECTION 0B to select the correct
fluid.

NOTICE: Do not reuse brake system fluids. Do not

mix power steering fluid with brake fluid. Swelling
and deterioration of rubber parts can resuit from
fluid contamination. This can lead to reduced
brake performance and the eventual loss of
braking capability.

Contaminated fluid causes swelling and

deterioration of rubber parts that can lead to
reduced brake performance and the eventual loss
of braking capability. Check the condition of the
fluid at reguiar intervals and note any unusual
consistency, color, and signs of contaminants in the
fluid. Do not reuse brake system fluids. Always
discard used fluids. Do not mix power steering fluid
with hydraulic brake fluid. If contamination occurs,
flush the hydraulic booster system with clean power
steering fluid.
Booster component bench servicing should be
done in a clean work area separated from the brake
servicing area. Wash hands before changing
between brake or booster work areas. Do not use
the same containers for fluids.

FLUSHING THE HYDRAULIC BOOSTER

SYSTEM
Flushing is required when dirt, sludge, or water is
found in the system. Flushing involves running
clean fluid through the system until the draining
fluid appears the same as clean fluid.
Contaminated fluid in the booster system can cause
rubber parts to deteriorate.
The hydraulic booster system should be cleaned
and flushed when the hydraulic pump is replaced.
Metal shavings from a worn hydraulic pump often
contaminate the system. Pipes and hoses should
be removed and blown clean of all metal shavings.
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-3

SYSTEM OUTLINE

[ RESERVOIR:HYDRO BOOST |
_|RESERVOIR:POWER
STEERING RESERVOIR:BRAKE
FLUID

BOOSTER}
4

‘OIL PUNPROWER ACCUMULATOR a

____ STEERING | PRESSURE || BOOST

ASTER hm SWITCH
OIL PUMP:HYDRO MLNS DER
BOOST CHARGE
> VALVE
PAA freer NN
Xf BRAKE PEDAL|
COOLER PIPE

COSLWwO01

Figure 1. System diagram

The Hydro Boost system, which functions as a Other units relating to this system include, as
brake force boosting device that allows the brake to shown in Figure 1, the power steering, the pump
be operated with less force than otherwise, includes and reservoir for the power steering, the master
the Hydro Boost, which has the booster, cylinder, which receives the output of the hydro
accumulator, charge valve, and pressure switch in boost and activates the brake, the reservoir for the
an integrated structure, a reservoir, and a cooler master cylinder, and the brake pedal that activates
pipe (figure 1). the booster.
The master cylinder is integrally bolted to the
[Functions of the main constituent parts] booster of the hydro boost. The pump for the power
steering is integrated as a tandem pump that
Booster: Controls the hydraulic oil ejected shares the hydro boost pump and the drive unit. But
from the oil pump and amplifies as systems, the hydro boost and the power steering
the force on the pedal. are independent of each other, and their reservoirs
Accumulator: Accumulates the hydraulic oil are separate as well.
under pressure for the boosting
operation after the pump stops.
Charge valve: performs switching operation and
feeds the hydraulic oil to the
accumulator when the
accumulator oil pressure declines.
Pressure switch: Detects that the accumulator oil
pressure has declined to the
warning set pressure and operates
the warning buzzer.
Oil pump: is driven by the engine rotation
and feeds the hydraulic oil to the
hydro boost through the piping.
Reservoir: The pump stores the hydraulic oil
for doing suction and expulsion.
Cooler pipe: Located before the radiator,
facilitates heat radiation of the
hydraulic oil in the system piping,
and inhibits an increase in the
temperature of the oil.
5A2-4 HYDRAULIC BOOSTER BRAKE SYSTEM

HYDRAULIC BOOSTER TROUBLESHOOTING

[
1
State Cause Action

Large force 1. Booster operation insufficient * With the engine on, press the brake pedal
pressing on the * Large internal leakage repeatedly, and confirm the presence of manual
brake pedal * Sticking of the spool valve operation.
(boosting : insufficient sliding around the With regard to manual operation, turn the
insufficient) input and output rods engine off, and judge whether the pedal is as
stiff and its play is as small as when the pedal is
pressed repeatedly ten times or more.
* When there is manual operation, the hydro
boost assembly is replaced.

Brake dragging . Bad dimensions of the booster * Confirm whether the amount of protrusion of the
¢ The amount of protrusion of the output rod (the distance from surface of the
output rod is large master cylinder attachment flange to the end of
the rod) is no greater than 18.2 mm.
lithe above dimension is outside the range,
replace the hydro boost assembly.

. Bad pedal circumference « Confirm whether the clevis position dimension

attachment dimensions (the distance frorn surface of the vehicle
« Clevis position dimension is large attachment flange to the center of the clevis
center) is in the range 109+1 mm.
* If the above dimension is outside the range,
loasen the lock nut and adjust the clevis
position dimension to be inside the above
range.
After making this adjustment, be sure to
securely tighten the lock nut and to do a stop
lamp switch reconfirmation.

. Booster return is bad « With the engine on, repeatedly press the brake
¢ Input-output rod circumference pedal and confirm the pedal return state.
sticks «If the pedal does not return, replace the hydro
« Bad spool valve operation boost assembly as necessary.

Oil leakage . Hydro boost assembly external » lf the oil leakage is caused by looseness in the
leakage piping connections, retighten the connections.
* Leakage from the seal material * If there is oil leakage from the connections of
the accumulator, replace the affected seals of
the connections with new seals.
«lf there is any oil leakage from parts other than
the above that are included in the hydro boost
assembly, replace the hydro boost assembly or
the repair setting parts (accumulator).

Bad brake . Poor operation of the booster « With the engine on, repeatedly press the brake
operation (lack « Input-output rod circumference pedal and confirm the pedal operation state.
of smoothness sticks + If there is sticking or some other abnormality in
in operation) * Bad spool valve operation the pedal operation, replace the hydro boost
assembly as necessary.
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-5

State Cause Action

Abnormal brake 1. Air in the hydraulic booster lines « With the engine running, check the amount of
noise hydraulic fluid remaining in the reserve tank for
(when pressing the hydraulic booster.
the pedal) «if low, add fluid (ATF Dexron®— II} and bleed to
remove air as necessary before starting the
engine. Operate the pump and repeatedly step
on the pedal to confirm the gear noise (caused
by cavitation).

2. Water in the hydraulic fluid * Check the color of the hydraulic fluid in the
reserve tank for the hydraulic booster (normal:
purple, abnormal: milky white).
«If the hydraulic fluid is milky white, change the
fluid (ATF Dexron®— Ill) and bleed to remove air
as necessary before starting the engine.
Operate the pump and strongly press the pedal
until reaching full boost range to confirm the
gear noise (caused by cavitation).
The length of time to keep the pedal pressed all
the way down is no more than five seconds.

No pedal 1. Faulty charge vaive «Keep the engine running for more than 10
boosting effect * Gas leaking from the seconds. Turn off the engine, and within 60
immediately accumulator seconds, step on the pedai once to confirm
after turning the - Leakage inside the charge valve boosting effect.
engine off Boosting effect means the same pedal effort if
the engine was running.
+ If boosting effect does not exist, either the
hydraulic booster assembly or the accumulator
may need to be replaced.

Warning buzzer 1. Faulty hydraulic booster assembly « Confirm that the electric devices (pressure
continuously » Faulty pressure switch switch, relay, buzzer, etc.) are working
sounds « Leakage inside the charge valve correctly.
«If all are working correctly, pump the brake
pedal at least 10 times after turning the engine
off to reduce pressure in the hydraulic booster.
Start the engine, and if the vehicle has a
manual transmission, release the parking brake
(with an automatic, put it in Drive). Check to see
if the alarm stops within ten seconds (if it does,
the electrical devices are working properly).
«When testing the electrical devices, always
keep your foot on the brake pedai with just
enough pressure to prevent the vehicle from
moving.
if the alarm does not stop, the hydraulic booster
assembly may have to be replaced.
5A2-6 HYDRAULIC BOOSTER BRAKE SYSTEM

State Cause Action

Charge 1. Bad charge valve operation «Turn the engine on, and without pressing the
operation - Bad valve switching operation brake pedal, check whether any charging sound
remains in continues, such as the sound of the fluid.
effect “If it continues and will not stop, replace the
hydro boost assembly as necessary.

NOTES SUPPLY PARTS REPLACEMENT

1. When the brake pedal is operated after the Precautions
engine is turned off and the oil pump stops, 1 . The hydro boost is a precision part that
during a few operations a fluid sound due to the operates with high-pressure hydraulic oil. Never
flow of high-pressure oil or a sound of remove any parts from the hydro boost except
movement by the charge spool may be replacement parts.
produced, but this sound is not abnormal; it Trouble may occur if a part other than a
merely indicates that boosting by the replacement part is removed and a non-
accumulator (accumulator operation) is matching part is included or the assembly is
proceeding normally. bad. For example, misoperation may occur and
Also, a similar fluid sound is produced during the brake becomes ineffective, or a bad seal
quick operation of the brake pedal even if the may allow high-temperature hydraulic oil under
engine is on, but this too is normal. high pressure to spatter and cause a burn.
2. If the pressure of the oil in the accumulator . The hydraulic oil to be used for the hydro boost
drops with operation of the brake pedal after the is ATF Dexron®— Ill. Using any other hydraulic
engine is turned off or when the engine has oil could adversely affect the rubber parts and
been off for a long time, then immediately after Cause poor operation or oil leakage.
the engine is turned on, fluid sound during In particular, the hydraulic oil for the hydro
charge valve operation or switching sound when boost is quite different from the brake fluid that
charging ends will be produced, but this sound ig used in the master cylinder.
is not abnormal; it merely indicates that the Be careful that hydro boost parts do not come
accumulator is being normally charged. into contact with the brake fluid for the master
Also, a similar charging operation sometimes cylinder, and that master cylinder parts do not
occurs and sound is sometimes produced when come into contact with the hydraulic oil for the
the pressure inside the accumulator drops even hydro boost.
when the engine is on and charging has ended, Any mixing together of the hydraulic oil for the
due to such causes as rapid operation of the hydro boost and the brake fluid for the master
brake pedal, internal leakage that is too slight to cylinder could cause degradation such as the
affect brake performance, or a change in swelling of rubber parts, brake faijure due to oil
temperature; this too is normal. leakage or bad operation, or a serious mishap
3. When the brake pedal is pressed strongly as far such as a vehicle fire caused by brake friction.
as the booster full load region while the engine . Operation of the pump while the engine is on
is on, sometimes sound is produced by the flow will cause the hydro boost hydraulic oil to get
of hydraulic oil discharged from the oil pump, hot. In particular, frequent repeated operation of
but this is not abnormal. Also, pressing the the brake will sometimes increase the
pedal in as far as this booster full load region temperature of the hydraulic oil in the hydro
can cause a significant increase in the oil boost assembly to 100°C or more. Be careful in
temperature inside the oil pump and can lead to handing.
a failure, so keep the pecial pressed for no When performing work such as removing the
ionger than 5 seconds. hydro boost assembly from the vehicle, before
starting the work, first turn the engine off, wait
30 minutes, and verify that the temperature has
cooled off.
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-7

4. Even when a long time passes after the engine @) If itis necessary at this time to bleed out the
is turned off, the high-pressure hydraulic oil in air from the brake fluid pressure system,
the accumulator of the hydro boost remains such as the master cylinder or the wheel
stored under pressure. cylinder, be sure to first complete step
Before removing the hydro boost assembly or above and make sure that the engine is on.
piping, be sure to repeatedly press the brake @ With the engine on, strongly press the brake
pedal at least ten times with the engine off, and pedal as far as the booster full load region
make sure the pressure of the hydraulic oil in slowly and repeatedly about 30 times (for 1-
the accumulator has been reduced to 3 seconds each time). When doing so, do
atmospheric pressure before doing the work. not keep the pedal at the full load region (no
In particular, when removing the replacement- longer than 1 second).
part accumulator from the hydro boost @ Then turn the engine off and repeatedly
assembly, the hydraulic oil may spatter if it press the brake pedai at least 10 times.
remains stored under high pressure inside the @@ Check the state of the hydraulic oil in the
accumulator, so be careful of this. reservoir, and if there is no foaming or
. After removing the hydro boost assembly or change in the level of the oil, the operation
piping and making repairs, do not run the of bleeding the air out is considered
vehicle until you perform the below-described completed. If any foam remains, let it stand
air bleeding and then verify that everything is for a while, wait for the foam to dissipate,
normal, including hydro boost boosting and then repeat the above steps (2—().
accumulator operation. . Precautions when bleeding the air from tne
. How to bleed out the air from the hydro boost brake fluid pressure system
when actually attaching it to the vehicle When doing air bleeding of the brake fluid
@ Attach the hydro boost and the master pressure system, such as the master cylinder or
cylinder to the vehicle and connect the wheel cylinder, verify that the air has been bled
piping. out of the hydro boost, and make sure that the
@) Fill the hydro boost reservoir with hydraulic engine is on.
oil between its minimum and maximum Be aware that if air bleeding of the brake fluid
range. system is to be done with the engine off, air
Turn the engine on for about 5 seconds. bleeding cannot be cone.
if air bleeding of the brake fluid pressure system
©©

Then turn the engine off and check the

quantity of hydraulic oil in the reservoir. is to be done at the same time as air bleeding of
) If the hydraulic oil is below the minimum, the hydro boost, do so when the operation of
pour in more hydraulic oil so that it is in the the above hydro boost air bleeding method @
range from minimum to maximum. has been completed.
© Repeat the above steps @-© until there is
no foaming or change in the level of the
hydraulic oil in the reservoir. But if the
hydraulic oi! foams during the above steps,
let it stand for a while, wait for the foam to
dissipate, then continue the work.
With the engine on, repeatedly press the
©

brake pedal slowly about five times.

Then turn the engine off and check the
quantity of hydraulic oil in the reservoir. If
the hydraulic oi! is below the minimum, once
again pour in more hydraulic oil so that it is
in the range from minimum to maximum.
© Leaving the engine off, repeatedly press the
brake pedal at least ten times.
Verify that there is no foam or change in the
level of the hydraulic oil in the reservoir. If
any foam remains, let it stand for a while,
wait for the foam to dissipate, then repeat
the above steps @-@).
 5A2-8 HYDRAULIC BOOSTER BRAKE SYSTEM

ON-VEHICLE SERVICE
ACCUMULATOR and O-RING then dispose of the accumulator.
REPLACEMENT Concerning disposal with the hydro boost
assembly as well, dispose of it after first
| Remove or Disconnect (Figure 2) letting out all the nitrogen gas inside the
* Block the vehicle and appliy the parking brake. ac lator, .
cumulator, by the above method
* Battery ground cable.
ACCUMULATOR
* Reduce the pressure of the hydraulic oil in the
accumulator by brake pedal operation with the STUD BOLT
angine off, and after confirming that the COVER BOSS
temperature of the hydro boost assembly has LOCK NUT
been reduced, remove the hydro boost assembly CLEVIS
from the vehicle.
1. Remove meter cluster.
2. Remove meter assembly and harness
connector.
3. Remove ventilation duct.
GUARD
Refer to STEERING COLUMN REPLACEMENT OPERATING
(SEC. 3B4). FLANGE ROD
4. Using an oil filter wrench, remove accumulator A
and O-ring. FOSLWOOt
Figure 2. Hydraulic Booster
foe] Install or Connect (Figure 2)

1. Verify that there is no foreign matter adhering to

the screw part of the accumulator or to the ACCUMULATOR DRILLING POINT
attachment part on the booster side. FOR GAS RELEASING
2. Put an O-ring coated with new hydraulic oil HEX25
(ATF Dexron®~ Ill) into the screw part of the
accumulator, being careful not to damage it.
Always use a new O-ring.
3. Using an oil filter wrench, hold the accumulator ~ ' ,
shell fixed, and tighten it via the wrench to the compey
speciifed torque. [ }

[2] Tighten JPL ROU\

Accumulator: 25-34 N-m (18-25 lb-ft)
/
THREAD
\
O-RING
FosLwoo2
4. install ventilation duct. Figure 3. Accumulator
5. Connect harness connector and install meter
assembly. HYDRAULIC BOOSTER REPLACEMENT
6. Install meter cluster.
7. Battery ground cable. [+9] Remove or Disconnect (Figure 2)
8. After attaching it to the vehicle, always * Block the vehicle wheels and apply the parking
replenish with new hydraulic oil (ATF Dexron®— brake.
lil), and completely release the air from the - Battéry ground cable.
hydro boost. « By brake pedai operation with the engine off,
9. Release the parking brake and remove the reduce the pressure of the hydraulic oil in the
wheel blocks. accumulator, and after confirming that the
* How to dispose of the accumulator (figure 3) temperature of the hydro boost assembly has
To dispose of the accumulator, drill a hole in been reduced, remove the hydro boost assembly
the position shown in the diagram below from the vehicle.
(figure 3)according to the indications printed
on the accumulator, completely release the 1. Remove meter cluster.
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-9

connector. « Remove brake pedal assembly mounting

3. Remove instrument panel assembly and bolts.
ventilation duct.
Refer to INSTRUMENT PANEL (SEC. 10).
4. Remove heat protector under the hydraulic
booster.
5. Steering wheel and column assembly (figure 4).
* Remove in spection window and mark
steering worm shaft and U-joint yoke.
Remove key bolt and nut. Refer to STEERING
COLUMN (SEC. 3B4).
« Remove screws: boots to floor.
« Remove bolts and nuts: support bracket to
floor.
« Remove bolts: steering column bracket to
instrument reinforcement assembly.
- Remove bolts: steering column bracket to
brake pedal bracket.

310LW003

Figure 5. Brake Pedai Assembly with Master

Cylinder and Hydraulic Booster

« Remove radiator grille and disconnect ATF

inlet pipe from flexible hose in front of the
radiator. Remove ATF inlet pipe.
« Remove brake pedal assembly.
9. Remove hydraulic booster and master cylinder
assembly (figure 5).
10. Clevis pin (3) (figure 8).
11. Four hydraulic booster mounting nuts (4) at
pedal bracket (6) (figure 8).
12. Master cylinder (1) with hydraulic booster (2)
(figures 6 and 8).
13. Four nuts (5) retaining master cylinder to
hydraulic booster (2) (figures 6 and 8).
430L W004

Figure 4. Steering Wheel and Column Assembly

6. ATF pipe: inlet and outlet.

* Disconnect pipes from the booster.
7. Brake pipe and hose: front and rear.
« Disconnect pipes and hoses from the brake
master cylinder.
8. Brake pedal assembly with master cylinder and
hydraulic booster (figure 5).
* Remove accelerator pedal bracket. Refer to
FUEL SYSTEM (SEC. 6C1).
5A2-10 HYDRAULIC BOOSTER BRAKE SYSTEM

a0LWo0t
Figure 6. Hydraulic Booster

Inspect

Make necessary correction or parts replacement.

Push Rod Length (Figure 7)

* Use a scale to measure the push rod length (push
rod to flange face clearance).
Push Rod Length “L” to 17.95 - 18.2 mm (0.707 -
0.717 in).
- if the push rod fength is not equal to the
specitication, it must be replaced.

AOSLWOO1
Figure 7. Push Rod Length
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-11

1. Master Cylinder
2. Hydraulic Booster
3. Clevis Pin
4, Hydraulic Booster Mounting Nuts
5. Master Cylinder Mounting Nuts
6. Brake Pedal Bracket
7. Bracket Mounting Bolts

Figure 8. Hydraulic Booster Components

; 5. Brake pedal assembly with master cylinder and

[+4] install or Connect (Figure 8) hydraulic booster (figure 9).
+. Hydraulic booster (2). . sseembly. pipe and install brake pedal

2. Master cylinder assembly (1).

[RX] Tighten Tighten

» Nuts (5) to 19 N-m (14 Ib-ft). M10 mounting bolts to 42 N-m (32 lb-ft).

3. Four hydraulic booster mounting nuts (4) to

pedal bracket (6).

[RI Tighten
* Nuts (4) to 19 N-m (14 Ib-ft).

4. Connect servo unit clevis to brake pedal, and

install clevis pin (3).
5A2-12 HYDRAULIC BOOSTER BRAKE SYSTEM

s10LWwao2 4s0L wood

Figure 9. Brake Pedal Assembly with Master Figure 10. Steering Wheel and Column Assembly
Cylinder and Hydraulic Booster
« Install key bolt and nut.
* Connect ATF inlet pipe with flexible hose.
* Install accel pedal bracket. Tighten
« Install radiator grille.
Key bolt to 38 N-m (28 Ib-ft).
6. Install ATF pipes to hydrawlic booster.
* Install inspection window.
7. install master cylinder hydralic lines to master
. Install hydraulic booster heat protector.
cylinder.
. Install ventilation duct and instrument panel
8. Steering wheel and column assembly (figure 10).
assembly.
* Set steering wheel and column assembly.
Refer to INSTRUMENT PANEL (SEC. 10).
Refer to STEERING COLUMN (SEC. 3B4).
11. Install meter assembly and harness connector.
« Install mouting bolts, nuts and screws to body.
12. install meter cluster.
13. Battery ground cable.
14. After attaching it to the vehicle, always
replenish with new hydraulic oi! (ATF Dexron®—
li), and completely release the air from the
hydro boost.
. Bieed brake lines. Refer to HYDRAULIC
BRAKES (SEC. 5A).
16. Release the parking brake and remove the
wheel blocks.
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-13

CLEVIS AND LOCK NUT REPLACEMENT using the four stud bolts on the surface of the
flange for attachment to the vehicie.
| Remove or Disconnect 3. Being careful not to exert any off-center load on
the operating rod, loosen the jock nut and
1. Remove hydraulic booster assembly. remove the clevis and lock nut.
Refer to "Remove or Disconnect" of 4, Remove the guard from the cover boss
HYDRAULIC BOOSTER in this section. anchoring groove and from the operating rod
2. Secure the hydro boost assembly to the jig anchoring groove, and pull it out.
using the four stud bolts on the surface of the
flange for attachment to the vehicle. [oe] Install or Connect (Figure 12)
3. Being careful not to exert any off-center load on
1. With a dry cloth, clean well the cover boss
the operating rod, loosen the lock nut and
anchoring groove and the operating rod
remave the clevis and lock nut.
anchoring groove, and verify that no foreign
| Install or Connect (Figure 11) matter is present.
2. Insert from the large diameter hole side of the
1. Screw the lock nut and then the clevis onto the guard end-face into the operating rod outside
operating rod. diameter part, assemble the small diameter hole
2. Adjust so that the booster clevis position part of the guard end-face into the anchoring
dimension (the dimension A in the diagram groove of the operating rod, then assemble the
below (figure 11): the distance to the center of large diameter hole part securely into the
the clevis hole from the surface of the flange for anchoring groove of the boss of the cover.
attachment to the vehicle) is 10941 mm 3. Screw the lock nut and then the clevis onto the
(4.29+0.04 in), and tighten the lock nut with the operating rod.
prescribed torque. 4. Adjust so that the booster clevis position
Prescribed tightening torque: dimension (the dimension A in the diagram
19 N-m (14 lb-ft) below (figure 12): the distance to the center of
When tightening the lock nut, be careful not to the clevis hole from the surface of the flange for
deform the clevis. attachment to the vehicle) is 10941 mm
3. Attach the hydro boost assembly to the vehicle. (4.29+0.04in), and tighten the lock nut with the
Refer to "Install or Connect" of HYDRAULIC prescribed torque.
BOOSTER in this section. When tightening the lock nut, be careful not to
deform the clevis.
Prescribed tightening torque:
ACCUMULATOR
19 N-m (14 lb-ft)
STUD BOLT 5. Attach the hydro boost assembly to the vehicle.
COVER BOSS Refer to "Install or Connect" of HYDRAULIC
LOCK NUT BOOSTER in this section.
CLEVIS
_ACCUMULATOR
STUD BOLT
COVER BOSS
/ LOCK NUT
GUARD iy mn / CLEVIS
OPERATING
a
oy
FLANGE ROD
A
|

Figure 11. Hydraulic Booster

GUARD REPLACEMENT
FOsLWo014

©
6)
Q O , 4
‘\ |
GUARD \
OPERATING
cat FLANGE ROD
A
fe] Remove or Disconnect
FO5LW001
1. Remove hydraulic booster assembly. Figure 12. Hydraulic Booster
Refer to "Remove or Disconnect" of
HYDRAULIC BOOSTER in this section.
2. Secure the hydro boost assembly to the jig
5A2-14 HYDRAULIC BOOSTER BRAKE SYSTEM

BRAKE PEDAL REPLACEMENT

[us] Remove or Disconnect (Figure 13)

* Block the vehicle wheels and apply the parking

brake.
* Battery ground cable.
1. Brake pedal bracket with master cylinder and
hydraulic booster. Refer to HYDRAULIC
BOOSTER REPLACEMENT of this section.
2. Clevis pin.
3. Hydraulic booster with master cylinder.
4. Return spring (1).
5. Pedal shaft (2) from brake pedal assembly.
6. Brake Pedal (3).

Inspect

* Bushings, return spring and bolt for wear or

damage.
* Replace all parts found defective.
1. Return Spring
x Install or Connect (Figure 13)
2. Pedal Shait
1. Pedal shaft (2) to brake pedal assembly (3). 3. Brake Pedal
2. Return spring (1).
3. Hydraulic booster with master cylinder. Figure 13. Brake Pedal Assembly

[A] Tighten BRAKE PEDAL ADJUSTMENT

» Nut to 19 N-m (14 lb-ft).

NOTICE: For steps 4 and 5 seen “NOTICE” on
4. Clevis pin.
page 5A1-1 of this section.
5. Install brake pedal assembly with master
cylinder and hydraulic booster.
1. Loosen the lock nut at the stop lamp switch.
Refer to HYDRAULIC BOOSTER of this section.
2. Loosen the lock nut on the hydraulic booster
push rod (figures 14 and 15).
3. Turn the push rad until the distance from the
cenire of clevis pin hole to mounting surface of
the brake pedal bracket should be set at
109+imm (4.29+0.04 in) (figure 15).
When fixed under this condition, there is no
need to adjust the brake pedal height and free
play (figure 14).
4. Tighten the push rod lock nut.

fA] Tighten

* Lock nut to 19 N-m (14 lb-ft).

5. Stop lamp switch so that the end of the switch

threaded portion contacts the brake pedal, then
back-off the switch 1/2 turn.

[QQ] Tighten
« Stop lamp switch lock nut to 20 N-m (74 lb-ft)

6. Check brake pedal operation to be sure it’s

operating properly.
 HYDRAULIC BOOSTER BRAKE SYSTEM 5A2-15

Measurement (Figure 14, 15) ACCUMULATOR

° Measure the brake pedal free play, after reducing STUD BOLT
the pressure of the hydraulic oil in the COVER BOSS
accumulator by pedal operations at least 10 times
LOCK NUT
with engine off.
CLEVIS
Brake pedal normal play is between 21-24 mm
(0.83-0.94 in).
Pressing the brake pedal with a force of 294.N
(66 Ib) with the engine on, the clearance between
the brake pedal and floor panel is more than
35mm (1.4 in). GUARD
Brake pedal height “B” is 167mm (6.58 in) OPERATING
(reference). FLANGE ROD
Brake pedal travel “A” is between 180+5mm A
(7.09+0.2 in) (reference).
A. .....109+1 mm (4.29+0.04 in)
FO5LWo01

Figure 15. Hydraulic Booster Operating Rod

Distance

A. Pedal Travel
(Reference) ............. 180+5mm (7.09+0.2 in)
B. Pedal Height
(Reference)............. 167mm (6.58 in)
STOLWOo0d
Figure 14. Pedal Height and Travel Measurement
5A2-16 HYDRAULIC BOOSTER BRAKE SYSTEM

SPECIFICATIONS
Hydraulic DOOSHEL.......... ee eee ec cece cceerecesssseneneenaessoeeenesteqersssenaessuseneusensueatscausvesseesaees GVWR 16500 Ibs Model

FASTENER TORQUES

Master Cylinder Mounting Nuts ............:::cccccsssscccsssssuseeenesevessssscsensussetesrsstesecasestevaceeceenacasersenss 19 N-m (14 lb-ft)

Hydraulic Booster Mounting Nuts 0.0... ceccecsnescssceesseeesssssessaserserccsusaccunsussavacessseecasensreeeeeeess 19 N-m (14 Ib-ft)
Push Rod Jam Nut... cece cecneenesaeeeceessesenensscasesseeeeeeeescenseeaueuususesveseseevereesanesecesteeterees 19 N-m (14 lb-ft)
Stop Lamp Switch Lock Nut ..........ccccescecesecsessseeecnnssueveessssavenseseenevanseceeeverseasrus beetesetetenesenenses 20 N-m (14 Ib-ft)
 HYDRAULIC FOUNDATION BRAKES 5A3-1

SECTION 5A3

HYDRAULIC FOUNDATION BRAKES

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
INCFOCGUCTION ........0ccceccessscsssceseesecconseseaaeneusecanseenecenensenacansuesuveauannersansasusavaeusensanaesuanesanecususvascenenunsousrepessaeradsensenteas 5A3- 2
DeSCTiIPtiON .........ccsecesssccessessseessenssnssunensecsneseaecseeneauetseneussanensneesensenenaseneceeaseecesessentanueseninnneeesaneteeeaecaenesaenen 5A3- 2
On-Vehicle Service of Brake ASSEMDIY ............:cccccscssecsteressersussiscuesercercsaesveseesseensoresecesouesonsesseenssesnesesanes 5A3- 3
Brake Shoe and Lining Replacement ............ccsecsessenensnesnesentecseserseusnniesesersansentisnesneerenanenees wee DAd- 3
Brake Assembly Replacement........c:cscssserranesscensessessessotersaseenscsnastenseienacsersnnesensasesenssostonsioaneenesanaunteas 5A3- 4
Caliper and Support Replacement ..........cssemsssessescatsennsecanseanens laranensaanapnsnenecuseuserseeevoensausaeusaesasensnesees 5A3- 6
Front Disc Brake Pad Replacement ..........ccsssssesenseusuussssssosessssneessnsesvsnssesnsoserssiessnsneensnansaonnesesseransegs 5A3-11
Wheel Cylinder ...........csccsuseisccosserseersneersserensseavensnsennaeneanarninarenses pavenneetestacseesneetanereunenstaesenuersnatssanusousans 5A3-13
AUto-AdjUster ........cceccssceesssererseesnestsonsorscensstsoscesnsersensgessennseneneatedsenacanaeeanen suepeseusevaneaseusseusuesosacuaausontneners 5A3-15
Brake Drum Removal and Installation (with Auto-Adjuster)...........:ccsssceeesscsssessstecsestsaeusesosscrmsenesenees 5A3-17
Brake Linings .......cccscesseseessnsecsssesscssonsnnsesenessesssessosvesnssesensnenenesssenenesunenssenseansersaersnerenstenseaceneasesanenanananennuanes 5A3-17
Brake DrulmS........cccceccsccrscsscecsesssssacssnsesiseeraedsoussuneccarsnneasnnentsvesuasauiessesdeuequnsensaanvecsanssaseaaunvontaneqtensnesseasenses 5A3-18
SpeCifiCATIONS..........cccecceeeeeeatescinessessacsenensenenersentronseseantenntes ceeedrasetouneuevanansensaesaessaeraurasueoueapnesseenineneeapeesserenesns 5A3-20
Foundation Brakes. ........cs:sccsccsenstscsersesnetssssesesssuecusaesunuanesneseeduanenscarsenearcsonesuraseesveersageegseteesenensnaceneanesnes 5A3-20
Fastener Torques........cssssssssssssceerscans cunsunsensuenseesanseeseeaessoueaenansuaudenuarsensveneaonseuscedsouraasausataeiasanapersonseaueren 5A3-21
Special TOOMS........ccssscsssecssssscsesseensesesnenesencerseessaescensnsvarnensserenesseeeseuausesensaeesveueranaussnuessisevenscausenesenenenoeecauatanses 5A3-21

CAUTION: When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by
cleaning wheel brake parts with a dry brush or with compressed air. A water-dampened cloth or water-
based solution should be used to remove any dust on brake parts. Equipment is commercially available to
perform this washing function. These wet methods will prevent asbestos fibers from becoming airborne.
5A3-2 HYDRAULIC FOUNDATION BRAKES

INTRODUCTION

DESCRIPTION has two return springs.

The dual two leading shoes are adjusted
Front disc brakes and rear brakes (dual two automatically.
leading with auto-adjuster type) are equiped to all
models.
Linings are riveted to the shoes. Each rear brake

ROTATION

om ba
War
r@)
‘a

Dual Two Leading

with Auto Adjuster

Figure 1. Front Disc Brake Figure 2. Rear Wheel Brake

 HYDRAULIC FOUNDATION BRAKES 5A3-3

ON-VEHICLE SERVICE OF BRAKE ASSEMBLY

These procedures are rear wheel brakes except where noted.

Po
ee

. Overtravel Spring
8. Adjuster Lever
9. Return Spring
10. Boot
1 . Hold-down Spring and Cup 11. Adjuster Screw
2 . Return Spring 12. Adjuster Gear
3 . Brake Shoe Assembly 13. Washer
4. Brake Pipe 14, Piston
5 . Brake Pipe 15. Piston Cup
6. Wheel Cylinder Assembly 16. Cylinder Body

Figure 3. Rear Brake Assembly Components

BRAKE SHOE AND LINING « Refer to REAR AXLE (SEC. 4A1) in this
REPLACEMENT manual.
2. Hold-down springs and cups.
1. Block vehicle wheels and apply the parking 3. Return springs.
brake. 4. Shoe and lining assemblies.
2. Raise the axle to clear the tire from the ground.
Position jack stands under vehicle. install or Connect (Figure 3)

| Remove or Disconnect (Figures 3 and 4) {. Shoe and lining assemblies in the mounting
plate.
1. Wheel and tire assembly and brake drum and 2. Return springs.
hub assembly. 3. Hold-down springs and cups.
* Pushing the rod and rotate adjusters at back 4. Hub and drum assembly and wheel! and tire
of the brake to provide clearance between assembly. Adjust wheel bearings.
lining and drum. « Refer to WHEELS AND TIRES (SEC. 3E).
» Refer to WHEELS AND TIRES (SEC. 36) in « Refer to REAR AXLE (SEC. 4A1).
this manual.
 5A3-4 HYDRAULIC FOUNDATION BRAKES

[3] Important

Be sure to push up the auto-adjuster lever.

Failure to do so will result in damage to the
teeth of the auto-adjuster lever.
Take care not to damage the rubber boot with
the bar or the screwdriver.

Figure 4. Removing the Brake Drum

5. Remove jack stands and lower the axie.

6. Remove wheel blocks.
7. Check brake operation. . Rod
oh
. Screw Driver
BRAKE ASSEMBLY REPLACEMENT
Figure 5. Release of Auto-Adjuster
1. Block vehicle wheels and apply parking brake.
2. Raise the axle to clear the tire from the ground. « Refer to WHEELS AND TIRES (SEC. 3E) in
Position jack stands under vehicle. this manual.
« Refer to REAR AXLE (SEC. 4A1) in this
[+9] Remove or Disconnect (Figures 3 and 4) manual.

1. Wheel and tire assembly and brake drum and . Hold-down springs and cups.
hub assembly. . Shoe return springs.
» Push the rod to push up the auto-adjuster . Shoe and lining assemblies.
lever. . Brake pipes.
» Remove the rubber cover from the brake . Mounting plaie.
lining clearance adjusting hole. —~ Rear brake: Six bolts.
« Hold the auto-adjuster lever stationary. 7. Wheel cylinders.
Use a screwdriver to rotate adjusters at back 8 Dust shields.
of the brake to provide clearance between
lining and drum. Inspect

« All components for wear or damage. Replace as

necessary.

Measure

Tool Required:
J-34913, Tension Scale
* Return spring tension (figure 6).

Free length Set length Set load

mm (in) mm (in) N (ib)

12,000 Ib Rear brake 208.0 (8.19) 224.0 (8.82) “49.6606.

14,500 Ib Rear brake 198.4 (7.81) 219.1 (8.63) “19.6-60.0)

17,950 Ib Rear brake 197.7 (7.78) 219.1 (8.63) 65 580.0)

 HYDRAULIC FOUNDATION BRAKES 5A3-5

4. Brake pipes.

Tighten

« Brake pipe nuts to 15 N-m (11 Ib-ft)

. Shoe and lining assemblies.

Dom
. Shoe return springs.
. Hold-down spring and cups.

On
. Measure the internal diameter of the brake
drum.
. Measure the external diameter of the brake

©
1. J-34913 shoe.
* Take measurement of the distance at @),
Figure 6. Checking Return Spring Tension and © points (figure 7).

[os] install or Connect (Figure 3)

NOTICE: See “NOTICE” on page 5A3-1 of this

section for steps 2, 3 and 4.

1. Dust shields.
2. Wheel cylinder assemblies.

[Q] Tighten
+ Wheel cylinder mounting bolts to the specified
torque.
N-m (lb-ft)
Figure 7. Measuring Shoe External Diameter
12,000 lb | Rear brake 33)
10. Turn the adjuster gear so that the difference
between the internal diameter of the brake drum
14,500 Ib | Rear brake 6) and the external diameter of the brake shoe
becomes 0.6 mm (0.024 in).
11. Hub and drum assembly and wheel and tire
17,950 Ib | Rear brake (60) assembly. Adjust wheel bearings.
¢ Refer to WHEELS AND TIRES (SEC. 36).
« Refer to REAR AXLE (SEC. 4A1).
3. Mounting plate. « Remove jack stands and lower axle.
— Rear brake: Six bolts. Run engine to build up vacuum.
«

Bieed hydraulic brakes.

#

[2] Tighten Remove wheel blocks.

¢

Check brake operation.

eo

- Rear mounting plate bolts to the specified

torque.
N-m (ib-ft)

108
(80)
14,500 Ib Rear brake

157
(146)
17,950 ib | Rear brake
5A3-6 HYDRAULIC FOUNDATION BRAKES

CALIPER AND SUPPORT REPLACEMENT

@:Pad kit
vr:Seal kit

NPR

1. Flexible hose.
2. Lock pin bolt
3. Guide pin bolt.
4. Caliper assembly.
5. Pin boot
6. Outer pad 11. Adapter
7. Inner pad 12. Boot ring.
8. Pad clip 13. Piston boot.
9. Support assembly 14. Piston.
10. Wind guide ; NPR 15. Piston seal.
(Wind guide and bracket; NQR) 16. Body assembly.
302LX001
Figure 8. Caliper and Support Assembly
 HYDRAULIC FOUNDATION BRAKES 5A3-7

1. Block vehicle wheels and apply the parking

brake.
2. Rise the axle to clear the tire from the ground.
Position jack stands under vehicie.

| KGa
3. Remove the wheel.
\ |

~~
| Remove or Disconnect (Figures 8 and 9)

SS
NOTICE: Seal parts indicated +« mark cannot be

S
reused. When reassembling, be sure to replace
with a new seal kit.

RX
1. Flexible hose (1).
2. Lock pin bolt (2).
3. Caliper assembly (4). Figure 10. Removing Piston
¢ Slide the caliper assembly free from the inside
(figure 9).
Inspect (Figures 11 and 12)
MS
\ 1. All parts for wear distortion or other conditions
] and replace as needed.
2. Inner and outer pads.
Zo in « Use a varnier caliper to measure the inner

< >) pad and outer pad thickness (figure 11).

Pad Thickness mm (in)
Standard 13 (0.51)
Limit 1 (0.04)
* If the measured value is less than the
specified limit, the pads must be replaced with
the repair pad kit.

Figure 9. Removing Caliper Assembly

4. Pin boot (5).

5. Outer pad (6).
6. Inner pad (7).
7. Pad clips (8).
8. Support assembly (9).
9. Wind guide (10).
» Remove the hub and disc before removing the
wind guide.
Refer to “Hub and Disc”.
10. Adapter (11).

Figure 11. Measuring Pad Thickness

[S] Disassemble (Figure 10)

1. Place a piece of wood across the body

assembly to prevent piston damage.
2. Apply approximately 196 kPa (28 psi) of
compressed air to the body assembly oil port to
remove the pistons.
5A3-8 HYDRAULIC FOUNDATION BRAKES

3. Piston and Cylinder Clearance (figure 12). Apply brake oil to the piston (14) outer
+ Use a micrometer to measure the piston circumference.
diameter. Use a hand vise to install the pistons (14) to
« Use an inside dial indicator to measure the the cylinder (figure 14).
cylinder bore. Apply special grease to the piston.
* Calculate the piston and cylinder bore This will prevent cylinder and piston corrosion.
clearance. install the piston boot (13) outer lip to the
Piston and cylinder bore clearance mm (in) cylinder bore groove.
Standard 0.08-0.18 (0.0031-0.0071) install the piston boot inner lip to the piston
Limit 0.23 (0.009) groove.
* If the clearance exceeds the specified limit, Handle the piston boot carefully.
the piston and/or the body assembly must be install the boot ring to the cylinder bore

e
replaced along with the repair seal kit. groove.
The boot ring (12) must be completely
installed to the groove.

14 16

14. Piston
16. Body Assembly
Figure 12. Measuring Piston and Cylinder Bore A. Hand Vise

Figure 14. installing Piston

fe] Assemble (Figures 13, 14 and 15)

1. Piston Seal (Figure 13)

* Apply rubber grease to the piston seal (15).
The rubber grease is included in the seal kit.
* Install the piston seal to the cylinder bore
groove.

13. Piston Boot

16. Body Assembly

Figure 15. Instailing Piston Boot

15. PistonSeal
16. Body Assembly

Figure 13. installing Piston Seai

2. Piston, Piston Boot and Boot Ring

(Figures 14 and 15)
 HYDRAULIC FOUNDATION BRAKES 5A3-9

x install or Connect

1. Adapter (Figure 16)

* Install the adapter to the knuckle.
* Tighten the fixing bolts and nuts to the
specified torque.

FQ] Tighten

» Fixing bolts and nuts to 162 N-m (119 (b-ft).

9. Support Assembly

Figure 18. Support Assembly Fixing Bolts

4. Pad Clips (Figure 19)

* Be sure that the clips (8) are completely
installed to the support assembly (9).

|
11. Adapter
302LX002

Figure 16. Adapter Fixing Bolts and Nuts

2. Wind Guide (Figure 17)

* Tighten the fixing bolts to the specfied torque.

Tighten

+ Fixing bolts to 13 N-m (113 Ib-in)

8. Pad Clip

Figure 19. Installing Pad Clips

5, Pads (Figure 20)

» Install the inner pad (7) and the outer pad (6)
to the support assembly (9).

10. Wind Guide

11. Adapter
302LX003

Figure 17. Wind Guide Fixing Bolts

3. Support Assembly (Figure 18)

* Tighten the fixing bolts to the specified torque.

Tighten
+ Fixing bolts 221 N-m (163 Ib-ft).
5A3-10 HYDRAULIC FOUNDATION BRAKES

fQ] Tighten

* Lock pin bolt to 137 N-m (101 Ib-ft).

os \

. Outer Pad
A >) 5
7. Inner Pad
9. Support Assembly

Figure 20. installing Pads

6. Pin Boot (Figure 21)

* Apply approximately 1g (0.035 oz) of special
grease to the pin boot (5) bore and pin boss 3. Guide Pin Bolt
(B) bore of support. 4, Caliper Assembly
This will prevent pin corrosion. 9. Support Assembly
The special grease is included in the seal kit.
* Install the pin boot (5) to the support Figure 22. Installing Caliper Assembly (1)
assembly (9).

4. Caliper Assembly
5. Pin Boot 9. Support Assembly
9. Support Assembly
B. Pin Boss of Support Figure 23. Installing Caliper Assembly (2)

Figure 21. Pin Boot Installation

7. Caliper Assembly and Lock Pin Bolt

(Figures 22 and 23)
- Install the caliper assembly (4) to the support
assembly (9) guide pin bolt (3) from the
inside.
« Return the caliper assembly to its original
position.
Take care not to pinch the pin boot.
* Tighten the lock pin bolt to the specified
torque.
 HYDRAULIC FOUNDATION BRAKES 5A3-11

8. Flexible Hose (Figure 24) FRONT DISC BRAKE PAD REPLACEMENT

* Tighten the flexible hose boit to the specified
torque. 1. Block vehicle wheels and apply the parking
brake.
Tighten 2. Raise the axle to clear the tire from the ground.
Position jack stands under vehicle.
* Hose bolt to 34 N-m (25 Ib-ft).
3. Remove the wheel.
Air Bleeding [= Remove or Disconnect (Figure 22 and 25)
Refer to “Air Bleeding’.
1. Loosen and remove the lock pin bolt (2) from
the lower side of the caliper.
2. Turn the caliper assembly up and wire it to the
frame firmly so that the hose is not stretched.

[3] Important

« Do not disconnect the brake hose.

. Remove the pad assembly with clips.

. Conduct disc wear check, and resurface or
replace it as required.
. When removing brake disc, slide caliper
assembly (4) inside of the vehicle, and take out
caliper assembly from support assembly (9).
Take care not to wipe the special grease from
Figure 24. Flexible Hose Installation guide pin bolt (3), and prevent from sticking
dust or any foreign material to guide pin bolt (3).
. See section 3C “FRONT AXLE AND
SUSPENSION? of this manual for disc wear
check and replacement procedures.
 5A3-12 HYDRAULIC FOUNDATION BRAKES

Steel plate 4

Hand vise

4. Caliper Assembly
14. Piston

Figure 26. Pushing Piston

3. Remove hand vise and install the new pads

along with new clips.

[3] Important

* Be careful not to assemble the inner and outer

pad reversely.

4. Install the lock pin into the support by turning

the caliper carefully so that the piston boot and
pin boot may not be wedged.
4 Caliper Agsemb| After assembling the caliper assembly, make
6. Outer Pad y sure that the piston boot and pin boot fitted
7. Inner Pad correctly, and not damaged.
9. Support Assembly 5. Tighten the lock pin bolt to the specified torque.
Tighten
Figure 25. Pads Removal al 9
+ Lock pin bolt to 137 N-m (101 Ib-ft).
[oe] Install or Gonnect

1. Keep the rotor face away from the brake oil or

grease.
2. Use a hand vise to push the piston backward
until it reaches the cylinder bottom, as the
piston was pushed forward by the distance
where the pad worn (figure 26).

[3] Important

+ When using a hand vise, push the piston at its

center,
 HYDRAULIC FOUNDATION BRAKES 5A3-13

WHEEL CYLINDER

Ge ——_—_#»,,.

* @ -0-

5 8 9
| 2

1. Cylinder Body 8. Adjuster Gear

2. Piston 9. Washer
3. Piston Cup 10. Adjuster Lever
4. Boot 11. Overtravel Spring
5. Adjuster Screw 12. Return Spring

Figure 27. Rear Brake Wheel Cylinder with Auto-Adjuster

Replacement inspect
Remove and install wheel cylinders as described
1. Repair kits are available which contain the parts
in “Brake Disassembly” previously in this section.
to be replaced when overhauling wheel
[§] Disassemble (Figure 27) cylinders.
Refer to Parts Book for repair kit part numbers.
Overtravel spring. 2. Inspect cylinder bore for scoring, scratches, or
*#

Return spring. corrosion.

8

Adjuster lever. Light scratches or slightly corroded spots may

@

Boot. be polished out with crocus cloth. Never use

#

Adjuster screw. emery cloth or sandpaper.

#©

Adjuster gear. if scratches or corrosion are too deep to be

@

Washer. polished out, replace cylinder.

®

Piston. Staining should not be confused with corrosion.

©

Piston cup. Corrosion can be identified as pits or excessive

©

Cylinder body. roughness.

e

3. Check fit of new pistons in the cylinder bore.

Clean Clearances should be within limits of the
following table.
1. Wash all parts to be reused in clean brake fluid.
2. Allow parts to air-dry on clean paper or lint-free
cloth.

GVWR Wheel Cylinder Diameter Clearance mm (in)

(Ib) mm (in) New Limit

26.99 0.02—0.105 0.15

12,500 Rear (1.0626) (0.0008—0.0041) (0.0059)
30.16 0.03—0.126 0.15
14,500 Rear (1.1874) (0.0012--0.005) (0.0059)
33.34 0.025—-0.126 0.15
17,950 Rear (1.313) (0.001—0.005) (0.0059)
5A3-14 HYDRAULIC FOUNDATION BRAKES

Repair
fe Assembie
NOTICE: Do not hone wheel cylinder bores.
When wheel cylinders are overhauled, it is + Cylinder body.
recommended that the cylinder bore be replaced
rather than “cleaned up” by honing the bore. NOTICE: See “NOTICE” on page 5A2-1 of this
Wheel cylinder bores have a hard, highly polished section.
“bearingized” surface, which is produced by
diamond boring followed by ball or roller « Boot.
burnishing under heavy pressure. Honing will « Piston cup.
destroy this surface, leaving a softer and rougher * Piston.
surface which will cause more rapid wear of + Washer.
rubber seal cups. + Adjuster gear.
* Adjuster screw.
It is permissible to clean minute surface « Adjuster lever.
irregularities with crocus cloth, providing the * Return spring.
irregularity is small enough to clean up by this * Overtravel spring.
method.
Before assembling wheel cylinder, clean each
part in brake fluid.

NOTICE: Dip each internal part in hydraulic brake

fluid before assembling. Do not use kerosene or
gasoline for cleaning wheel cylinder parts. The
use of these as solvents, or any other with a trace
of mineral oil, will damage rubber parts.
 HYDRAULIC FOUNDATION BRAKES 5A3-15

AUTO-ADJUSTER

12

1. Wheel Cylinder Body

10. Adjuster Lever
11. Overtravel Spring
12. Return Spring

Figure 28. Rear Brake Wheel Cylinder with Auto-Adjuster

[&] Disassemble (Figure 28)

1. Return spring (12).
2. Overtravel spring (11).
3. Adjuster lever (10).

fe] Assemble

1. Adjuster lever and overtravel spring

(Figures 29 and 30)

10. Adjuster Lever

11. Overtravel Spring

Figure 30. Wheel Cylinder Assembly (2)

* Hook one end of the overtravel spring (11) to

the adjuster lever (10) hole as shown in the
figure 29.
* Turn the overtravel spring 90 degrees
clockwise as shown in the figure 30.
10. Adjuster Lever
11. Overtravel Spring

Figure 29. Wheel Cylinder Assembly (1)

5A3-16 HYDRAULIC FOUNDATION BRAKES

2. Wheel Cylinder Body

Install the adjuster lever and the overtravel
spring to the wheel cylinder body.
* Hook the overtravel spring fitting siot side to
the wheel cylinder body bracket hole (figure Cylinder Body Hook
a

31).
+ Turn the adjuster lever and the overtravel
spring 90 degrees clockwise as shown in the
figure 32.
Turn the adjuster lever slightly clockwise to
attach the adjuster lever hole ta the wheel
cylinder body hook (figure 33).
+ Push the wheel cylinder body and bracket to
the left as shown in the figure 34.
+ Turn the adjuster lever clockwise to install the
pin head through the adjuster lever hole.

11 To
10

1 Wheel Cylinder
10. Adjuster Lever
Figure 34. Wheel Cylinder Assembly (6)
11. Overtravel Spring
3. Spring
Figure 31. Wheel Cylinder Assembly (3) Hook the return spring to the wheel cylinder
body pin.

10
1 \ees
pon _
ca
i
“ t

oe | Uy

1. Wheel Cylinder
Figure 32. Wheel Cylinder Assembly (4) 10. Adjuster Lever
12. Return Spring

Figure 35. Wheel Cylinder Assembly (7)

 HYDRAULIC FOUNDATION BRAKES 5A3-17

BRAKE DRUM REMOVAL AND Do this several times to ensure accurate

INSTALLATION (WITH AUTO-ADJUSTER) adjustment.

1. Block vehicle wheels and apply the parking

brake.
2. Raise the axle to clear the tire from the ground.
Position jack stands under vehicle.

[es] Remove or Disconnect (Figure 36)

1. Wheel and tire assembly and brake drum and

hub assembly.
» Pushing the rod and rotate adjusters at back
of the brake to provide clearance between
lining and drum (figure 36).
« Refer to WHEELS AND TIRES (SEC. 3E) in Adjuster
this manual.
¢ Refer to REAR AXLE (SEC. 4A1) in this
manual. Figure 37. Brake Lining Clearance

BRAKE LININGS
Brake Shoe Relining
Brake linings on these models are riveted to the
brake shoes and may be replaced. These linings
may be purchased in replacement sets of eight
linings and sufficient rivets of correct specifications
for the front or rear axle. Refer to Parts Book for
lining replacement kits. When replacing linings, be
sure that shoes have been thoroughly cleaned and
all burrs or rough spots have been removed from
shoe surface. DO NOT use shoes with elongated
rivet holes. Install linings in a manner that will
prevent gaps between lining and shoe.
Figure 36. Removing Brake Drum Do not let brake fluid, oil, or grease tough the
brake lining.
[><] Install or Connect (Figure 37) Riveting New Linings and Shoes
1. Set the brake shoe outside diameter so that the Before riveting new linings and shoes be sure
brake lining clearance is approximately 0.6 mm shoe and lining contact faces are clean. Have rivets
(0.024 in). of the correct body diameter, head size and shape,
Check the clearance at three positions (A, B length, and material ready for use.
and C). 1. Remove old linings by drilling out rivets.
This will facilitate brake lining clearance Punching out rivets may distort or damage the
adjustment after brake drum installation. shoe rim. File off any burrs or high spots.
2. Hub and drum assembly and wheel and tire 2. Clamp the lining to the brake shoe with C-
assembly. Adjust wheel bearings. clamps so the rivet holes in both pieces are in
- Refer to WHEELS AND TIRES (SEC. 3E). alignment.
« Refer to REAR AXLE (SEC. 4A1). Keep hands clean while handling brake linings.
3. Rotate the brake drum. 3. Locate the C-clamps as close as possible to the
Depress the brake pedal as far as possible. rivet holes; clamp firmly in position.
4. Repeat Step 3 five times to automatically adjust 4. Start riveting at center of shoe and lining and
the brake drum clearance. work toward the ends.
5. Drive rivets squarely into the holes with a flat
NOTICE: Brake lining clearance can also be head drift.
automatically adjusted by depressing the 6. Form the rivet heads with the correct tubular
brake pedal as far as possible with the vehicle rivet set. A roll set is recommended as a star
in motion. set might split the tubular end and then the rivet
 5A3-18 HYDRAULIC FOUNDATION BRAKES

will not fill the hole. BRAKE DRUMS

7. After riveting is completed, check lining to shoe
contact with 1.0 mm (0.04 in) feeler gage. Brake drum installations are illustrated and
Measure midway between rivets. It should not removal described in REAR AXLE (SEC. 4A1) in
be possible to insert a 1.0 mm (0.04 in) feeler this manual.
gage between the lining and shoe.
Brake Drum Checks
Brake Lining Checks
The brake drum and linings should be checked
The following procedure is for use when brake whenever a wheel and drum assembly is removed
action is unequal, severe, hard, noisy, or otherwise from the vehicle.
is unsatisfactory and the brake linings have had
little wear. Inspect
1. Check fluid level in master cylinder reservoir.
Add fluid as necessary. Tool Required:
2. Check brake pedal for proper feel and return. Starrett No. 124, Inside Micrometer, or
3. Remove wheels and drums. Brake pedal must equivalent.
not be operated while drums are removed. 1. Visually check drum for cracks, scoring, pitting,
4. Clean and inspect drums. Replace or or grooves.
recondition as necessary. . Check edge of drum for cracks or broken areas.

Go PO
5. Clean brake assemblies. Inspect linings for . Drum should not be “blue” inside, glazed
uneven wear, oi! soaked, embedded foreign (glassy appearance), or severely heat-checked.
material, and loose rivets. If linings are oil Severe heat-check will cause rapid lining wear.
soaked, they should be replaced. These conditions are a result of severe
6. If linings are otherwise serviceable, tighten or overheating, possibly from too thin remachined
replace loose rivets, remove embedded foreign drums, not complete or spotty lining contact,
material, and clean rivet counterbores. incorrect linings, or overloading of the vehicle.
7. If linings at any wheel show a spotty wear A probable driver complaint would be brake-
pattern or uneven contact with brake drum, it is fade.
an indication that the linings are not centered in 4. If linings appear unevenly worn, check the drum
the drums. Linings should be circle ground to for barrel-shaped or bell-mouthed (taper)
provide better contact with the drum. condition. Maximum allowable taper is 0.08 mm
8. Check and torque brake assembly mounting (0.003 in) measured from outside edge to base
bolt nuts. of drum to lining contact surface.
5. Check for out-of-round condition on the
Brake Lining Replacement Check diameter using an inside micrometer, Starrett
Brake linings are considered to be worn out when No. 124, or equivalent. Measure drum at the
worn down to the rivet heads; however, it is front and rear of the machined surface at a
minimum of 4 locations (45 degrees apart) and
suggested that, for practical reasons, linings be
replaced when found to be worn to 1.0 mm (0.04 in) record the readings. A maximum of 0.38 mm
over the rivet heads (figure 38). (0.015 in) out-of-round is allowed. A typical
driver complaint would be pulsating brakes.
6. Remove drum from wheel and inspect for stress
cracks at mounting bolt holes.
1
Servicing Brake Drums
CAUTION: When servicing wheel brake parts, do
not create dust by grinding or sanding brake
linings or by cleaning wheel brake parts with a dry
brush or with compressed air. Many wheel brake
parts contain asbestos fibers which can become
airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may
cause serious bodily harm. A water-dampened
1. Clearance to Rivet Head cloth or waterbased solution should be used to
1.0 mm (0.04 in) remove any dust on brake parts. Equipment is
commercially available to perform this washing
Figure 38. Lining to Rivet Clearance function.
 HYDRAULIC FOUNDATION BRAKES 5A3-19

These wet methods will prevent asbestos fibers available to aid in replacement of drums or linings.
from becoming airborne. 1. Measure brake drum inside diameter using tool
J-22364-01 (figure 39).
Clean the outside of.the drum of mud, dirt, rust, or 2. Turn adjusting knob to desired clearance,
other accumulation of materials. Clean inside of approximately 0.8 mm (0.03 in) is
drum with a water-dampened cloth. Do not paint the recommended 0.4 mm (0.015 in) to each side
outside of the drum. Paint will act as an insulator (figure 40).
and prevents rapid heat dissipation. . Adjust brake shoes to just touch tool.
. install hub and drum assembly.

&
New drums must have the protective coating
removed from the friction surface before being
placed in service. Use a suitable non-toxic,
greaseless type and wipe the surface clean with
clean cloths.

NOTICE: Do not use gasoline, kerosene, or other

oil base solvents. These solvents may leave an \S
oily residue on the surface which is damaging to
the brake linings and is flammable.

A drum with slight scores or grooves should be

polished with fine emery cloth. A grooved drum, if
used with a new lining, will not only wear the lining
quickly but also will not obtain efficient brake
performance.
Severe scoring, pitting or grooves, and barrel-
shaped, bell-mouthed, or out-of-raund condition, 1. J-22364-01
and severe checking requires the drum to be
replaced.
A cracked drum is unsafe for further service and Figure 39. Measuring Brake Drum Inside Diameter
must be replaced. Do not weld and reuse a
cracked drum.

Machining
Machining or grinding of brake drums increases
the inside diameter of the drum and changes the
lining to drum fit. When machining drums, it is
recommended that the maximum oversizes listed
not be exceeded.

Drum Diameter
Original Discard
320 mm (12.60 in) 322 mm (12.68 in)

When it is found that machining to this maximum

limit does not provide a suitable braking surface,
discard the worn drum and replace with a new
standard drum.

NOTICE: Do not exceed these limits. This is a

safety precaution. With severely worn drums, the
possibility of drum failure increases and
subsequent brake malfunction. 1. J-22364-01
2. Adjusting Knob
Replacement
Refer to REAR AXLE (SEC. 4A1) in this manual Figure 40. Setting Drum to Lining Clearance
for brake drum replacement procedure.
Drum to Lining Clearance Gage J-22364-01 is
 5A3-20 HYDRAULIC FOUNDATION BRAKES

SPECIFICATIONS
FOUNDATION BRAKES
Brake Type
Front: All MOdEeIS 0.0.0... cc cseccsccsscessseneassnaetscnesseseesuseessseustssssessssevasessessassusaessssasassassssasescassancececceeeeces Disc
Rear: All Models ............cccssssssesseseecesssessessssesssarsucnevssssuvsuuessacausatssesseaectenscenseees Drum-Dual Two Leading
ACJUStMEONE oo. cesecesescscssenceesssnseancsesscecsessesssuasstssauseuesssvacsaeusucessesusssssucsasasscsessvsuvassusatsasuecsessuteciecececeeeeees Self

Lining Size
Length GVWR 12,000 ID oo... ce eeccessscseesssessusessreessevsessscusesesssussuaeseasevsusssisescesensssecereeses 307 mm (12.1 in)
GVWR 14,500 and 17,950 Ib oo... ccccccecsssecsscsssscsenscssstoacsucarcsusssesscsccevsesteesneses 335 mm (13.2 in)
Width GVWR 12,000 1b 000... ceccceecsseccessseesevsueesenaesevsescecasesevaeestestesaueacesiesaesssesacsaceececcecs 75mm (3.0 in)
GVWR 14,500 ID ooo. cceesescsssneecsuseneucsusuesssessssensssensevaueacessneccuasuesseranacenseeesces 100mm (3.9 in)
GVWR 17,950 ID oc ceeceeesseceesesesssenescsuesesnsusessesessuseeessuesassvausauseasseuseuseacanseness 120mm _ (4.7 in)
Thickness GVWR 12,000 ID oo. ee ecccseseessesseessenssesnseecsususssessuacevassserseesersecsracsaseusesess 9.6mm _ (0.38 in)
GVWR 14,500 and 17,950 Ib oo... eee seceecesesssscssevssscssessteasuectsessaeceuessanerssuss 11.0 mm (0.43 in)
Lining to Drum Clearance... cccccssececsesesesessecreersenstssucscnansesavecetsererseeses 0.26 mm (0.01 in) (6-9 Notches)
Lining to Revet Clearance ooo... cesecesscsteccseusnesssusesseseseusissscssesessteeensueecessuarssspenseccssuueenes 1.0 mm (0.04 in)

Shoe Return Springs

GVWR 12,000 Ib uw... Rear Brake
Free Length ..........cecccsceeesenes cedevuueseseuaeeeesneesareereeesensa 208.0mm (8.19 in)
Set LENQHh 0... seeeesesneecessneusenseeuecsnsaseesesaseeennees 224.0 mm (8.82 in)
Set LOAM ooo... ceesceevsesnesentesueesusnenseacueres 220.6-269.7 N (49.6—60.6 Ib)
GVWR 14,500 Ib ou... Rear Brake
Fr@@ LENG oo... eesstecescssceeccssnesesssneasensencoasceseeseesuans 198.4 mm (7.81 in)
Set LEngth ooo... cceccssseeccesseevsssecessnseseverestserseneenss 219.1 mm (8.63 in)
Set LOA ooo ecesnseessseeeensenseuesneeeneeees 220.6-269.7 N (49.6-60.6 Ib)
GVWR 17,950 Ib oe Rear Brake
Free LOMGtn o.oo... cencsssecenecsssnecauecsucsesenserneeeeeceneneeanss 197.7 mm (7.78 in)
Set LONG ooo escecessessaccevessusveuseenuescessnsnseeesesemnanss 219.1 mm (8.63 in)
DOt LOA’ oo... cececntscsecessesesnaneepeanssnsccsansnseersne 291-356 N (65.5-80.0 Ib)

Wheel Cylinder
GVWR 12,000 Ib oo... Rear Brake
Inside Diameter .............cesessececcsseeeeessecuesseeuteenss 26.99 mm (1.0626 in)
Piston Clearance ..0.......ccccecsesseaceneens 0.02-0.105 mm (0.0008--0.0041 in)
Piston Clearance Limit .............cencssccossessscseccsresessenee 0.15 mm (0.0089 in)
GVWR 14,500 Ib oo... Rear Brake
INSide DiaMeter .............ccccrcsescesesscessseesssensecsreseeeens 30.16 mm (1.1874 in)
Piston Clearance .........cccccsccsseeseceees 0.03—-0.126 mm (0.0012-0.0050 in)
Piston Clearance Limit ..........scccssccessessnsccseseseeessees 0.15 mm (0.0059 in)
GVWR 17,950 Ib ............. Rear Brake
Inside Diameter ................. ped ceueeenenucceaseueuereneusensuans 33.34 mm (1.313 in)
Piston Clearance ........ccccceesseseveseeesens 0.025—0.126 mm (0.001-G.005 in)
Piston Clearance Limit ............cc:ccscssecessssesenscnseseenes 0.15 mm (0.0059 in)
 HYDRAULIC FOUNDATION BRAKES 5A3-21

Disc
Diameter GVWR 12,000 and 14,500 bo ooo. ee eceaeeeeeetnereeneuecnseeesaseresecesenereerneneseseneneese 293mm (171.5 in)
GVWR 16,500 ID oo... cece ccecssneeeceneeeercesneeeesnussuseaaansenesaeessesnsnaeeeeeseneeeeeneeneneene 363mm (14.3 in)
Pad THICKNESS ........c cc ccccccsceceeeeceeseureeceeeeeeeeeteneteseneseesendeevenoneenionentiaensenseeninenneneene Standard 13 mm (0.51 in)
Limit 1 mm (0.04 in)
Piston and Cylinder Clearance.........cceccccssseeeserseeeeenesertnaeesees Standard 0.08-0.18 mm (0.0031-0.0071 in)
LUMI... eee eee eect ee eneen renee 0.23 mm (0.009 in)

Brake Drum
Inside Diameter ..........ccceeesecseesscencecesccoeanesneeeeeenesseuneeeuenensedeneredoeneegaceneresueeeaoanersenteeeeneees 320 mm (12.60 in)
Inside Diameter Limit ...........cc cece cseesessseseeeeeteeneseuuacucamemeeneseeeueseusueaueeseneceanananonaadaneeaeas 322 mm (12.68 in)
Width GVWR 12,000 Ib .i.cc.ccccceecccseseccesseerereteseuesesssnesnecaeeseneneeeesceneuaeeseacseaeeneeneceeesnaenenaaes 75 mm (2.95 in)
GVWR 14,500 ID o.oo... ceecececseecessereseesseeeressenseeseenaeeenes sa aneceeseeeseuecseceneasaetentenssneseseoae 100mm (3.94 in)
GVWR 16,500 ID ....cceccceecccesseerceseeecssesecsnesesuenseceeseeseeeeeessneeerseeserseeestaeeneasaseeanenes 120mm (4.72 in)

FASTENER TORQUES

Wheel Cylinder Mounting Bolts

GVWR 12,000 Ib Rear Brake ..........ccecessseceueessseseeneeeeersnnneranes bpvpunecneaueneenceeseeranentteseessenes 44 N-m (33 Ib-ft)
GVWR 14,500 Ib Rear Brake .......ceccseescecessecesneeseeaeenscueesnecerneeersneeerenesenpnesesneeneenaeesenennngs 75 N-m (55 Ib-ft)
GVWR 16,500 ib Rear Brake .......ccccsccnsceserseseeerssnseecseescenseneeseeaeeeseuaasesnesensnanersesesseneeeeas 94 N-m (69 Ib-ft)

Rear Mounting Plate Bolts

GVWR 12,000 and 14,500 ID... ceccececeessessesecuenaeceesennessusseucarsnnenseeessneaneusnesessemessonns 108 N-m (80 Ib-ft)
GVWR 16,500 too. cccceceseesereteeesenancneernsecsusneceesusecsesnueceateniastiseersnaneauceaeeneessanensaeenes 157 N-m (116 lb-ft)

Brake Pipe Nut ...........:cceccesssesereeeeetereneneren aueveauasaeceseeeecenucceseeaececscneceesaesesasuesaessanensnssesenensenss 15 N-m (11 Ib-ft)

Disc Brake Caliper
Support Fixing BoltS 0... eeseeesesenecsceeecererteenesiessneseneesssnnensosaesaeneresenessnearesaneressenes 221 N-m (163 Ib-ft)
Adapter Fixing Bolts and Nuts ........ccccccsesecsesecntcssenneeesnenenneesneereneeneaseeraescesassnaneneeenes 162 N-m (119 Ib-ft)
Wind Guide Bolts ............c.c.ccccccssessssncrccnnccccemenensenaenenesmeeueeenaseseseaeeneuserenseneeeenseusussengneeens 13 N-m (113 Ib-in)
LOCK Pin Bolt ...ccccccccccccsccccsessesseecusceeconssncecteeneeteeseeaeanunsenseceassevensesnnegaenaseseeeasteuseceuarenseens 137 N-m (101 Ib-ft)
Flexible Hose Bolt .......0...ccccccccssccesssssnsescseeeescsscessesnesueemensncosanssccaeesoremsssasusansaacaneausseseaensceaeaeneas 34 N-m (26 Ib-ft)
Bleeder SCrew. ......-ccscsesseeseseneees duoesuetucueaacessvenecucsnsacanseacanesaccaeconeneeceserenensaneesenaeenesenerenerenteneeeny 10 N-m (7 lb-ft)

SPECIAL TOOLS

TOOL NO.
ILLUSTRATION TOOL NAME

J-34913
Tension Scale

J-22364-01
Drum Clearance Gage
MEMO
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-1

SECTION 5A4

ANTI-LOCK BRAKE SYSTEM (ABS)

CONTENTS

Service Precaution. .........0..ccesceesneeeesseereres 5A4 - 2 Chart A-5,TA-5 Braking Sound (From

General Description ........... cece eeeeneneeeenes 5A4 - 3 Hydraulic Unit) is Heard While Not
System ComponentS .......c cece 5A4 -3 Braking oc ect teerrerecerenereaees 5A4 - 31
Electronic Brake Control Module (EBCM) . 5A4-3 Diagnostic Trouble Codes |... 5A4 - 32
Hydraulic Unit (HU)... cccecereereee errr cnees 5A4 - 3 Diagnosis By “ABS” Warning Light |
ABS Warning Light: ............eeeeeseentterenees 5A4 - 4 llumination Pattern... cere eee 5AA4 - 34
Wheel Speed Sensor ............ceceterrerereiees 5A4 - 4 Diagnostic Trouble Codes (DTCs) ............. 5A4 - 34
Normal and Anti-lock Braking ............0... 5A4 - 4 Chart B-1-1 With the key in the ON
Brake Pedal Travel ...........:.cceccsserereeen 5A4 - 4 position(Before starting the engine).
Acronyms and Abbreviations ..............205 5A4 - 4 Warning light(W/L) is not activated. ......... 5A4 - 37
General Diagnosis ......... cee cceeeteseeertneenes 5A4-5 Chart B-1-2 (DTC 20) Reference Voltage
General Information .0........cceeeetneeeee 5A4 -5 HIGH... cee cece reer ree tee tees ceen een egies 5A4 - 38
ABS Service Precautions ..........eee 5A4 -5 Chart B-2 (DTC 14 / C0271) EBCM
Computer System Service Precautions ..... 5A4-5 Abnormality 2.0.00... cence eee bette 5A4 - 40
General Service Precautions ...............00 5A4 - 5 Chart B-3 (DTC 15 / C0277) Low Power
Note on IntermittentS ......00.0. 0 eeeceeeees 5A4 -5 AYL8)|C-0, - cE 5AA - 40
Test Driving ABS Complaint Vehicies ....... 5A4-5 Chart B-4 (DTC 25 / C0299) Exhaust
“ABS” Warning Light ............:ccccceeereeeees 5A4 -6 Brake Cut Relay Abnormality ...........0.... 5A4 - 44
Normal Operation .........ccccccseceeecreeeeneees 5A4 - 6 Chart B-5 (DTC 33 / C0267) Motor Relay
Basic Diagnostic Flow Chart ............:c0 5A4 -7 Abnormality 2000000 ei ctenetrereereen ines 5AA - 42
Basic Inspection Procedure ...........:cee 5A4 -7 Chart B-6 (DTC 34 / C0268) Abnormal
Tech 2 Scan TOO oo... eseeseeeeerenneeees 5A4 - 8 Motor Rotation... ener 5A4 - 43
Tech 2 Features 00... ccc cseeteceninesccenes 5A4 -9 Chart B-7 (DTC 41 / C0265) Solenoid
Getting Started oo... eeeer teeter rtenieee 5A4 -9 ee 5A4 - 44
Valve Relay Abnormality ........0...0:
Operating Procedure (For Example) ......... 5A4 - 10 Chart B-8 (DTC 42/ C0241) Abnormal
DTC MOd@S .....cec ec eececesteetsrersreeesneenenees 5A4 - 11 Solenoid Valve Power Line «0.0... 5A4 - 46
DTC Information Mode ........... cece 5A4 - 11 Chart B-9-1 (DTC 43 / C0241) Open or
Plotting Snapshot Graph... eee 5A4 - 12 Shorted Solenoid Valve(FL Valve) ........... 5A4 - 48
Plotting Graph Flow Chart (Plotting Chart B-9-2 (DTC 43 / C0241) Open or
graph after obtaining vehicle Shorted Solenoid Valve(FR Valve) .......... 5A4 - 49
TPOPATION) ose eee eres ssn este eeseeeneeeenaneraeneen 5A4 - 13 Chart B-9-3 (DTC 43 / C0241) Open or
Flow Chart for Snapshot Replay Shorted Solenoid Valve(RL Valve) .......... 5A4 - 50
(Plotting Graph)... cece a. 5A4- 14 Chart B-9-4 (DTC 43 / C0241) Open or
Tech 2 Data Display .........c ccs 5A4 - 15 Shorted Solenoid Valve(RR Valve) .......... 5A4 - 51
Special FUNCHION ....... cece nseeetees 5A4 - 15 Chart B-10-1 (DTC 45 / C0242) Shorted
EBCM Connector Pin-out Checks ............. 5A4 - 22 Solenoid Valve Circuit (FL Holding Valve) 5A4 - 52
Circuit Diagram oo... cece eenereeteees .. 5A4 - 24 Chart B-10-2 (DTC 45 / C0242) Shorted
Connector List 0... cece cee cceneeeeneeneens 5A4 - 26 Solenoid Valve Circuit (FR Holding
Part LOCALION oo... cece ceeesnettenetseeeeeeeneeee? 5A4 - 27 A)=) ES 5A4 - 53
Symptom Diagnosis.......... ccc ern 5A4 - 28 Chart B-10-3 (DTC 45 / C0242) Shorted
Chart A-1 ABS Works Frequently But Solenoid Vaive Circuit (RL Holding
Vehicle Does Not Decelerate .................. 5A4 - 28 VAIVE) oc ere erect nieriree .. 5A4 - 54
Chart TA-1 ABS Works Frequently But Chart B-10-4 (DTC 45 / C0242) Shorted
Vehicle Does Not Decelerate Solenoid Valve Circuit (RR Holding
(Use TECH 2) oo cccccceecceeerssetetettererestes 5A4 - 28 VAIVE) occ cece eee teeccnnteneerenneaseneateeriaees 5A4 - 55
Chart A-2 Uneven Braking Occurs While Chart B-10-5 (DTC 45 / C0242) Shorted
ABS WOrKS ooo cect eeetiseeneeecesecnseeneaes 5A4 - 29 Solenoid Valve Circuit (FL
Chart A-3, TA-3 The Wheels Are Locked .. 5A4 - 29
Decompression Vaive) ...........c cee 5A4 - 56
Chart A-4 Brake Pedal Feed Is Abnormal . 5A4 - 30
5A4—2 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-10-6 (DTC 45 / C0242) Shorted PROCOGUIG ooo. cecccccesccesesseessessseecsseaeceeveees 5A4 - 75
Solenoid Valve Circuit (FR Hydraulic Unit cc cccccsecssssscenerseseersenes 5A4 - 77
Decompression Valve) ........0.cccceees 5A4 - 57 Hydraulic Unit and Associated Parts .......... 5A4 -77
Chart B-10-7 (DTC 45 / C0242) Shorted REMOVAL... ec ccccecccceceeesercesetessessvessesseneres 5A4 - 77
Solenoid Valve Circuit (RL Installation... ccc ccceccccsseccceesssecnseevnneens 5A4 - 78
Decompression Valv@) ...........ccccen 5A4 - 58 HU Relay Box uo... cc ccccscessessssseesesnesnrsecees 5A4 - 79
Chart B-10-8 (DTC 45 / C0242) Shorted REMOVAL... cececcsccsseeenssetecccssseptaeeneneras BAA - 79
Solenoid Valve Circuit (RR Inspection and Repair... 5A4 - 80
Decompression Valve@) .......... eer 5A4 - 59 Prstallation 2... ecececccesecssessceseecnsersseesees 5A4 - 80
Chart B-17 (DTC 51 / C0225) Open or Electronic Brake Control Module (EBCM) ..... 5A4 - 84
Shorted FL Speed Sensor Circuit ............ 5A4 - 60 REMOVAL... acececcceseecseeesevessescevenesberseenses 5A4 - 81
Chart B-12 (DTC 52 / C0221) Open or Wstallation occ eeccsecsseceevussssesrsvensesses 5A4 - 84
Shorted FR Speed Sensor Circuit ........... 5A4 - 61 Front Speed S@nsor........ cc ccesescsceenseneees 5A4 - 82
Chart B-13 (DTC 53 / C0235) Open or Front Speed Sensor and Associated
Shorted RL Speed Sensor Circuit ............ 5A4 - 62 PAI... ccc ceescetuesseeerseseceusseeseeuensusenseers 5A4 - 82
Chart B-14 (DTC 64 / C0231) Open or REMOVAL... ci cecceccccstesseteneecvessesueseunssersrs 5A4 - 82
Shorted RR Speed Sensor Circuit ........... 5A4 - 63 inspection and Repair...........0... cece 5A4 - 82
Chart B-15 (DTC 61/ C0226) Abnormal PStallatiOn oe cascecccsssccsssessssesecssnearenens 5A4 - 83
FL Speed Sensor Signal .............ee 5A4 - 64 Front Speed Sensor Rotor.......0.0000c ee 5A4 - 84
Chart B-16 (DTC 62/ C0222) Abnormal Front Speed Sensor Rotor and Associated
FR Speed Sensor Signal 0.0... 5A4 - 66 PAS. cece cetecteeeteceesesssseceuessiuseerseees 5A4 - 84
Chart B-17 (OTC 63/ C0236) Abnormal CLL: | 5A4 - 84
RL Speed Sensor Signal 0.0.0... cee 5A4 - 67 inspection and Repair... eee 5A4 - 85
Chart B-18 (OTC 64/.C0232) Abnormal Prstallation oo... ccccseescessnescssseceeseneernveas 5SA4 - 85
RR Speed Sensor Signal ....0...e 5A4 - 68 Rear Speed Sensor .........0.ccccccesseeersenes 5A4 - 86
Unit Inspection Procedure ooo... eee 5A4 - 69 Rear Speed Sensor and Associated
Chart C-1-1 FL Speed Sensor Output Part... ec ecceccsssesccseseceseseecenpeesssvecstnavenees 5A4 - 86
Inspection Procedure ..........cccececceeseeeeens 5SA4 - 69 REMOVAL... eee cececessceescnseceseasuerennanersas 5A4 - 87
Chart C-1-2 FR Speed Sensor Output Inspection and Repair... 5A4 - 87
Inspection Procedure ............cccccsceeeeees 5A4 - 70 Installation... ccceccscccesecessenecssereneeens 5A4 - 87
Chart C-1-3 RL Speed Sensor Output Rear Speed Sensor Rotor .............cceccccceenees 5A4 - 88
Inspection Procedure ..............cc cece 5A4 - 74 Rear Speed Sensor Rotor and
Chart C-1-4 RR Speed Sensor Output Associated Parts 0.0... ..cccccccccssscseseeeserenes 5A4 - 88
Inspection Procedure .....0....cccceeeceees 5A4 - 73 REMOVAL... ec eecceececcesnteeseensesesseceeessseanenies 5A4 - 88
Chart TC-1 Sensor Output Inspection Inspection and Repair... eens 5A4 - 88
Procedure (Use TECH 2) 000... ceeeeees 5A4 - 74 TSA ALON... eee ccceneeecesesenteeeversseeessas 5A4 - 88
Chart C-2 HU Relay Box Inspection Special TOS... csccccecsseseneeenseressnenees 5A4 - 90
Service Precaution
CAUTION: Always use the correct fastener in the
proper location. When you repiace a fastener, use
ONLY the exact part number for that application.
ISUZU will cail out those fasteners that require a
replacement after removal. ISUZU will aiso call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-3
when a wheel is about to stop turning and adjust brake
General Description
pressure to maintain best braking.
The Anti-lock Brake System (ABS) works on all four This system helps the driver maintain greater control of
wheels. A combination of wheel speed sensor and the vehicle under heavy braking conditions.
Electronic Brake Control Module (EBCM) can determine

coscyne+

Legend
(1) Hydraulic Line (7) Load Sensing Proportioning Valve (LSPV)
(2) Electronic Line (8) Battery
(3) Electronic Brake Control Module (EBCM) {9} ABS Warning Light
(4) Front Wheel Speed Sensor (10) Brake Switch
(5) Rear Wheel Speed Sensor
(6) Hydraulic Unit

System Components Hydraulic Unit (HU)

The Anti-lock Brake System consists of a Hydraulic The hydraulic unit is mounted on the frame near the
Unit, Electronic Brake Control Module (EBCM), four rear spring front bracket. It consists of a Motor, Plunger
Wheel Speed Sensors and Warning Light. Pump, Solenoid Valves and Check Valve.
On the outside, the relay box containing a motor relay
Electronic Brake Control Module (EBCM) and a valve relay is installed.
Solenoid Valves: Reduces or holds the caliper fluid
The EBCM consists of ABS control circuits, fault pressure for each front disc brake or both rear drum
detector, and a fail-safe. It drives the hydraulic unit brakes according to the signal sent from the EBCM.
according to the signal from each sensor, cancelling Reservoir: Temporarily holds the brake fluid that returns
ABS to return to normal braking when a malfunction has from the front and rear wheel brake so that pressure of
occurred in the ABS. front wheel brake can be reduced smoothly.
The EBCM is self-diagnosing function which can Plunger Pump: Feeds the brake fluid held in the
indicate faulty circuits during diagnosis. reservoir to the master cylinder.
The EBCM is located behind the glove box.
SA4—4 ANTI-LOCK BRAKE SYSTEM (ABS)
Motor: Drives the pump according to the signal from succession. The brake pedal puisation will continue
EBCM. Check Valve: Controls the brake fluid flow. until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or popping
ABS Warning Light noise may be heard during brake applications when the
Anti-lock features is being used.
When the Anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on the
pedal will provide the shortest stopping distance.

ABS Brake Pedal Travel

Vehicles equipped with the Anti-lock Brake System may
NN be stopped by applying normal force to the brake
— pedal. Although there is no need to push the pedal
me beyond the point where it stops or holds the vehicle, by
~ applying more force the pedal will continue to travel
4 2D 3 Mio Tans OO ABS toward the floor.
as This extra brake pedal travel is normal.
S71 BRAKE ul
[el AKE
tistn Mg
Acronyms and Abbreviations
Several acronyms and abbreviations are commonly
used throughout this section:
a2tLyoo3
Vehicles equipped with the Anti-lock Brake System ABS
have an amber “ABS” warning light in the instrument Anti-lock Brake System
panel. The “ABS” warning light will illuminate if a
CKT
malfunction in the Anti-lock Brake System is detected
Circuit
by the Electronic Brake Control Module (EBCM). In
case of an electronic malfunction, the EBCM will turn DLC
“ON” the “ABS” warning light and disable the Anti-lock Data Link Connector
braking function. DT¢c
The “ABS” light will turn “ON" after the ignition switch is Diagnostic Trouble Code
to the “ON?” position.
“ABS” light will normally go on and off two times and DVM
then will go out after the engine starting. Digital Volt Meter (High Impedance Multimeter)
lf the “ABS” light comes “ON” and stays “ON” while EBCM
driving, the Anti-lock Brake System shouid be inspected Electronic Brake Control Module
for a malfunction according to the diagnosis procedure.
FL
Wheel Speed Sensor Front Left

It consists of a sensor and arotor. The sensor is FR

attached to the knuckle on the front wheels and to the Front Right
bracket on the brake back plate on the rear wheels. GEN
The front speed sensor is coil type and rear is Halt IC Generator
type.
HU
The sensor rotors press-fitted to front and rear wheel
Hydraulic Unit
hubs output pulse frequency depending on wheel
rotation. MY
The speed sensors find vehicle speed from its Millivolts
frequency.
RL
Rear Left
Normal and Anti-lock Braking
RR
Under normai driving conditions, the Anti-lock Brake
Rear Right
System functions the same as a standard power
assisted brake system. However, with the detection of RPS
wheel lock-up, a slight bump or kick-back will be felt in Revolution per Second
the brake pedal. This pedal “bump” will be followed by a
series of short pedal pulsations which occurs in rapid
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—5
SW General Service Precautions
Switch
The following are general precautions which should be
vpc observed when servicing and diagnosing the Anti-lock
Volts DC Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock
VAC
Brake Systern damage.
Volts AC
* |f welding work is to be performed on the vehicle
WIL using an electric arc welder, the EBCM and valve
Warning Light block connectors should be disconnected before the
WSs welding operation begins.
Wheel Speed Sensor * The EBCM and valve block connectors should never
be connected or disconnected with the ignition “ON”.
General Diagnosis * The Hydraulic Unit of the Anti-lock Brake System are
not separately serviceable and must be replaced as
General Information assemblies. Do not disassemble any component
ABS malfunction can be classified into two types, those which is designated as non-serviceable in this
which can be detected by the ABS warning light and Section.
those which can be detected as a vehicle abnormality * {f only rear wheels are rotated using jacks or drum
by the driver. tester, the system will diagnose a speed sensor
in either case, locate the fault in accordance with the malfunction and the “ABS” warning light will
“BASIC DIAGNOSTIC FLOWCHART’ and repair. ituminate. But actually no trouble exists. After
Please refer to Section 5A for the diagnosis of inspection stop the engine once and re-start it, then
mechanical troubles such as brake noise, brake judder make sure that the “ABS” warning light does not
(brake pedal or vehicle vibration felt when braking), illuminate.
uneven braking, and parking brake trouble. If the battery has been discharged
The engine may stall if the battery has been completely
ABS Service Precautions discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS)
Required Tools and Items: requires a large quantity of electricity. In this case, wait
* Box Wrench until the battery is recharged, or set the ABS to a
* Brake Fluid nan-operative state by removing the fuse for the ABS.
After the battery has been recharged, stop the engine
¢ Special Tool
and install the ABS fuse. Start the engine again, and
Some diagnosis procedures in this section require the
confirm that the ABS warning light does not light.
installation of a special tool.

J-39200 High Impedance Multimeter Note on Intermittents

When circuit measurements are requested, use a circuit As with virtually any electronic system, it is difficult to
tester with high impedance. identify an intermittent failure. in such a case duplicating
the system malfunction during a test drive or a good
Computer System Service Precautions description of vehicle behavior from the customer may
be helpful in locating a “most likely” failed component or
The Anti-lock Brake System interfaces directly with the circuit. The symptom diagnosis chart may also be useful
Electronic Brake Control Module (EBCM) which is a in isolating the failure. Most intermittent problems are
control computer that is similar in some regards to the caused by faulty electrical connections or wiring. When
Engine Control Module. These modules are designed an intermittent failure is encountered, check suspect
to withstand normal current draws associated with circuits for:
vehicle operation. However, care must be taken to
* Suspected harness damage.
avoid overloading any of the EBCM circuits. In testing
for opens or shorts, do not ground or apply voltage to * Poor mating of connector halves or terminals not fully
any of the circuits unless instructed to do so by the seated in the connector body (backed out).
appropriate diagnostic procedure. These circuits should * Improperly formed or damaged terminals.
only be tested with a high impedance multimeter
(J-39200) or special tools as described in this section. Test Driving ABS Compiaint Vehicles
Power should never be removed or applied to any
In case that there has been an malfunction in the
contro! module with the ignition in the “ON” position.
lighting pattern of “ABS” warning light, the fault can be
Before removing or connecting battery cables, fuses or
located in accordance with the “DIAGNOSIS BY “ABS”
connectors, always turn the ignition switch to the “OFF”
WARNING LIGHT ILLUMINATION PATTERN”. In case
position.
5A4—6 ANTI-LOCK BRAKE SYSTEM (ABS)
of such trouble as can be detected by the driver as a
vehicle symptom, however, it is necessary to give a test
drive following the test procedure mentioned below,
thereby reproducing the symptom for trouble diagnosis
on a symptom basis:
1. Start the engine and make sure that the “ABS” W/L
goes OFF. if the W/L remains ON, it means that
the Diagnostic Trouble Code (DTC) is stored.
Therefore, read the code and locate the fault.
2. Start the vehicle and accelerate to about 30 km/h
(19 mph) or more.
3. Slowly brake and stop the vehicle compietely.
4, Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop
the vehicle.
6. Be cautious of abnormality during the test. If the W/
Lis actuated while driving, read the DTC and locate
the fault.
7. If the abnormality is not reproduced by the test,
make best efforts to reproduce the situation
reported by the customer.
8. if the abnormality has been detected, repair in
accordance with the “SYMPTOM DIAGNOSIS”.
NOTE:
* Be sure to give a test drive on a wide, even road with
little traffic.
« If an abnormality is detected, be sure to suspend the
test and start troubie diagnosis at once.

“ABS” Warning Light

When ABS trouble occurs and actuates when possible
the “ABS” warning light, the trouble code corresponding
to the trouble is stored in the EBCM. Only the ordinary
brake system is available when the ABS is turned off.
When the “ABS” warning light is actuated, if the starter
switch is set ON after setting it OFF once, the EBCM
checks up on the entire system and, if there is no
abnormality, judges ABS to work currently and the
warning light works normally even though the trouble
code is stored.
NOTE: Illumination of the “ABS” warning light indicates
that anti-lock braking is no longer availabie. Power
assisted braking without anti-lock control is still
available.

Normal Operation
“ABS” Warning Light
When the ignition is first moved from “OFF” to “ON”, the
amber “ABS” warning light will turn “ON”. The “ABS”
warning light will blink twice and will turn “OFF” after
engine is started.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—7

Basic Diagnostic Flow Chart

Step Action Yes No

1 1. Customer complaint.
2. Questioning to customer.
3. Basic inspection (Refer to “Basic inspection procedure’)
Using TECH 2? Go to Step 2 Go to Step 3
2 Make sure of DTC by TROUBLE CODE.
Is EBCM including DTC? Go to Step 5 Go to Step 4
3 Check if the DTC is stored.
Is EBCM including DTC? Go to Step 5 Go to Step 4
4 Test drive. Trouble diagnosis
is W/L lit? based on symptom
(Refer to
“SYMPTOM
DIAGNOSIS") Go
Go to Step 5 to Step 5
5 1. Repair of faulty part.
2. Elimination of DTC. Repeat the
3. Inspection of “ABS” W/L Illumination pattern with ignition SW | diagnosis if the
“ON”, symptom or DTG
4. Test drive. appears again Go
Dose repeat trouble? to Step 1 Go to Step 6
6 1. Reconnect all components and ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished? Finished Go to Step 6

Basic Inspection Procedure

1. Basic inspection of Service Brake
Step Action Yes No

1 Is the fluid level normal? Replenish with

fluid.
Go to Step 2 Go to Step 2

2 Does not fiuid leak? Repair.

Go to Step 3 Go to Step 3

3 Is the booster functioning normal? Repair.

Go to Step 4 Go to Step 4

4 Is the pad and rotor normal’? Repair.

Go to Step 5 Go to Step 5

5 Reconnect all components and ensure all components are

properly mounted.
Was this step finished? Finished Go to Step 5

2. Ground Inspection
Step Action Yes No

1 Are ABS—related ground points ok? Repair.

Go to Step 2 Go to Step 2

2 Reconnect all components and ensure all components are

properly mounted.
Was this step finished? Finished Go to Step 2
5A4-8 ANTI-LOCK BRAKE SYSTEM (ABS)
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2
scan tool user guide.

SOT RW1BG

Legend
(1) PCMCIA Cara {4} DLC Cable
(2) RS 232 Loop Back Connector (5) Tech—2
(3) SAE 16/19 Adapter
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-9
Tech 2 Features 6. Turn on the vehicle ignition.
7. Power the Tech 2 ON and verify the Tech 2 power
1. Tech 2 is a 12 volts system. Do not apply 24 volt.
up display.
2. After connecting and/or installing the Vehicie
Commumications Interface (VCl) module, PCMCIA
card and DLC connector to the Tech 2, connect the
tool to the vehicle DLC.
3. Make sure the Tech 2 is powered OFF when

‘Xd 0)
removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the
Tech 1 Mass Storage Cartridge.
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and
static electricity, so care should be taken in the Press (ENTER) To Continue
handling of the card.
7. The Tech 2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu by pressing the
EXIT key several times before shutting down.
9. To clear Diagnostic Trouble Codes (DTCs), open
V60RWO0S
Application Menu and press “F1: Clear DTC Info”.
NOTE: The RS232 Loop back connector is only to use
for diagnosis of Tech 2. Refer to user guide of the Tech
Getting Started
2.
« Before operating the isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The isuzu 2000 Model year System PCMCIA card
(1) inserts into the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech 2 (5).
. Make sure the vehicle ignition is off.
if

5. Connect the Tech 2 SAE 16/19 adapter to the

vehicle DLC.

Data link
connector
oe,

ot
Web lsle zs)
[9 Fup ia] ists)

B2BLYo93
5A4—10 ANTI-LOCK BRAKE SYSTEM (ABS)
Operating Procedure (For Example)
The power up screen is displayed when you power up
the tester with the Isuzu systems PCMCIA card. Follow
the operating procedure below.
Vehicle Identification
Select one of the following
Vehicle Type(S)

xan
ISUZU

' ISUZU )
Press (ENTER) To Continue ENTER
System Selection Menu
(Y)2000 ISUZU

FG : Powertrain
Fi : Service Programing | Fi : Chassis |
F2 : View Captured Data

F3: Tool Options ’ (F1 ENTER)

F4: Getting Started
Vehicle Identification
’ (FO) Select one of the following
ISUZU Line8 Chassis
Vehicle Identification
Select one of the following NPR/NQR
Model Year(S) Other
patentee

(Y} 20000
(X} 1999
(Y) 2000
¥ (2000,ENTER)

oSOMY OOS
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-11
Menu
* The following table shows which functions are used
for the available equipment versions.
Diagnostic Trouble Codes

FO: DTC Info

Chassis
Fi: Clear DTC Info
FO : Diagnostic Trouble Codes

F
: Data Display
—

F2 : Special Functions

F3 : Snapshot

D6OMYO01

The following is a brief description of each of the sub

menus in DTC Info and DTC. The order in which they
appear here is alphabetical and not necessarily the way
OGOMY OOS
they will appear on the Tech 2.
DTC Modes
DTC Information Mode
Use the DTC info mode to search for a specific type of
stored DTC information. There are two choices. The
service manual may instruct the techinician to test for
Chassis DTCs in a certain manner. Always fotlow published
service procedures.
FO : Diagnostic Trouble Codes

F1 : Data Dispiay
DTC Information
F2 : Special Functions
FO : Current Diagnostic Trouble Codes
F3 : Snapshot
Fi: History Diagnostic Trouble Codes

OGOMYGOS

There are two options available in Tech 2 DTC mode to

display the enhanced information available. After
selecting DTC, the following menu appears.
« DTC Info
* Clear Info osOMYODZ
5SA4—-12 ANTI-LOCK BRAKE SYSTEM (ABS)
DTC Status

Current Diagnostic Trouble Codes

This selection will display all DTCs that have failed
during the present ignition cycle.

History Diagnostic Trouble Codes

This selection will display only DTCs that are stored in
the EBCW’s history memory.

Plotting Snapshot Graph

This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. This test can check ABS performance and
defect by graphing wheel speed differences between
right and left sides, and front and rear sides obtained
fram the ABS data list menu.

— Left Front Wheel Speed

osomyvooy

For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed.
Therefore, accurate diagnosis is possible, even though
the vehicle is not available.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—13

Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)

Procedure Based on Trigger

Procedure Based on Data Display
Type Decision

Alter confirming FLOW “MAIN MENU Alter confirming FLOW “MAIN MENU
DIAGNOSIS’ -ID, select “DATA DIAGNOSIS’ -ID, select “SNAP
DISPLAY” fram APPLICATION MENU. SHOT” from APPLICATION MENU.

After display of vehicle data,

Select when the items have
select “QUICK SNAPSHOT” lower
been displayed.
part of the monitor screen.

Alter display of snapshot

option, decide on a trigger
type, and select “RECORD
SNAPSHOT”, under screen.

|
it (STANDBY) blinks, upper
After lapse of some time, push
right of screen, select
“EXIT” button.
“TRIGGER”, under screen.

Confirm the trigger type.

li “CONTINUE” is displayed
under screen after the screen
is changed, select.

if “PLOT” is displayed under screen,

select “PLOT”.

When changed to the item selecting screen,

push the enter key in accordance with the
items up to three items, and select “ACCEPT”,
under screen.

The graph is displayed on teh screen.

5A4—14 ANTI-LOCK BRAKE SYSTEM (ABS)
Flow Chart for Snapshot Replay (Plotting Graph)

Press the enter-key in initial display.

Select "VIEW CAPTURE DATA"

if snapshot option is displayed, decide on a

trigger type, and siect “REVIEW DATA’ under
screen.

When the data triggered by vehicle is displayed,

select the data.
(Plural display of data depending on the number
of times of triggering.)

data is displayed on the screen.

To see the graph, select “PLOT under screen.

Changed to the item selection screen, push the

enter key up to three times, and select “ACCEPT”
under screen,

The graph is displayed on the screen.

OGORXO4O
 ANTI-LOCK BRAKE SYSTEM (ABS) SA4—-15
Tech 2 Data Display Special Function
Use the Tech 2 Data Values only after the ABS There are 12 different menus available for this test. The
Diagnostic System Check has been completed, no state of each circuit can be tested by using these
DTC(s) were noted, and you have determined that the menus. Especially when DTC cannot be detected, a
on-board diagnostics are functioning properly. Tech 2 faulty circuit can be diagnosed by testing each circuit by
values from a properly-running engine may be used for means of these menus.
comparison with the engine you are diagnosing. Even when DTC has been detected, the circuit tests
using these menus could help discriminate between a
ABS Data mechanical trouble and an electrical trouble.
Ignition SW is “ON” position. in all cases test condition; Engine stops with the key
turned to the “ON” position. To be more specific, the test
(For example) is conducted with the brake pedal stepped on after
stepping once and releasing.
* Engine: Stop
* Ignition SW: ON
* Brake Pedal: ON-OFF-ON
F1; ABS DATA If the Ignition SW was turned OFF or communication
Lefi Front Wheel Speed 2mph was lost, make sure to apply the brake pedal ON-OFF-
Right Front Wheel Speed 2mph ON once again and then continue the test.
Left Rear Wheel Speed 2 mph
Right Rear Wheel Speed 2mph
Brake Switch Status OFF
ABS Lamp Command OFF Special Functions
ABS Pump Motor OFF
LR Release Valve Command OFF ABS Warning Lamp
LR Hold Vaive Command OFF
AR Release Valve Command OFF ABS Relay
RAR Hold Valve Command OFF
LF Release Valve Command OFF
ABS Motor
LF Hold Valve Command OFF
RF Release Valve Command OFF
Exhaust Brake Cut Relay
RF Hold Valve Command OFF
LR Release Valve Feed back OFF
Right Ft Release Valve
LR Hold Valve Feed back OFF
RAR Release Vaive Feed back OFF
Right Fi Hoid Valve
RR Hold Valve Feed back OFF
LF Release Valve Feed back OFF
LF Hold Valve Feed back OFF
Left Ft Release Valve
RF Hold Vaive Feed back OFF
RF Release Valve Feed back OFF
Left Ft Hold Valve
Battery Voltage 12~-16V
Left Rr Release Valve

Left Rr Hold Vaive

Select oTc Quick More
items Snapshot Right Rr Release Valve

Right Rr Hold Valve

ogomyoos.

OoOMYOOs
5A4—16 ANTI-LOCK BRAKE SYSTEM (ABS)
ABS Warning Lamp ABS Relay
Test condition: Engine stops with the key turned to the
Test condition: Engine stops with the key turned to the
“ON’ position. To be more specific, the test is conducted
“ON” position. To be more specific, the test is conducted
with the brake pedal stepped on after stepping once and
with the brake pedal stepped on after stepping once and
releasing.
releasing.
Make sure of the working sound of the ABS relay.
* The circuit is normal if the warning light in the meter The circuit is normal if the working sound of the ABS
panel comes on and goes out in accordance with relay is made in accordance with Tech2’s instruction.
Tech2’s instruction.

Special Functions
Special Functions
ABS Warning Lamp
ABS Warning Lamp

ABS Relay
ABS Motor
ABS Motor
Exhaust Brake Cut Relay
Exhaust Brake Cut Relay
Right Ft Release Valve
Right Fi Release Vaive
Right Ft Hold Valve
Right Ft Hold Valve
Left Ft Release Valve
Left Ft Release Valve
Left Ft Hold Valve
Left Ft Hold Vaive
Left Rr Release Valve
Left Rr Release Valve
Left Rr Hold Valve
Left Rr Hold Valve
Right Rr Release Valve
Right Rr Release Valve
Right Rr Hold Valve
Right Rr Hold Valve

OGOMYD12

aGOMYO1O
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-17
ABS Motor Exhaust Brake Cut Relay
Test condition: Engine stops with the key turned to the Test condition: Engine stops with the key turned to the
“ON” position. To be more specific, the test is conducted “ON” position. To be more specific, the test is conducted
with the brake pedal stepped on after stepping once and with the brake pedal stepped on after stepping once and
releasing. releasing.
Make sure of the working sound of the ABS motor. Make sure of the working sound of the exhaust brake
The circuit is normal if the working sound of the ABS cut relay.
motor is made in accordance with Tech2’s instruction. The circuit is normal if the working sound of the exhaust
brake cut relay is made in accordance with Tech2’s
instruction.

Special Functions

ABS Warning Lamp Special Functions

ABS Relay ABS Warning Lamp

ABS Motor ABS Relay

Exhaust Brake Cut Relay ABS Motor

Right Ft Release Vaive

Right Ft Hold Valve Right Ft Release Valve

Left Ft Release Valve Right Fi Hold Valve

Left Ft Hold Valve Left Ft Release Valve

Left Rr Release Valve Left Ft Hold Valve

Left Rr Hold Valve Left Rr Release Valve

Right Rr Release Vaive Left Rr Hold Valve

Right Rr Hold Valve Right Rr Release Vaive

Right Rr Hold Valve

OBOMYOI1

Osemyo16
5A4-18 ANTI-LOCK BRAKE SYSTEM (ABS)
Hold Valve Test Test procedure:
Purpose: The purpose of this test is to detect brake pipe 1. Connect Tech 2 with the vehicle, and select Special
and valve line harness wire wrong connections and Function from the menus.
valve trouble. 2. Select a Hold Valve Menu from the Special Function
This test will help you confirm the result of your repair Menus.
service including the removal/reinstallation of brake
pipe, valve line harness and valve.

Special Functions

Special Functions ABS Warning Lamp

ABS Warning Lamp ABS Relay

ABS Relay ABS Motor

ABS Motor Exhaust Brake Cut Relay

Exhaust Brake Cut Relay Right Ft Release Valve

Right Ft Release Valve Right Ft Hold Vaive

ite ie ae eel eich Left Ft Release Valve

Left Ft Release Valve

Left Ft Hold Valve Left Rr Release Valve

Left Rr Release Valve Left Rr Hold Valve

Left Rr Hold Vaive Right Rr Release Valve

Right Rr Release Valve Right Rr Hold Vaive

Right Rr Hold Valve

oeOMYa21

3. Press the Hold Valve “ON” Soft Key with the brake
sonora pedal stepped on.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is 4. Release the brake pedal.
stepped on, released and stepped on again with the 5. Make sure that the Hold Vaive “ON” aimed at by
parking brake released. Tech 2 and the wheel locked position are the same.
If different, check brake pipe, valve line harness
wiring and H/UNIT. Repair is needed if abnormality
is found.

Release Valve Test

Purpose: The purpose of this test is to detect brake pipe
and valve line harness wire wrong connections and
vaive trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-19
Test procedure:
1. Connect Tech 2 with the vehicle, and select Special
Function from the menus.
Special Functions
2. Select a Release Valve Menu from the Special
Function Menus.
ABS Warning Lamp

ABS Relay

ABS Motor Special Functions

Exhaust Brake Cut Relay ABS Warning Lamp

Right Ft Release Valve ABS Relay

Right Ft Hold Valve ABS Motor

Exhaust Brake Cut Relay

Left Ft Hold Valve Right Ft Relgase Valve

Left Rr Release Valve Right Fi Hold Valve

Left Rr Hold Valve Left Ft Release Valve

Right Rr Release Valve Left Ft Hold Valve

Right Rr Hold Valve Left Rr Release Valve

Left Rr Hold Valve

OBOMYO13 Right Rr Release Valve

Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is Right Rr Hold Vaive
stepped on, released and stepped on again with the
parking brake released.
OsOMyYOTS

3. Press the Release Valve “ON” Soft Key with the

brake pedal stepped on.
4. Make sure that the Release Valve “ON” aimed at by
Tech 2 and the wheel released position are the
same. If different, check brake pipe, valve line
harness wiring and H/UNIT. Repair is needed if
abnormality is found.
5A4—20 ANTI-LOCK BRAKE SYSTEM (ABS)
5. Conduct Step 2 through Step 4 above on all the four
wheels.

Special Functions

ABS Warning Lamp

ABS Relay

ABS Motor

Exhaust Brake Cut Relay

Right Ft Release Valve

Right Ft Hold Vaive

Left Ft Hold Valve

Left Rr Release Valve

Left Rr Hald Valve

Right Rr Release Vaive

Right Rr Hoid Valve

OgoMYO13

CAUTION: When conducting this test, please

observe the following cautions.
41. Do not start the engine without fail.
2. Lift up the vehicle at a level floor.
* Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
§. Do not load the vehicle.
° When lifting up the vehicle, be sure to
observe the lifting up points. Refer to vehicle
lifting points in 0A section.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—21
6. Conduct Step 2 through Step 5 above on all the four
wheels.

Special Functions

Special Functions ABS Warning Lamp

ABS Warning Lamp ABS Relay

ABS Relay ABS Motor

ABS Motor Exhaust Brake Cut Relay

Exhaust Brake Cut Relay Right Ft Release Valve

Right Ft Release Valve Right Ft Hold Valve

Right Ft Hold Valve Left Ft Release Valve

Left Ft Release Vaive Left Ft Hold Valve

Left Ft Hold Vaive Left Rr Release Valve

Left Rr Release Valve Left Rr Hold Valve

Right Rr Release Valve

Right Rr Release Valve Ra mee esse

Right Rr Hoid Valve

OGOMY OT?

CAUTION: When conducting this test, please

osomvers observe the following cautions.
1. Do not start the engine without fail.
2. Lift up the vehicle at a /evel floor.
¢ Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.
* When lifting up the vehicle, be sure to
observe the lifting up points. Refer to vehicle
lifting points in 0A section.
5A4—22 ANTI-LOCK BRAKE SYSTEM (ABS)
EBCM Connector Pin-out Checks * Perform checks with high impedance digital
multimeter J-39200 or equivalent.
- Disconnect Electronic Brake Control Module.

Measure
Key between Pin
bea . Muitimeter Number Nominal
No. | Circuit to be Tested eit Scale/Range (A: B-109, Value Note
B: B-110
connectors)
1 | Contrel Module Power OFF VDC A-14(+) — B-22(-) 0~0.3V
Circuit OFF VDC A-24,25,26,B- 9~16V Back up Power
12,13 - B-22(-) Source
ON VDC A-14(+) — B-22(-) 9~16V
2 | Exhaust Brake Cut OFF VDC B-16(+) - B-22(-) 0~0.3V
Relay Circuit OFF Q B-5 — Ground 81~99Q | Engine is running
ON VDC B-16(+) ~ B-22(-) 9~16V
3 | Charge Relay Signal OFF VDC B-6(+) ~ B-22(-) 0~0.3V _., ;
Circuit ON vbc B-6(+) ~ B-22(-) Q-tev | natn 's running
4 | Brake Switch Signal OFF VDC B-17(+) - B-22(-) 0~0.3V
Circuit OFF VDC B-17(*)~ B22) | o=1ev | PPIY Brake Pedal
5 | ABS WIL Circuit ON VDC B-3(+) — B-22(-) 0~0.3V Disconnect
ON VDC B-3(+) — B-22(-) | 0~0.3/9~16V | Diagnosis
connector
Engine is stationary
6 | Valve Relay Circuit OFF Q B-4 ~ B-15 92~1140
7 | Motor Relay Circuit OFF Q B-4 — B-14 72~88Q
8 | FL Holding Valve OFF Q A-13 —A-4 4,5~50
FL. Decompression OFF Q A-12 — A-4 2.8~3.20
Valve
FR Holding Valve OFF Q A-i1 - A-4 4.5~50Q
FR Decompression OFF Q Ar2 — A-4 2.8~3.20
Valve
RL Hoiding Vaive OFF Q Aet - A-4 4.5~5Q
RL Decompression OFF Q B-11 -- A-4 2.8~3.2Q
Valve
RR Hoiding Valve OFF Q B-2 - A-4 4.5~50
RR Decompression OFF Q B-1 —- A-4 2.8-3.20
Valve
9 | Valve Power Signal OFF Q A-4 — Ground Less than
Circuit 0.012
10 | Motor Power Signal OFF Q A-3 — B-22 Continuity
Circuit Exist
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—23

Measure
Key between Pin
: . Multimeter Number Nominal Note
No. | Circuit to be Tested olan Scale/Range (A: B-109, Value
B: B-110
connectors)
11 | FL Speed Sensor OFF kQ A-6 — A-19 1.6~2.0kQ
OFF kQ A-6 — B-22 More than
1000kQ
OFF mVAC A-6 — A-19 More than Turn Wheel at 0.5
200mV RPS

FR Speed Sensor OFF kQ A-7 — A-20 1.6~2.0kQ

OFF kQ A-? — B-22 More than
1000kQ
OFF mVAC A-7 — A-20 More than Turn Wheel at 0.5
200mV RPS
RL Speed Sensor OFF VDC A-9 - B-22 0.2~4.5V Turn Wheel at 0.5
RPS

RR Speed Sensor OFF VDC A-8 - B-22 0.2~4.5V Turn Wheel at 0.5
RPS
5A4—24 ANTI-LOCK BRAKE SYSTEM (ABS)
Circuit Diagram

[FL4] 60a
ABS BWA.

STARTER SW
FL-2 | soa OFF
KEYSW ay, to 2 oo ACE [F-25] 108
+ . 3WiB_ TL 3B |B. (On
of ONO [4-7 } {5-87}42o" 6"
g08 on 3 SE.
{[p-67-— apy _GAUGE, BACK
9 SL}
[F-9 25A
ABSIBAT} 1L25W/G

= z F.8 | 108 —
fe)

z
R
ka

<
&
312
: g
al
& =

& g oO o g o * z B51 5
z =;
rey
#2)
ip
3s]ry S]
in
=
in
4a ¢ [8:61]a 2
o N A “ nw mw x
ke r - co o ee uu
Ww
g
wo
en
3< Ea
« ; O.BY
yy oh

gy
ee
Gy Bi erg =
x
= a8 OQ e
e 8
co

8 al 8
o a a
Peers nas

6e 7 26 | 25 2 ody 2 16 18 3 14
z e109) pil fat09 fan [eis e110 fi 1061
5 EBCM EBCM

8-110 18-1701 {8-110

~T 70 5 16

@—~-——- EXH:BRAKE SW

a
3 @——---P ENG. WARMING UP SW
a

g @
3 a
uy
5 -

5: [2 “|
2 | [a7]
S svn An) 5

2) [9 [B79 <> - Ex
on ee os
iFoo al
Be)be E
3) 9 25 Lo
oe3 a xEO asa
ee bse 4
+—— 2oO =
oo
a ° a
o es
® ¥

oO z|
™ a

le-27a|__|? 8 4

JOINT CONNECTOR
[ eel

2
el
| ,

sone SA
HEADLIGHT Hee 38
BRACKET(LH}
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-25

SVL

om
15
— HYDRAULIC UNIT
I
3 SOLENOID VALVE
RELAY MOTOR RELAY
4 ye | oO
IGT

Ltd

: at f
16 _
a fas] J-79 [4-80 J-79 (| J-79] [3-79] [4-79 J-79| (5-79 [4-79] [J-80 J-79| [J-79
oe =|" 1 ¥2 .2 71 3 oe 5 16 2 a i.
a 2) a a =| S) wl Ss) BF x
a s
a
o
2]
3
3]
a
gi
3
2)
o
gs}
3
8) 2)
a a
gs] &
oS a
&
: 42 18 2 4 7 8 14 15 21 18 413 4 6
°
Hs] [He]
c=
fH? He
APS |f HsLES 3
fA
——
ULES ]{ JUSHS |[As
ILS | SLES
H-3|[A-8| 7
ILS[He |[omerHs | [H-69]
-
69
oO a

2] g é “ 3*
3 o el = ™

28us ¢ &) 3)a ; 8) 8)~|, 2=i 8)ow]| 2)oa& @ alss

ei
o °
i
Sia
o Oo a o ° o a
g
01 FA°
>
1 4 14 1 2 VW 12 13 14 3

[5-116]
190 fo-170) [103] [109] [= 109] [&- 09] [8-109] [6-110] [e109]
EBCM

\8- 106]8-109)/B-109) 8-110

23 120 [7 22

a ae
Qa
| a

> > >

3 16 1/2 15 {to |17_ liz z [8 [4
[22] (Ha) [h3] (He) (Helaslrs|es] (hel He|He)
| 1
< 2 oe > &€ a
a
oO
ca7

=| 3 %/ | &| & a]
o @

o o eo o o ot a a

2 41 2 is [2 1 2 l1
3-78) (3-75 Evel na ena 57a) (3-74

fa | [ ma |[ mr | | rr |
SPEEO SENSOR

3
[4] JOINT CONNECTOR
HEADLIGHT 3B 2
BRACKETILH) |! 487}
FRAME-LH
icT HiL-{sah
DOSLYo0z
5A4—26 ANTI-LOCK BRAKE SYSTEM (ABS)

Connector List

| B7 | [ 5-34 | | 8-51 | B-66 |

11 J2/3/4|5 je [7 Ja feral lel ia lS

19 hola palishaisie fh2 1311141151 16/171 18] 19/2021 22
EE

7 |e}}/ 9 [10) IT EO)

DaSLYoos
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-27

Part Location

FUSE BOX (F-23~F-25) RELAY BOX (8-34)

8-113 DIAG CONNECTOR / STARTER SW J-148 BR SENSOR
FUSE BOX ASM (F-3, F-8, F-19)

J-149 RL SENSOR
B-109, B-110 EBCM \

B-272 JOINT nen

H-5~H-8

J-80 HYRAULIC UNIT

J-74 FR SENSOR Nae BATTERY

RELAY BOX ASM
) \. FL+1 ~ FL-4 FUSIBLE LINK
B-66 STOPLIGHT SW Ce i SYS
(BRAKE SW) 69 ~~ mv)\ |“~f SY ~ ~
B-79 DLC
J-75 FL SENSOR
“ B-51 ABS WARNING LIGHT (METER)

DGaLYoo3
5A4—28 ANTI-LOCK BRAKE SYSTEM (ABS)
Symptom Diagnosis 4, Brake pedal feel is abnormal.
5. Braking sound (from Hydraulic Unit) is heard while
The symptoms that cannot be indicated by the warning
not braking.
light can be divided in the following five categories:
These are all attributable to problems which cannot be
1. ABS works frequently but vehicle does not detected by EBCM self-diagnosis. Use the customer
decelerate. complaint and a test to determine which symptom is
2. Uneven braking occurs while ABS works, present. Then foliow the appropriate flow chart listed
3. The wheels lock during braking. below.

Diagnostic Flow Charts

No. Symptom -
Without TECH 2 With TECH 2
1 ABS works frequently but vehicle does not decelerate. Chart A~1 Chart TA-1
2 | Uneven braking occurs while ABS works. Chart A~2 Chart TA~2
3. | The wheels are locked. Chart A-3 Chart TA-3
4 | Brake pedal feel is abnormal. Chart A-4 ~—
5 Braking sound (from Hydraulic Unit) is heard while not braking. Chart A-5 Chart TA-5

Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate

Step Action Yes No

1 Is braking force distribution normal between the front and rear of Repair brake
the vehicle? paris.
Go to Step 2 Go to Step 6
2 Are axie parts installed normaily? Repair axle
parts.
Go to Step 3 Go to Step 6
3 Is there play in each wheel speed sensor? Repair wheel
speed sensor.
Go to Step 4 Go to Step 6
4 Is there damage, or powdered iron sticking to each wheel speed Replace sensor
sensor/sensor rotor? or sensor rotor.
Go to Step 5 Go to Step 6
5 is the output of each wheel speed sensor normal? (Refer to Repiace wheel
chart C-1 or TC-1) speed sensor or
Replace EBCM. repair harness.
Go to Step 6 Go to Step 6
6 Reconnect all components and ensure all components are Repeat the “Basic
properly mounted. diagnostic flow
Was this step finished? chart.” Go to Step 6

Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)

Step Action Yes No

1 1. Connect TECH 2.
2. WHEEL SENSORS make sure of the output conditions of Replace wheel
each sensor. speed sensor.
is the output of each sensor normal? Go to Step 2 Go to Step 3
2 Return to Chart A-1.
Was the Chart A-1 finished? Go to Step 3 Go to Step 2
3 Reconnect all components, ensure all components are properly | Repeat the “Basic
mounied. diagnostic flow
Was this step finished? chart.” Go to Step 3
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—-29

Chart A-2 Uneven Braking Occurs While ABS Works

Step Action Yes No

1 Is there play in each sensor? Repair.
Go to Step 2 Go to Step 5
2 Damage or powdered iron sticking to each sensor/sensor rotor? Repair.
Go to Step 3 Go to Step 5
3 Is the output of each sensor normal? (Refer to chart C-1 or Replace sensor
TC-7) or repair
harness.
Go to Step 4 Go to Step 5
4 is brake pipe connecting order correct? Reconnect
brake pipe
Replace EBCM. correctly.
Go to Step 5 Go to Step 5
5 Reconnect all components, ensure all components are properly Repeat the “Basic
mounted. diagnostic flow
Was this step finished? chart.” Go to Step 5

Chart A-3, TA-3 The Wheels Are Locked

Step Action Yes No

1 Is ABS working? Go to Step 2 Go to Step 4
2 Is vehicle speed under 10 km/h (6mph}? Go to Step 3 Normal.
3 is sensor output normal? (Chart C-1 or TC-1) Replace sensor
or repair
harness.
Go to Step 4 Go to Step 5
4 Is hydraulic unit grounded properly? Replace
hydraulic unit. Correct.
Go to Step 5 Go to Step 5
5 Reconnect all components, ensure ali components are properly | Repeat the “Basic
mounted. diagnostic flow
Was this step finished? chart.” Go to Step 5
5A4—30 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart A-4 Brake Pedal Feed Is Abnormal

Step Action Yes No

4 Is the stop light actuated when the brake pedal is depressed? Go to Step 2 Go to Step 3
2 1. Turn the key off.
2. Disconnect EBCM connector. Harness NG
3. Measure the voltage between B-110 EBCM connector between brake
terminals 17 and 22, when brake pedal is depressed. SW and EBCM.
Is the voltage between 9 ~ 16 V? Go to Step 4 Go to Step 7
3 Is stop light fuse F-8 normal? Replace fuse
F-8.
Go to Step 5 Go to Step 7
4 Is there continuity between B-110 EBCM connector terminal 22 Repair body
to body ground? grounded
harness.
Go to Step 6 Go to Step 7
5 is the brake SW normal? Repair stop Replace brake
light harness. SW.
Go to Step 7 Go to Step 7
6 Is the check harness/connector for suspended disconnection? Hydraulic
system leakage
or air entry Repair harness.
Go to Step 7 Go to Step 7
7 Reconnect all components and ensure all components are Repeat the “Basic
properly mounted. diagnostic flow
Was this step finished? chart.” Go to Step 7
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-31

Chart A-5,TA-5 Braking Sound (From Hydraulic Unit) Is Heard While Not Braking

Step Action Yes No

1 Is this the first time the vehicle is being driven after starting the itis self
engine? checking
sound.
Normal. Go to Step 2

2 is vehicle speed under 10 km/h (6 mph)? it is self

checking
sound.
Normal. Go to Step 3
3 Check for the following condition:
* At the time of shift down or clutch operation.
» At the time of low p drive (ice or snow road) or rough road
drive.
* At the time of high-speed turn.
* At the time of passing curb ABS may
en p g , sometime be
* At the time of operating electrical equipment switches. actuated even
* At the time of racing the engine. when brake pedal
Did it occur under any one condition above? is not applied. Go to Step 4
4 is there play in each sensorAwheel speed sensor rotor? Repair.
Go to Step 5 Go to Step 7

5 Damage or powdered iron sticking to each sensor/wheel speed Repair.

sensor rotor? Go to Step 7 Go to Step 6
6 is each sensor output normal? (Refer to chart C-1 or TC-4). Check harness/
connector for
suspected
disconnection.
lf no
disconnection is
found, replace
EBCM. Repair.
Go to Step 7 Go to Step 7

7 Reconnect all components, ensure all components are properly | Repeat the “Basic
mounted. diagnostic flow
Was this step finished? chart.” Go to Step 7
5A4—32 ANTI-LOCK BRAKE SYSTEM (ABS)
Diagnostic Trouble Codes
Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.

Code
rlash Serial Diagnosis item (except Chart No.
Communi Wiring)
out .
cations
12 — Normal _— -—
14 C0271 EBCM Abnormality EBCM B-2
15 C0277 Low Power Voltage EBCM B-3
*20 — Reference Voltage High Ground B-1-2
25 C0299 Exhaust Brake Cut Relay Abnormality Relay B-4
33 C0267 Motor Relay Abnormality Relay B-5
34 C0268 Abnormal Motor Rotation Motor B-6
41 C0265 Solenoid Valve Relay Abnormality Relay, EBCM B-7
42 C0241 Abnormal Solenoid Valve Power Line Relay, EBCM B-8
43 C0241 Open or Shorted Solenoid Valve(FL Valve) B-9-1
43 C0241 Open or Shorted Solenoid Valve(FR Valve} B-9-2
" - Valve, Relay
43 C0241 Open or Shorted Solenoid Valve(RL Valve) B-9-3
43 C0241 Open or Shorted Solenoid Valve(RR Valve) B-9-4
45 C0242 Shorted Solenoid Valve Circuit (FL Holding Valve) B-10-1
45 C0242 Shorted Solenoid Valve Circuit (FR Holding Vaive) B-10-2
45 C0242 Shorted Solenoid Valve Circuit (RL Holding Valve) B-10-3
45 C0242 Shorted Solenoid Valve Circuit (RR Holding Valve) B-10-4
45 co242 Shorted Solenoid Valve Circuit (FL. Decompression B-10-5
Valve) Valve, EBCM
45 C0242 Shorted Solenoid Valve Circuit (FR Decompression B-10-6
Valve)
45 C0242 Shorted Solenoid Valve Circuit (RL Decompression B-10-7
Valve) ‘
45 C0242 Shorted Solenoid Valve Circuit (RR B-10-8
Decompression Valve)
514 C0225 Open or Shorted FL Speed Sensor Circuit B-11
52 C0221 Open or Shorted FR Speed Sensor Circuit B-12
53 C0235 Open or Shorted RL Speed Sensor Circuit B-13
54 C0231 Open or Shorted RR Speed Sensor Circuit B-14
P P ~ Sensor, EBCM
61 C0226 Abnormal FL. Speed Sensor Signal B-15
62 C0222 Abnormal FR Speed Sensor Signal B-16
63 C0236 Abnormal RL Speed Sensor Signal B-17
64 C0232 Abnormal RR Speed Sensor Signal B-18

* Important: DTC 20 (Reference Voltage High) cannot be indicated by Tech 2. DTC 20 can be indicated and
confirmed by flashing using Diagnosis Switch.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—33
NOTE: Incase of indicating DTC 20, there are three CAUTION:
different defective cases as follows: * Be careful not to allow the harness to interfere
1. No ground cable is installed to the outside of the H/ with the brake pipe.
Unit mounted frame: * Be careful to allow the band clip on corrugate
The ground cable illustrated below is invisible. tube with the harness.

Verify Repair
Ground (1) Clear DTC.
canle (2) Run at a vehicle speed of 6 miles or more per hour
at the first engine run, making sure that there is no
/ failure.
(3) if No DTC (Code 12 is repeated four or more times)
i * is indicated by flashing, the repair is completed.

\
Bolt
2. Aground cable is installed to the outside of the H-
~~, Band Unit mounted frame, which is branched from the
Band Clip 7 Clip extension harness:
H/Unit i The ground cable and extension harness illustrated
Eatension| below are visible. ~ y
Extension . .
Harness _| Measure: Refer to Chart B-1-2 (DTC 20).

Measure: Install extension harness. _ 3. A ground cable is installed to the outside of the H/
* Extension harness (897226-3170) Install Procedure; om mounted frame, which is branched form the
. . chassis harness:
(1) Stop re engine: apply parking brake and scotch The ground cable illustrated below is visible.
; pielery. ; Measure: After checking the ground cable and fixing
(2) Disconnect the negative cable of the battery. bolts, follow the chart. Refer to Chart B-1-2 (DTC
(3) Remove the connector from H/Unit. 20).
(4) Connect connector extension harness.
(5) Connect the extension harness connector to H/
Unit. C/Harmess
(6) Tighten ground cable terminal to the frame side. A
(7) Fix the harness with band clips. i) Ground
a Cable
4 Terminal
/ ot [Ha /

Ground “, !
Cable “ '
a Terminal !
cil] ty eat
. ed \

iy 1 a Bolt

Bolt
i

)~~, Band
Band Clip a Clip osomyoza

H/Unit
Extension
Harness

OOM a24
5A4—34 ANTI-LOCK BRAKE SYSTEM (ABS)
Diagnosis By “ABS” Warning Light warning light illumination pattern while the key is in the
ON position or if the warning light is actuated during
illumination Pattern driving, trouble should be diagnosed on a illumination
in the event that there is abnormality in the “ABS” pattern basis as follows:

No. Condition “ABS" Warning Light Illumination Pattern Diagnostic

1 | Warning light is Normal
actuated normally

warning ON LL
N peace) ps
Warning

{
START ' i
|
Starter OWN lr Ngee ntemnenetnvnt tetera terrains nest tees sterettntrtiet et em

SW OFF eenenneempeneneensenel

2 | Warning light is not lit Warning light lighting circuit

trouble—Go to Chart B-1
ON
Warning .
light OFF

ON 000 pee
Starter
SW OFF __

3 | Warning light is Diagnostic trouble codes are

actuated while driving stored.
ON ee _ Display diagnostic trouble
Warning
light orr | La pt codes and diagnose ona
code basis according to the
flow charts.
Starter
Sw OFF —

Diagnostic Trouble Codes (DTCs)

When the warning light in the meter remains ON, the
EBCM stores the fault identification and disables the
ABS.
1. How to start DTC display:
¢ Confirm that the vehicle has come to a compiete
stop (with the wheels standing still) and that the
brake pedal is not depressed. (Unless these two
conditions are satisfied, DTC display cannot be
started.)
* With the key switch OFF, disconnect B-113
diagnosis connector. Then turn the key switch
ON.
- DTCs can be displayed also by TECH 2.
 ANTI-LO CK BRAKE SYSTEM (ABS) 5A4—-35
The DLC (for Tech 2) and Diagnosis connector are located be hind the driver side lower cluster panel

Data link
connector

Brake pedal ww . \ \

\—

Diagnosis connector

2, DTC display: 3. How to erase code:

* OTC is displayed by blinking warning light. * Conduct brake switch ON/OFF operation 6 or
more times within 3 seconds of self-diagnosis
* Double-digit display.
startup.
* First, normal OTC 12 is displayed three times and
The code cannot be erased if more than 3
then any other DTCs are displayed three times.
seconds have passed since self-diagnosis
(If no other DTCs have been stored, the display
startup, or if self-diagnosis has started with brake
of DTC 12 will be repeated.)
switched on (brake pedal depressed).
« OTCs can be erased also by Tech 2.

Disconnect --------7- 77>"

Diagnosis
connector
Connect
For 3 seconds
"|

TULIP
ON ee ee ee

Brake switch
OFF ea

Transmitted code 12 ee i200 12 ~ - 33 ~ 12 |» 12 57 Seal

BOSLYOO1
5A4—36 ANTI-LOCK BRAKE SYSTEM (ABS)
4, An example of DTC display
Display of DTC 23

<In case of DTC 23 display»

(Unit: sec.)
32 0404 12 0404 .
(tf ft | ———— hf ied

“ “ a ] | | | ||
OF F/—— PL a Co -

Self-diagnosis starts

After displaying DTC 12 three times, one DTC after The DTC 12 is displayed repeatedly. (display is
another is displayed, starting with the most recent discontinued after about 5 minutes)
one. (However, display is discontinued after about
5 minutes.)

<In case there are two or more DTCs: 44 & 23>

[
Te + ia 12 rom 44 [om 44 EPEAT)

«<in case no DTC has been stored>

BosRaess-4
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-37
Chart B-1-1 With the key in the ON position(Before starting the engine). Warning light(W/L)
is not activated.

Step Action Value(s) Yes No

1 Is W/L fuse F-25 disconnected? Go to Step 5 Go to Step 2
2 Is W/L burnt out? Go to Step 6 Go to Step 3

3 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Turn the key on.
4, Using DVM, measure the voltage between B-110
EBCM connector terminalis 3 and 22.
Does the DVM display a voltage within the specified
value? 9~16V Go to Step 4 Go to Step 7
Check the continuity between B-110 EBCM connector
terminal 22 and body ground.
is there continuity? Go to Step 9 Go to Step 8
Replace the fuse.
Is action complete? Go to Step 10
Replace the W/L bulb.
is action complete? Go to Step 10
Locate and repair open circuit, poor connection or
short circuit in the ignition feed circuit.
Is action complete? Go to Step 10
Locate and repair open circuit, poor connection or
short circuit in the ground circuit.
Is action complete? Go to Step 10
4. Check the harness for suspected disconnection.
2. If no fault found, replace the EBCM.
Is action complete? Go to Step 10

10 4. Reconnect all components, ensure all

components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.”
 5A4—38 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-1-2 (DTC 20) Reference Voltage High

WA
18
fi7s
—_

4
‘
i
| Extension
1 | Harness HYDRAULIC UNIT

Extension SOLENOID MOTOR

3 VALVE RELAY
3 Harness ° RELAY
oe
loll 4
05Y

: Extension
‘ Harness
O5Y

[79] 180 1-79

i

———1 = m 1 72

oO a

lig tae |e
fas] [Rs HT

OgOMYO22

Circuit Description Conditions for Clearing the DTC

A solenoid continuity check is made at the first start of Conduct brake switch ON/OFF operation 6 or more
the vehicle after the ignition system is switched on, and times within 3 seconds of self-diagnosis startup.
almost concurrently ABS motor begins to rotate. As this The code cannot be erased if more than 3 seconds
motor current flows, the ground wire level rises. To have passed since self-diagnosis startup, or if self-
prevent a rise of the ground current, ground harness is diagnosis has started with brake switched on (brake
branched from the extension harness. If the extension pedal depressed).
harness is not installed correctly, the ground level goes
up to indicate DTC 20. Diagnostic Aids
Check for the following conditions:
Action Taken When the DTC Sets
® Poor connection at extension harness — Inspect
« ABS control is a no action.
harness connectors for backed-out terminals,
« DTC 20 (Reference Voltage High) cannot be improper mating, broken locks, improperly formed or
indicated by Tech 2. damaged terminals, and poor terminal-to-wire
« DTC 20 can be indicated and confirmed by flashing connection.
using Diagnosis Connector. Damaged harness — Inspect the wiring harness for
* Light indication for DTC 20 is as follows: damage.
1. 12 is indicated three times.
2. 2is indicated three to nine times.
3. 12 is indicated three times.
4. 2s indicated three to nine times.
5. 1 to 4 are indicated repeatedly.
The ist order (0) of 20 is not indicated. History
trouble is indicated by engine stop. Current troubie
is indicated by engine run.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—39
* If poor or wrong is found, correct the extension CAUTION: Be careful not to allow the harness to
harness. interfere with the brake pipe.

Verify Repair
Ground 1. Clear DTC.
ts Cable 2. Run at a vehicle speed of 6 miles or more per hour
Terminal
at the first engine run, making sure that there is no
failure.
_ lf No DTC (Code 12 is repeated four or more times)
is indicated by flashing, the repair is completed.

Band Clip

H/Unit

Extension
Harness

OGOMYI24

Chart B-1-2 (DTC 20) Reference Voltage High

Step Action Value(s) Yes No

1 1. Ignition “OFF”.
2. Install a Tech 2.
3. Ignition “ON”, engine “OFF”. Go to
4, Check DTC by Tech 2. applicable DTC
Was DTC indicated? table Go to Step 2
1. Start the engine.
2. Check present DTC 20 indication by flashing
using Diagnosis connector.
Was DTC 20 indicated? Go to Step 4 Go to Step 3
1. Ignition “ON”, engine “OFF”.
2. Check history DTC 20 indication by flashing using
Diagnosis connector. Go to
Was DTC 20 indicated? Go to Step 4 Diagnostic Aids
1. Make a visual check on the joint harness.
2. If poor or wrong work is found, correct the joint
harness. Go to
Was poor or wrong work found out? Verify repair Diagnostic Aids
5A4—40 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-2 (DTC 14 / C0271) EBCM Abnormality

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Check the continuity between B-110 EBCM
connector terminal 22 and body ground.
Isthere continuity? ne Go to Step 2 Go to Step 3
2 1. Turn the key off.
2. Erase the trouble code.
3. Turn the key off, then on, to perform system seif-
check.
Does the trouble repeat? ee Go to Step 4 Go to Step 5
3 Locate and repair open circuit, poor connection or
short circuit in the ground circuit.
is action complete? ‘me Go to Step 5 —
4 Replace the EBCM.
Is action complete? — Go to Step 5 —
5 1. Reconnect all components, ensure alt
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? ~ chart.” —

Chart B-3 (DTC 15 / C0277) Low Power Voltage

Step Action Value(s) Yes No

4 is the baterry boltage normal? (Battery capacity
check) _— Go to Step 2 Go to Step 5
2 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Start the engine.
4. Check the voltage between B-109 EBCM
connector terminals 24, 25, 26, B-110 connector
terminals 12 or 13 to B-110 connector terminal 22.
Is the voltage within the specified value? 9- 16V Go to Step 3 Go to Step 6
3 Check the harness for suspected disconnection.
Does fault found? ~~ Go to Step 4 Go to Step 8
4 Repair and perform system self-check.
Does the trouble repeat? — Go to Step 7 Go to Step 8
5 Charge or replace the battery.
Is action compiete? ~_ Go to Step 8 —
6 Locate and repair open circuit, poor connection or
short circuit in the EBCM ignition feed circuit.
Is action complete? ~e Go to Step 8 —
7 Replace the EBCM.
Is action complete? — Go to Step 8 —
8 1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? _ chart.” Go to Step 8
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-41
Chart B-4 (DTC 25 / C0299) Exhaust Brake Cut Relay Abnormality

Step Action Value(s) Yes No

1 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Start the engine.
4. Using DVM, measure the voltage between B-110
EBCM connector terminals 16 and 22.
Does the DVM display a voltage within the specified
value? 9—- 16V Go to Step 2 Go to Step 4
Using DVM, measure the resistance between B-110
EBCM connector terminals 5 and 22.
Does the DVM display a resistance within the
specified value? 81 — 99 ohms Go to Step 3 Go to Step 6
1. Apply battery voltage between B-110 EBCM
connector terminais 5 and 22.
2. Using DVM, measure the voltage between B-110
EBCM connector terminals 16 and 22.
Does the DVM display a voltage within the specified
value? 0 -0.3V Go to Step 11 Go to Step 7
1. Stop the engine and turn the key off.
2. Remove the cut relay .
3. Check the continuity between B-34 relay
connector terminals 3 and 5 (relay side).
is there continuity? Go to Step 5 Go to Step 7
1. Start the engine .
2. Using DVM, measure the voltage between B-34
relay connector terminals 3 and 4 (harness side).
Does the DVM display a voltage within the specified
value? 9—16V Go to Step 9 Go to Step 10
1. Stop the engine and turn the key off.
2. Remove the cut relay .
3. Using DVM, measure the resistance between B-
34 relay connector terminals 2 and 4 (relay side).
Does the DVM display a resistance within the
specified value? 81-99 ohms Go to Step 8 Go to Step 7
Replace the exhaust brake cut relay.
is action complete? Go to Step 11

Locate and repair open circuit, poor connection or

short circuit in the cut relay ground circuit.
is action complete? Go to Step 11
Locate and repair open circuit, poor connection or
short circuit in the cut relay signal circuit.
Is action complete? Go to Step 11

10 Locate and repair open circuit, poor connection or

short circuit in the cut relay ignition feed circuit.
Is action complete? Go to Step 11

11 4. Reconnect all components, ensure all

components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 11
5A4—42 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-5 (DTC 33 / C0267) Motor Relay Abnormality

Step Action Vaiue(s) Yes No

4
1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the voltage between B-109
EBCM connector terminal 3 and B-110 connector
terminal 22.
Does the DVM display a voltage near the specified
value? OV Go to Step 2 Go to Step 5
Check the continuity between B-109 EBCM connector
terminal 3 and B-110 connector terminal 22.
Is there continuity? Go to Step 3 Go to Step 6
Using DVM, measure the resistance between B-110
EBCM connector terminals 4 and 14.
Does the DVM display a resistance within the
specified value? 72 ~— 88 ohms Go to Step 4 Go to Step 8
Check the continuity between B-110 EBCM connector
terminals 14 and 22.
Is there continuity? Go to Step 12 Go to Step 9
1. Disconnect HU connectors.
2. Using DVM, measure the voltage between B-109
EBCM connector terminal 3 and B-110 connector
terminal 22.
Does the DVM display a voltage near the specified
value? OV Go to Step 15 Go to Step 12
Check the fuse F-24 for breakage.
Is the fuse normal? Go to Step 7 Go to Step 14
1, Disconnect HU connectors.
2. Check the continuity between J-79 HU connector
terminal 9 and ground.
Is there continuity? Go to Step 12 Go to Step 15
4. Disconnect HU connectors.
2. Using DVM, measure the resistance between J-80
HU connector terminals 1 and 2.
Does the DVM display a resistance within the
specified value? 72 — 88 ohms Go to Step 12 Go to Step 15
4. Disconnect HU connectors.
2. Check the continuity between B-109 EBCM
connector terminal 3 and B-110 connector
terminal 22.
is there continuity? Go to Step 12 Go to Step 10
10 Using DVM, measure the voltage between J-79 HU
connector terminal15 and ground.
Does the DVM display a voltage within the specified
value? 9- 16V Go to Step 11 Go to Step 13
11 1. Apply battery voltage between J-80 HU connector
terminals 1 and 2 (HU side).
2. Check the continuity between J-79 HU connector
terminals 15 and 16 (HU side).
Is there continuity? Go to Step 18 Go to Step 15
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—43

Step Action Value(s) Yes No

12 1. Locate open circuit or short circuit to ground line
on the harness between EBCM and HU
connectors.
2. Repair the harness.
is action complete? — Go to Step 19 _—
13 1. Locate open circuit or short circuit to ground line
on the harness between FL-4 and HU connector.
2. Repair the harness.
Is action complete? _ Go to Step 19 —
14 4. Check for an open or a poor connection between
the EBCM and fuse F-24(ABS-2).
2. if a problem is found, repair as necessary.
3. Replace fuse.
Is action complete? _ Go to Step 19 —

15 Check the HU relay box. (Refer to Chart C-2; Item

No.1)
Is the HU relay box normai? —_ Go to Step 17 | Go to Step 16
16 Replace HU relay box.
is action complete? _ Go to Step 19 _
17 Replace HU.
is action complete? —_ Go to Step 19 —

18 Replace EBCM.
Is action complete? — Go to Step 19 —
19 4. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? —_ chart.” Go to Step 19

Chart B-6 (DTC 34 / C0268) Abnormal Motor Rotation

Step Action Value(s) Yes No

4 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Apply battery voltage between B-110 EBCM
connector terminals 4 and 14 to operate pump
motor. Go to “Basic
4. Check the motor sound. diagnostic flow
Does the motor rotate smoothly? —_ chart.” Go to Step 2

2 Replace the HU.

is action complete? —_ Go to Step 3 —_

3 4. Reconnect all components, ensure all

components are properly mounted, Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? _ chart.” Go to Step 3
5SA4—44 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-7 (DTC 41 / C0265) Solenoid Valve Relay Abnormality

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
110 EBCM connector terminals 4 and 15
Does the DVM display a resistance within the 92-114
specified value? ohms Go to Step 2 Go to Step 7
2 Check the continuity between B-110 EBCM connector
terminals 4 and 22.
Is there continuity? ~— Go to Step 11 Go to Step 3
3 Check the continuity between B-110 EBCM connector
terminals 15 and 22.
is there continuity? vo Go to Step 11 Go to Step 4
4 Check the continuity between B-109 EBCM connector
terminal 4 and B-110 connector terminal 22.
Isthere continuity? ae - Go to Step 5 Go to Step 8
5 1, Disconnect HU connectors.
2. Check the continuity between B-109 EBCM
connector terminal 4 and B-110 connector
terminal 22.
Is there continuity? — Go to Step 11 Go to Step 6
6 1. Apply battery voltage between J-80 HU connector
terminal 1 and J-79 connector terminal 11(HU
sicle).
2, Check the continuity between J-79 HU connector
terminals 12 and 13(HU side).
Is there continuity? ~— Go to Step 17 Go to Step 10
7 1. Disconnect HU connectors.
2. Using DVM, measure the resistance between J-80
Hi) connector terminal 71 and J-79 HU connector
terminal 11 (HU side).
Does the DVM display a resistance within the 92-1714
specified value? ohms Go to Step 11 Go to Step 14
8 Check the fuse F-23(ABS-1} for breakage.
Is the fuse normal? — Go to Step 9 Go to Step 13
9 1. Disconnect HU connectors.
, @, Check the continuity between J-79 HU connector
; terminal 12 and ground(HU side).
i is there continuity? — Go to Step 17 Go to Step 14
10 1. Disconnect J-79 HU connector.
2. Using DVM, measure the voltage between J-79
HU connector terminal15 and ground.
Does the DVM display a voltage within the specified
value? 9— 16V Go to Step 14 | Goto Step 12
11 1. Locate open circuit or short circuit to ground line
on the harness between EBCM and HU
connectors.
2, Repair the harness.
Is action complete? Go to Step 18
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—45

Step Action Value(s) Yes No

12 {. Locate open circuit or short circuit to ground line
on the harness between FL-4 and HU connecter.
2. Repair the harness.
Is action complete? _ Go to Step 18 —
13 1. Check for an open or a poor connection between
EBCM and fuse F-23(ABS-1).
2. If a problem is found, repair as necessary.
3. Replace fuse.
is action complete? — Go to Step 18 —
14 Check the HU relay box. (Refer to Chart C-2; Item
No.2)
Is the HU relay box normal? _ Go to Step 16 | Goto Step 15
15 Replace HU relay box.
Is action complete? —_ Go to Step 18 —
16 Replace HU.
Is action complete? _ Go to Step 18 _
17 Replace EBCM.
is action complete? — Go to Step 18 —_—
18 4. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 18
5A4—46 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-8 (DTC 42/ C0241) Abnormal Solenoid Valve Power Line

Step Action Value(s) Yes No

1 {. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
110 EBCM connector terminals 4 and 15
Does the DVM display a resistance within the 92-114
specified value? ohms Go to Step 2 Go to Step 7
Check the continuity between B-110 EBCM connector
terminals 4 and 22.
Is there continuity? Go to Step 11 Go to Step 3
Check the continuity between B-110 EBCM connector
terminals 15 and 22.
Is there continuity? Go to Step 11 Go to Step 4
Check the continuity between B-109 EBCM connector
terminal 4 and B-110 connector terminal 22.
Is there continuity? Go to Step 5 Go to Step 8
1. Disconnect HU connectors.
2. Check the continuity between B-109 EBCM
connector terminal 4 and B-110 connector
terminal 22.
Is there continuity? Go to Step 11 Go to Step 6
1. Apply battery voltage between J-80 HU connector
terminal 1 and J-79 connector terminal 11(HU
side).
2. Check the continuity between J-79 HU connector
terminals 12 and 13(HU side}.
is there continuity? Go to Step 17 Go to Step 10
1. Disconnect HU connectors.
2. Using DVM, measure the resistance between J-80
HU connector terminal 1 and J-79 HU connector
terminal 11 (HU side).
Does the DVM display a resistance within the 92-114
specified value? ohms Go to Step 11 Go to Step 14
Check the fuse F-23(ABS-1) for breakage.
Is the fuse normal? Go to Step 9 Go to Step 13
4. Disconnect HU connectors.
2. Check the continuity between J-79 HU connector
terminal 12 and ground(HU side).
Is there continuity? Go to Step 11 Go to Step 14
10 1. Disconnect J-79 HU connector.
2. Using DVM, measure the voltage between J-79
HU connector terminal15 and ground.
Does the DVM display a voltage within the specified
value? 9~- 16V Go to Step 14 Go to Step 12
11 4. Locate open circuit or short circuit to ground line
on the harness between EBCM and HU
connectors.
2. Repair the harness.
is action complete? Go to Step 18
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—47

Step Action Value(s) Yes No

12 1. Locate open circuit or short circuit to ground line
on the harness between FL-4 and HU connector.
2. Repair the harness.
Is action complete? — Go to Step 18 —
13 1. Check for an open or a poor connection between
EBCM and fuse F-23(ABS-1).
2. If a problem is found, repair as necessary.
3. Replace fuse.
Is action complete? — Go to Step 18 _
14 Check the HU relay box. (Refer to Chart C-2; Item
No.2)
Is the HU relay box normal? _ Goto Step 16 | Goto Step 15
15 Replace HU relay box.
Is action complete? _ Go to Step 18 —
16 Replace HU.
is action complete? ~_ Go to Step 18 —
17 Replace EBCM.
is action complete? _ Go to Step 18 _
18 1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 18
5A4—48 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-9-1 (DTC 43 / C0241) Open or Shorted Solenoid Valve(FL Valve)

Step Action Vaiue(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminals 4 and 13
Does the DVM display a resistance within the
specified value? 45~—5 ohms Go to Step 2 Go to Step 3
Using DVM, measure the resistance between B-109
EBCM connector terminals 4 and 12.
Does the DVM display a resistance within the 2.8-~-3.2
specified value? onms Go to Step 9 Go to Step 4
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 6 (HU side).
Does the DVM display a resistance within the
specified value? 4.5 —-5 ohms Go to Step 5 Go to Step 6
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 5 (HU side).
Does the DVM display a resistance within the 2.8—-3.2
specified value? ohms Go to Step 5 Go to Step 6
1. Locate open circuit or short circuit to ground line
on the harness between EBCM and HU
connectors.
2. Repair the harness.
Is action complete? Go to Step 10
Check the HU relay box. (Refer to Chart C-2; Item
No.3 & 4)
is the HU relay box normal? Go to Step 8 Go to Step 7
Replace HU relay box.
is action complete? Go to Step 10
Replace HU.
is action complete? Go to Step 10
Check the solenoid valve relay circuit. Refer to Chart
B-7.
is action complete? Verify repair
10 4. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 10
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—49
Chart B-9-2 (DTC 43 / C0241) Open or Shorted Solenoid Valve(FR Valve)

Step Action Value(s) Yes No

4
1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminals 4 and 11
Does the DVM display a resistance within the
specified value? 4.5—-5 ohms Go to Step 2 Go to Step 3
Using DVM, measure the resistance between B-109
EBCM connector terminals 4 and 2.
Does the DVM display a resistance within the 2.8 — 3.2
specified value? ohms Go to Step 9 Go to Step 4
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 8 (HU side).
Does the DVM display a resistance within the
specified value? 4.5 - 5 ohms Go to Step 5 Go to Step 6
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 3 (HU side).
Does the DVM display a resistance within the 2.8 — 3.2
specified value? ohms Go to Step 5 Go to Step 6
1. Locate open circuit or short circuit to ground line
on the harness between EBCM and HU
connectors.
2. Repair the harness.
is action complete? Go to Step 10
Check the HU relay box. (Refer to Chart C-2; Item
No.5 & 6)
Is the HU relay box normal? Go to Step 8 Go to Step 7
Replace HU relay box.
is action complete? Go to Step 10
Replace HU.
is action complete? Go to Step 10
Check the solenoid valve relay circuit. Refer to Chart
B-7.
is action complete? Verify repair
10 4. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 10
5A4-50 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-9-3 (DTC 43 / C0241) Open or Shorted Solenoid Valve(RL Valve)

Step Action Vaiue(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminals 4 and 1
Does the DVM display a resistance within the
specified value? 4.5 —-5 ohms Go to Step 2 Go to Step 3
Using DVM, measure the resistance between B-109
EBCM connector terminals 4 and B-110 connector
terminal 11.
Does the DVM display a resistance within the 2.8 ~ 3.2
specified value? ohms Go to Step 9 Go to Step 4
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 1 (HU side).
Does the DVM display a resistance within the
specified value? 4.5 —5 ohms Go to Step 5 Go to Step 6
41. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 2 (HU side).
Does the DVM display a resistance within the 2.8 -~- 3.2
specified value? ohms Go to Step 5 Go to Step 6
1. Locate open circuit or short circuit to ground fine
on the harness between EBCM and HU
connectors.
2. Repair the harness.
Is action complete? Go to Step 10
Check the HU relay box. (Refer to Chart C-2; Item
No.7 & 8)
Is the HU relay box normal? Go to Step 8 Go to Step 7
Replace HU relay box.
Is action complete? Go to Step 10
Replace HU.
Is action complete? Go to Step 10
Check the solenoid valve relay circuit. Refer to Chart
B-7.
Is action complete? Verify repair
10 1. Reconnect ail components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 10
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—51
Chart B-9-4 (DTC 43 / C0241) Open or Shorted Solenoid Valve(RR Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminals 4 and B-110
connector terminal 2.
Does the DVM display a resistance within the
specified value? 4.5 —5 ohms Go to Step 2 Go to Step 3
Using DVM, measure the resistance between B-109
EBCM connector terminals 4 and B-110 connector
terminal 1.
Does the DVM display a resistance within the 2.8 ~3.2
specified value? ohms Go to Step 9 Go to Step 4
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 4 (HU side).
Does the DVM display a resistance within the
specified value? 4.5 --5 ohms Go to Step 5 Go to Step 6
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 12 and 14 (HU side).
Does the DVM display a resistance within the 2.8 —-3.2
specified value? ohms Go to Step 5 Go to Step 6
1. Locate open circuit or short circuit to ground line
on the harness between EBCM and HU
connectors.
2. Repair the harness.
Is action complete? Go to Step 10
Check the HU relay box. (Refer to Chart C-2; Item
No.9 & 10)
Is the HU relay box normal? Go to Step 8 Go to Step 7
Replace HU relay box.
is action complete? Go to Step 10
Replace HU.
is action complete? Go to Step 10
Check the solenoid valve relay circuit. Refer to Chart
B-7.
Is action complete? Verify repair
10 1. Reconnect ali components, ensure ail
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 10
5A4—52 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-10-1 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (FL Holding Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminal 13 and B-110
connector terminal 22.
Does the DVM display a resistance within the
specified value? 4.5 —-5 ohms Go to Step 2 Go to Step 3
Check for a poor connection and an open circuit on
the harness between EBCM and HU connectors.
Refer to “Note on intermittents” described in earlier
this section.
Is action complete? Go to Step 8
{. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 6 and 12.
Does the DVM display a resistance within the
specified value? 4,.5—5 ohms Go to Step 4 Go to Step 5
1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
Is action complete? Go to Step 9
Check the HU relay box. (Refer to Chart C-2; Item
No.3)
Is the HU relay box normal? Go to Step 7 Go to Step 6
Replace HU relay box.
is action compiete? Go to Step 9
Replace HU.
ls action complete? Go to Step 9
Replace EBCM.
is action complete? Go to Step 9
1. Reconnect ail components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 9
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-53
Chart B-10-2 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (FR Holding Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminal 11 and B-110
connector terminal 22.
Does the DVM display a resistance within the
specified value? 4.5-5 ohms Go to Step 2 Go to Step 3
Check for a poor connection and an open circuit on
the harness between EBCM and HU connectors.
Refer to “Note on Intermittents” described in earlier
this section.
is action complete? Go to Step 8
1. Disconnect J-79 HU connector.
2, Using DVM, measure the resistance between J-79
HU connector terminals 8 and 12.
Does the DVM display a resistance within the
specified value? 4.5-—5 ohms Go to Step 4 Go to Step 5
4, Locate open circuit, poor connection or short
circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
is action complete? Go to Step 9
Check the HU relay box. (Refer to Chart C-2; Item
No.5)
Is the HU relay box normal? Go to Step 7 Go to Step 6
Replace HU relay box.
ts action complete? Go to Step 9
Replace HU.
Is action complete? Go to Step 9
Replace EBCM.
is action complete? Go to Step 9
1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 9
5A4—54 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-10-3 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (RL Holding Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminal 1 and B-110
connector terminal 22.
Does the DVM display a resistance within the
specified value? 4.5 ~5 ohms Go to Step 2 Go to Step 3
Check for a poor connection and an open circuit on
the harness between EBCM and HU connectors.
Refer to “Note on Intermittents” described in earlier
this section.
is action complete? Go to Step 8
41. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 1 and 12.
Does the DVM display a resistance within the
specified value? 4.5—5 ohms Go to Step 4 Go to Step 5
1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
Is action complete? Go to Step 9
Check the HU relay box. (Refer to Chart C-2; Item
No.7)
Is the HU relay box normal? Go to Step 7 Go to Step 6
Replace HU relay box.
is action complete? Go to Step 9
Replace HU.
is action complete? Go to Step 9
Replace ESCM.
is action complete? Go to Step 9
1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Siep 9
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—55

Chart B-10-4 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (RR Holding Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
110 EBCM connector terminal 2 and 22.
Does the DVM display a resistance within the
specified value? 4.5~—-5 ohms Go to Step 2 Go to Step 3
Check for a poor connection and an open circuit on
the harness between EBCM and HU connectors.
Refer to “Note on Intermittents” described in earlier
this section.
is action complete? Go to Step 8

4. Disconnect J-79 HU connector.

2. Using DVM, measure the resistance between J-79
HU connector terminals 4 and 12.
Does the DVM display a resistance within the
specified value? 4.5 ~-5 ohms Go to Step 4 Go to Step 5

4. Locate open circuit, poor connection or short

circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
is action complete? Go to Step 9

Check the HU relay box. (Refer to Chart C-2; Item

No.9)
Is the HU relay box normal? Go to Step 7 Go to Step 6

Replace HU relay box.

is action complete? Go to Step 9

Replace HU.
is action complete? Go to Step 9

Replace EBCM.
Is action complete? Go to Step 9

4. Reconnect all components, ensure all

components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 9
5A4—56 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-10-5 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (FL Decompression Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminal 12 and B-110
connector terminal 22.
Does the DVM display a resistance within the 28- 3.2
specified value? ohms Go to Step 2 Go to Step 3
Check for a poor connection and an open circuit on
the harness between EBCM and HU connectors.
Refer to “Note on Intermittents” described in earlier
this section.
Is action complete? Go to Step 8
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 5 and 12.
Does the DVM dispiay a resistance within the 2.8-—3.2
specified value? ohms Go to Step 4 Go to Step 5
1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
Is action complete? Go to Step 9
Check the HU relay box. (Refer to Chart C-2; Item
No.4)
Is the HU relay box normal? Go to Step 7 Go to Step 6
Replace HU relay box.
ig action compiete? Go to Step 9
Replace HU.
is action complete? Go to Step 9
Replace EBCM.
is action complete? Go to Step 9
1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished’? chart.” Go to Step 9
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—-57

Chart B-10-6 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (FR Decompression Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminal 2 and B-110
connector terminal 22.
Does the DVM display a resistance within the 2.8~-3.2
specified value? ohms Go to Step 2 Go to Step 3
Check for a poor connection and an open circuit on
the harness between EBCM and HU connectors.
Refer to “Note on Intermittents” described in earlier
this section.
Is action complete? Go to Step 8
1. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 3 and 12.
Does the DVM display a resistance within the 28—3.2
specified value? ohms Go to Step 4 Go to Step 5
1. Locate open circuit, peor connection or short
circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
Is action complete? Go to Step 9

Check the HU relay box. (Refer to Chart C-2; Item

No.6)
is the HU relay box normal? Go to Step 7 Go to Step 6

Replace HU relay box.

Is action complete? Go to Step 9

Replace HU.
Is action complete? Go to Step 9

Replace EBCM.
is action complete? Go to Step 9
4, Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 9
5A4—58 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-10-7 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (RL Decompression Valve)

Step Action Value(s) Yes No

4
1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
110 EBCM connector terminal 11 and 22.
Does the DVM display a resistance within the 2.8 -— 3.2
specified value? ohms Go to Step 2 Go to Step 3
Check for a poor connection and an open circuit on
the harness between EBCM and HU connectors.
Refer to “Note on Intermittents” described in earlier
this section.
Is action complete? Go to Step 8
1. Disconnect J-79 HU connector.
2. Using OVM, measure the resistance between J-79
HU connector terminals 2 and 12.
Does the DVM display a resistance within the 2.8 —-3.2
specified vaiue? ohms Go to Step 4 Go to Step 5
1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
is action complete? Go to Step 9
Check the HU relay box. (Refer to Chart C-2; Item
No.8)
Is the HU relay box normal? Go to Step 7 Go to Step 6
Replace HU relay box.
Is action complete? Go to Step 9
Replace HU.
Is action complete? Go to Step 9
Replace EBCM.
Is action compiete? Go to Step 9
1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 9
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—59

Chart B-10-8 (DTC 45 / C0242) Shorted Solenoid Valve Circuit (RR Decompression Valve)

Step Action Value(s) Yes No

1 1. Turn the key off.

2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
110 EBCM connector terminal 1 and 22.
Does the DVM display a resistance within the 2.8—3.2
specified value? ohms Go to Step 2 Go to Step 3

Check for a poor connection and an open circuit on

the harness between EBCM and HU connectors.
Refer to “Note on Intermittents” described in earlier
this section.
Is action complete? Go to Step 8
4. Disconnect J-79 HU connector.
2. Using DVM, measure the resistance between J-79
HU connector terminals 14 and 12.
Does the DVM display a resistance within the 2.8-3.2
specified value? ohms Go to Step 4 Go to Step 5

1. Locate open circuit, poor connection or short

circuit on the harness between EBCM and HU
connectors.
2. Repair the harness.
is action complete? Go to Step 9

Check the HU relay box. (Refer to Chart C-2; Item

No. 10)
Is the HU relay box normal? Go to Step 7 Go to Step 6

Replace HU relay box.

is action complete? Go to Step 9

Repiace HU.
is action complete? Go to Step 9

Replace EBCM.
is action complete? Go to Step 9

1. Reconnect all components, ensure all

components are properly mounted. Go to “Basic
diagnostic flow
2. Clear diagnostic trouble code.
chart.” Go to Step 9
Was this step finished?
5SA4—60 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-11 (DTC 51 / C0225) Open or Shorted FL Speed Sensor Circuit

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
109 EBCM connector terminal 6 and 19.
Does the DVM display a resistance within the 1.6—2.0
specified value? k ohms Go to Step 2 Go to Step 3
Using DVM, measure the resistance between B-109
EBCM connector terminal 6 and ground.
Does the DVM display a resistance within the 1000 k ohms
specified value? or more Go to Step 7 Go to Step 4
1. Disconnect FL sensor connector.
2. Using DVM, measure the resistance between J-75
sensor connector terminals 1 and 2.
Does the DVM display a resistance within the 16-2.0
specified value? k ohms Go to Step 5 Go to Step 6
1. Disconnect FL sensor connector.
2. Using DVM, measure the resistance between J-75
sensor connector terminals 1 and ground.
Does the DVM display a resistance within the 1000 k ohms
specified value? or more Go to Step 5 Go to Step 6
1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
Is action complete? Go to Step 8
Replace FL sensor.
Is action complete? Go to Step 8
Replace EBCM.
is action complete? Go to Step 8
1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 8
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—61

Chart B-12 (DTC 52 / C0221) Open or Shorted FR Speed Sensor Circuit

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors.
3. Using DVM, measure the resistance between B-
409 EBCM connector terminal 7 and 20.
Does the DVM display a resistance within the 4.6 — 2.0
specified value? k ohms Go to Step 2 Go to Step 3

Using DVM, measure the resistance between B-109

EBCM connector terminal 7 and ground.
Does the DVM display a resistance within the 1000 k ohms
specified value? or more Go to Step 7 Go to Step 4

4. Disconnect FR sensor connector.

2. Using DVM, measure the resistance between J-74
sensor connector terminals 1 and 2.
Does the DVM display a resistance within the 16-2.0
specified value? k ohms Go to Step 5 Go to Step 6

4. Disconnect FR sensor connector.

2. Using DVM, measure the resistance between J-74
sensor connector terminals 1 and ground.
Does the DVM display a resistance within the 1000 k ohms
specified value? or more Go to Step 5 Go to Step 6

4. Locate open circuit, poor connection or short

circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
Is action complete? Go to Step 8

Replace FR sensor.
is action complete? Go to Step 8

Replace EBCM.
is action complete? Go to Step 8

+, Reconnect all components, ensure all

components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 8
5A4—62 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-13 (DTC 53 / C0235) Open or Shorted RL Speed Sensor Circuit

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connectors and RL sensor.
3. Check the continuity between B-109 EBCM
connector terminal 9 and J-149 sensor connector
terminal 2.
Is there continuity? —_ Go to Step 2 Go to Step 4
2 1. Turn the key on.
2. Using DVM, measure the voltage between J-149
sensor connector terminal 1 and ground.
Does the DVM display a voltage within the specified
value? 9—- 16V Go to Step 3 Go to Step 5
3 Check the RL sensor output. (Refer to Chart C-1-3 or
TC-1)
Is action complete? — Go to Step 6 —_
4 1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
is action complete? — Go to Step 7 —
5 1. Locate open circuit, poor connection or short
circuit on the harness between F-25 fuse and
sensor connectors.
2. Repair the harness.
Is action complete? _ Go to Step 7 —
6 Replace EBCM.
Is action compiete? _ Go to Step 7 —
7 1. Reconnect all components, ensure all
components are properly mounted. Go te “Basic
2. Clear diagnostic trouble code. diagnestic flow
Was this step finished? _ chart.” Go to Step 7
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-63

Chart B-14 (DTC 54/ C0231) Open or Shorted RR Speed Sensor Circuit

Step Action Value(s) Yes No

4
1. Turn the key off.
2. Disconnect EBCM connectors and RR sensor.
3. Check the continuity between B-109 EBCM
connector terminal 8 and J-148 sensor connector
terminal 2.
ts there continuity? Go to Step 2 Go to Step 4
1. Turn the key on.
2. Using DVM, measure the voltage between J-148
sensor connector terminal 1 and ground.
Does the DVM display a voltage within the specified
value? 9-—16V Go to Step 3 Go to Step 5

Check the RR sensor output. (Refer to Chart C-1-3 or

TC-1)
is action complete? Go to Step 6
1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
is action complete? Go to Step 7
4. Locate open circuit, poor connection or short
circuit on the harness between F-25 fuse and
sensor connectors.
2. Repair the harness.
is action complete? Go to Step 7

Replace EBCM.
Is action complete? Go to Step 7
1. Reconnect all components, ensure ail
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 7
5A4—64 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-15 (DTC 61/ C0226) Abnormal FL Speed Sensor Signal

Step Action Vaiue(s) Yes No

1 Is there play inthe FL wheel bearing? fmm Go to Step 10 Go to Step 2
2 Is there play inthe FL speed sensor/sensor rotor? | — - Go to Step 11 Go to Step 3
3 Is there powdered iron sticking to Fl. speed sensor/
sensor rotor? —_ Go to Step 12 Go to Step 4
4 Check the FL speed sensor. (Refer to Chart C-1-1 or
TC-1)
Is the FL sensor output normal? _— Go to Step 5 Go to Step 8
5 Is there a broken tooth or indentation in the sensor
rotor? —_ Go to Step 13 Go to Step 6
6 Using DVM, measure the resistance between B-109
EBCM connector terminal 19 and ground.
Does the DVM display a resistance within the 1000 k ohms
specified value? or more Go to Step 7 Go to Step 9
7 1. Clear diagnostic trouble code.
2. Test drive and perform system self-check.
Does repeat trouble? _ Goto Step 18 | Go to Step 16
8 Is there damage or indentation in the speed sensor? —_ Goto Step 14 | Go to Step 15
9 1. Disconnect FL sensor connector.
2. Using DVM, measure the resistance between J-75
sensor connecior terminal 2 and ground.
Does the DVM display a resistance within the 1000 k ohms
specified value? or more Goto Step 17 | Go to Step 14
10 Adjust wheel bearing preload.
Is action complete? — Go to Step 19 —
11 Repair or replace speed sensor/sensor rotor.
is action complete? —_ Go to Step 19 —
12 Repair speed sensor/sensor rotor.
Is action complete? ~_ Go to Step 19 —_
13 Replace sensor rotor.
Is action complete? _ Go to Step 19 —
14 Replace FL. speed sensor.
Is action complete? — Go to Step 19 —
15 Check the FL speed sensor circuit. Refer to Chart B-
11.
ls action complete? ~~ Verify repair —
16 Check for a poor connection and an open circuit on
the harness between EBCM and sensor connectors.
Refer to “Note on Intermittents” described in earlier
this section.
Is action complete? _ Go to Step 19 —
17 1, Locate open circuit, poor corinection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
is action complete? _ Go to Step 19 | Goto Step 19
18 Replace EBCM.
is action complete? Go to Step 19
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-65

Step Action Value(s) Yes No

19 4. Reconnect ail components, ensure alll
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? — chart.” Go to Step 19
SA4—66 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-16 (DTC 62/ C0222) Abnormal FR Speed Sensor Signal

Step Action Value(s) Yes No

1 Is there play in the FR wheel bearing? — Go to Step 10 Go to Step 2
2 Is there play in the FR speed sensor/sensor rotor? “ Go to Step 11 Go to Step 3
3 Is there powdered iron sticking to FR speed sensor/
sensor rotor? ~ Go to Step 12 Go to Step 4
4 Check the FR speed sensor. (Refer to Chart C-1-2 or
TC-1)
is the FR sensor output normal? ~— Go to Step 5 Go to Step 8
5 Is there a broken tooth or indentation in the sensor
rotor? — Go to Step 13 Go to Step 6
6 Using DVM, measure the resistance between B-109
EBCM connector terminal 20 and ground.
Does the DVM display a resistance within the 1000 k ohms
specified value? or more Go to Step 7 Go to Step 9
7 1. Clear diagnostic trouble code.
2. Test drive and perform system self-check.
Does repeat trouble? —_ Goto Step 18 | Goto Step 16
8 Is there damage or indentation in the speed sensor? — Go to Step 14 | Goto Step 15
9 1. Disconnect FR sensor connector.
2. Using DVM, measure the resistance between J-74
sensor connector terminal 2 and ground.
Does the DVM dispiay a resistance within the 1000 k ohms
specified value? or more Go to Step 17 | Goto Step 14
10 Adjust wheel bearing preload.
is action compiete? _ Go to Step 19 —
11 Repair or replace speed sensor/sensor rotor.
Iisaction complete? fe Go to Step 19 _
12 Repair speed sensor/sensor rotor.
Is action compiete? ~_— So to Step 19 —
13 Replace sensor rotor.
is action complete? ~ Go to Step 19 _
14 Replace FR speed sensor.
Is action complete? _ Go to Step 19 _
15 Check the FR speed sensor circuit. Refer to Chart B-
12,
is action complete? — Verify repair —_
16 Check for a poor connection and an open circuit on
the harness between EBCM and sensor connectors.
Refer to “Note on Intermittents” described in earlier
this section.
Is action complete? —— Go to Step 19 _
17 4. Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
Is action complete? _ Go to Step 19 | Goto Step 19
18 Replace EBCM.
Is action complete? Go to Step 19
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—67

Step Action Value(s) Yes No

19 1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? - chart.” Go to Step 19

Chart B-17 (DTC 63/ C0236) Abnormal RL. Speed Sensor Signal

Step Action Value(s) Yes No

1 Is there play inthe RL wheelbearing? Go to Step 8 Go to Step 2

2 Is there play in the RL speed sensor/sensor rotor? _ Go to Step 9 Go to Step 3

3 Is there powdered iron sticking to RL speed sensor/

sensor rotor? — Go to Step 10 Go to Step 4

4 Check the RL speed sensor. (Refer to Chart C-1-3 or

TC-4)
is the RL sensor output normal? _— Go to Step 5 Go to Step 7

5 Is there a broken tooth or indentation in the sensor

rotor? — Go to Step 11 Go to Step 6
6 1. Clear diagnostic trouble code.
2. Test drive and perform systern self-check.
Does repeat trouble? —— Go to Step 15 Go to Step 14

7 is there damage or indentation in the speed sensor? _ Goto Step 12 | Goto Step 13
8 Adjust wheel bearing preload.
is action complete? ~~ Go to Step 16 _

9 Repair or replace speed sensor/sensor rotor.

is action complete? _— Go to Step 16 —
10 Repair speed sensor/sensor rotor.
is action complete? _ Go to Step 16 —

11 Replace sensor rotor.

is action complete? —_ Go to Step 16 -

12 Replace RL speed sensor.

Is action complete? nm Go to Step 16 —_

13 Check the RL speed sensor circuit. Refer to Chart B-

13.
Is action complete? —_ Verify repair —_

14 Check for a poor connection and an open circuit on

the harness between EBCM and sensor connectors.
Refer to “Note on Intermittents” described in earlier
this section.
is action complete? — Go to Step 16 —

15 Replace EBCM.
Isaction complete? Go to Step 16 _

16 4. Reconnect ali components, ensure ail

components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? — chart.” Go to Step 16
5A4—68 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart B-18 (DTC 64/ C0232) Abnormal RR Speed Sensor Signal

Step Action Value(s) Yes No

1 is there play in the RR wheel bearing? — Go to Step 8 Go to Step 2
2 is there play in the RR speed sensor/sensor rotor? — Go to Step 9 Go to Step 3
3 Is there powdered iron sticking to RR speed sensor/
sensor rotor? — Go to Step 10 Go to Step 4
4 Check the RR speed sensor. (Refer to Chart C-1-4 or
TC-1}
ig the RR sensor output normal? _ Go to Step 5 Go to Step 7
5 Is there a broken tooth or indentation in the sensor
rotor? _— Go to Step 11 Go to Step 6
6 1. Clear diagnostic trouble code.
2. Test drive and perform system self-check.
Doesrepeattrouble? te Go to Step 15 | Go to Step 14
Is there damage or indentation in the speed sensor? —_ Go to Step 12 | Goto Step 13
Adjust wheel bearing preload.
Is action complete? —_ Go to Step 16 —_
9 Repair or replace speed sensor/sensor rotor.
is action complete? — Go to Step 16 —
10 Repair speed sensor/sensor rotor.
Is action complete? —_ Go to Step 16 —_
11 Replace sensor rotor.
Is action complete? _ Go to Step 16 —
12 Repiace RR speed sensor.
Is action complete? —_ Go to Step 16 —
13 Check the RR speed sensor circuit. Refer to Chart B-
14.
is action complete? ne Verify repair —
14 Check for a poor connection and an open circuit on
the harness between EBCM and sensor connectors.
Refer to “Note on Intermittents” described in earlier
this section.
Is action complete? _ Go to Step 16 —_
15 Replace EBCM.
Is action complete? — Go to Step 16 —
16 1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 16
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—69
Unit Inspection Procedure procedures referred to during “SYMPTOM DIAGNOSIS”
and “DIAGNOSIS BY ‘ABS’ WARNING LIGHT
This section describes the following inspection ILLUMINATION PATTERN”:

without TECH 2 with TECH 2

Speed Sensor Output Inspection Chart C-1-1 to C-1-4 Chart TC-1
HU Relay Box Inspection Chart C-2 —

Chart C-1-1 FL Speed Sensor Output inspection Procedure

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connector.
3. Jack up the vehicle, with all wheels off the ground.
4. Measure the AC voltage between B-109 EBCM
connector terminals 6 and 19 while turning FL
wheel at a speed of 0.5 RPS.
Does the DVM display a voltage within the specified 200 mV or
value? more Go to Step 5 Go to Step 2
1. Disconnect FL sensor connector.
2. Using DVM, measure the resistance between J-75
sensor connector terminals 1 and 2.
Does the DVM display a resistance within the 1.6 - 2.0
specified value? k ohms Go to Step 4 Go to Step 3
1, Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
is action complete? _ Go to Step 5 —
Replace FL sensor.
is action complete? — Go to Step 5 _—
4. Reconnect all components, ensure ail
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? — chart.” Go to Step 5
5A4—70 ANTI-LOCK BRAKE SYSTEM (ABS)
Chart C-1-2 FR Speed Sensor Output Inspection Procedure

Step Action Value(s) Yes No

1 . Turn the key off.
BOM =

. Disconnect EBCM connector.

. Jack up the vehicle, with all wheels off the ground.
. Measure the AC voltage between B-109 EBCM
connector terminals 7 and 20 while turning FR
whee! at a speed of 0.5 RPS.
Does the DVM display a voltage within the specified 200 mV or
value? more Go to Step 5 Go to Step 2
2 1. Disconnect FR sensor connector.
2. Using DVM, measure the resistance between J-74
sensor connector terminals 1 and 2.
Does the DVM display a resistance within the 1.6-~2.0
specified value? k ohms Go to Step 4 Go to Step 3
3 1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
Is action complete? _ Go to Step 5 —
4 Replace FR sensor.
is action complete? —_ Go to Step 5 —
5 1. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? — chart.” Go to Step 5
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-71

Chart C-1-3 RL Speed Sensor Output Inspection Procedure

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connector.
3. Jack up the vehicle, with all wheels off the ground.
4. Connect a 120 ohms resistor between B-109
EBCM connector terminal 9 and ground.
5. Turn the key on.
6. Using DVM, measure the DC voltage between B-
109 connector terminal 9 and ground while turning
RL wheel at a speed of 0.5 RPS.
Does the DVM display a voltage within the specified
value? 0.2-4.5V Go to Step 5 Go to Step 2
2 1. Turn the key off.
2. Disconnect RL sensor connector.
3. Connect a 120 ohms resistor between J-149
sensor connector terminal 2 (sensor side} and
ground.
4. Apply battery voltage at J-149 sensor connector
terminal 1 (sensor side).
5. Turn the key on.
6. Using DVM, measure the DC voltage between J-
149 connector terminal 2(sensor side} and ground
while turning RL wheel at a speed of 0.5 RPS.
Does the DVM display a voltage within the specified
value? 0.2~-4.5V Go to Step 4 Go to Step 3
3 1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
is action complete? _ Go to Step 5 —
4 Replace RL sensor.
is action complete? “ae Go to Step 5 —
5 4. Reconnect all components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? — chart.” Go to Step 5
5A4—72 ANTI-LOCK BRAKE SYSTEM (ABS)

IH
SS0LYO09
Legend
(1) Battery (4) Speed Sensor
(2) DVM
(3) Resistor
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-73

Chart C-1-4 RR Speed Sensor Output Inspection Procedure

Step Action Value(s) Yes No

1 1. Turn the key off.
2. Disconnect EBCM connector.
3. Jack up the vehicle, with all wheels off the ground.
4, Connect a 120 ohms resistor between B-109
EBCM connector terminal 8 and ground.
5. Turn the key on.
6. Using DVM, measure the DC voltage between B-
109 connector terminal 8 and ground while turning
RR wheel at a speed of 0.5 RPS.
Does the DVM display a voltage within the specified
value? 0.2~-4.5V Go to Step 5 Go to Step 3
2 1. Turn the key off.
2. Disconnect RR sensor connector.
3. Connect a 120 ohms resistor between J-148
sensor connector terminal 2 (sensor side) and
ground.
4. Apply battery voltage at J-148 sensor connector
terminal 1 (sensor side).
5. Turn the key on.
6. Using DVM, measure the DC voltage between J-
148 connector terminal 2(sensor side) and ground
while turning RR wheel at a speed of 0.5 RPS.
Does the DVM display a voltage within the specified
value? 0.2 -4.5V Go to Step 4 Go to Step 3
3 1. Locate open circuit, poor connection or short
circuit on the harness between EBCM and sensor
connectors.
2. Repair the harness.
isactioncomplete? em Go to Step 5 _
4 Replace RR sensor.
is action complete? — Go to Step 5 —
5 1. Reconnect ail components, ensure all
components are properly mounted. Go to “Basic
2. Clear diagnostic trouble code. diagnostic flow
Was this step finished? chart.” Go to Step 5
5A4-74 ANTI-LOCK BRAKE SYSTEM (ABS)

ae an
2 =
(bev) LL

Os —

23

Legend SSeLYooo

(1) Battery (4) Speed Sensor

(2) DVM
(3) Resistor

Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

Step Action Yes No

1 1. Connect TECH 2.
2. Check the minimum speed of each sensor by WHEEL
SENSORS.
is the sensor speed more than 5 km/h (3 mph)? Go to Step 2 Go to Step 6
2 Check the sensor harness for suspected disconnection (check Replace speed
while shaking harness/connector), sensor. Repair.
is the sensor harness connection normal? Go to Step 3 Go to Step 3
3 Check the minimum speed of each sensor by WHEEL
SENSORS.
Is ihe sensor speed more than 5 km/h (3 mph)? Go to Step 4 Go to Step 6
4 Check the sensor rotor. Replace sensor
Is the sensor rotor normal? rotor.
Go to Step 5 Go to Step 5
5 Check the minimum speed of each sensor by WHEEL Repair harness
SENSORS. or connector
is the sensor speed more than 5 km/h (3 mph)? between EBCM
and speed
sensor.
Go to Step 6 Go to Step 6
6 Reconnect all components and ensure all components are Repeat the “Basic
properly mounted. diagnostic flow
Was this step finished? chart.” Go to Step 6
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—75

Chart C-2 HU Relay Box Inspection Procedure

« Remove the HU relay box.
* Check the continuity and the resistance between the relay box connector terminals by referring the following table.

Item | Circuit to be Tested | Measure Measure between Pin No. Nominal Note
No. item From To Value or
; : Condition
Gonn.| Pin | Conn.) Pin
1 Motor relay Continuity J-79 16 ¥-5 2 Continuity
Continuity J-79 9 Y-5 4 Continuity
Resistance | J-79 15 J-79 16 | More than
1000kQ
Resistance | J-80 2 J-80 4 72 - B8Q
Continuity d-79 15 J-79 9 Continuity Apply battery
voltage between
J-80(2) and J-80(1).
2 Solenoid vaive relay Resistance | J-79 12 J-79 16 | More than
1000kQ2
Resistance | J-79 11 J-80 1 92 - 1140
Continuity J-79 13 J-79 16 | Continuity
Continuity J-79 12 J-79 16 | Continuity Apply battery
voitage between
J-79(11) and
J-80(1).
3 FL Holding Valve Continuity J-79 12 ¥-3 3 | Continuity
Continuity J-79 6 ¥-3 4 Continuity
4 FL Decompression Continuity J-79 12 Y-3 4 Continuity
Valve Continuity | J-79 | 5 Y-3 2 | Continuity
5 FR Holding Valve Continuity J-79 12 Y-4 3 Continuity
Continuity J-79 8 Y¥-4 4 Continuity
6 FR Decompression Continuity J-79 12 Y-4 4 Continuity
Valve Continuity | J-79 | 3 Y-4 2 | Continuity
7 RL. Holding Valve Continuity J-79 12 Y-1 3 Continuity
Continuity J-79 4 Yet 1 Continuity
8 RL Decompression Continuity J-79 12 Y-1 4 Continuity
Vaive Continuity | J-79 | 2 | Y-1 2 | Continuity
9 RR Holding Valve Continuity J-79 42 Y-2 3 Continuity
Continuity J-79 4 Yo! 4 Continuity
10 | RR Decompression Continuity J-79 12 Y~2 4 Continuity
Valve Continuity | J-79 14 Y-2 2 | Continuity
5A4-76 ANTI-LOCK BRAKE SYSTEM (ABS)

¥-2(RR)

Y-7(RL)
(FR)Y-4

(FLYY-3

3
8
&

2\t ¥-5(MOTOR)

DEEL YDES
 ANTI-LOCK BRAKE SYSTEM (ABS) SA4-77

Hydraulic Unit
Hydraulic Unit and Associated Parts

3S0LYOR6

Legend
(1) Connector (6) Bolt
(2) Hydraulic Unit Assembly (7) Bolt
(3) Pipe {8) Lower Bracket
(4) Nut (9) Bracket
(5) Bolt (10) Front

Removal 4. Remove boits (6).

5, Support the bracket assembly and remove bolts (5).
1. Disconnect battery ground cable. 6. Remove hydraulic unit fixing nuts (4).
2. Disconnect 2 (two) harness connectors (1).
3, Disconnect 6 (six) brake pipes (3).
+ After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry of
foreign matter.
5A4—78 ANTI-LOCK BRAKE SYSTEM (ABS)
Installation
To install, follow the removai steps in the reverse order,
noting the following points:
Torque
Hydraulic unit fixing nuts (4) : 20 N-m (14 ibft)
Brackets fixing bolts (5) : 52 N-m (38 ibft)
Bracket fixing bolt (6) : 25 N-m (18 Ibft)
Bracket lower to upper : 25 N-m (18 Ibft)
Brake pipe flare nuts (3) : 16 N-m (12 Ibft)
* After installing the hydraulic unit, bleed brakes
completely. See Section 5A “Hydraulic Brakes’.
When bleeding, disconnect the fuse (60A) for ABS
hydraulic unit.

SBOLYORS

Legend
(1) Front Left Wheel Cylinder
(2) Front Right Wheel Cylinder
(3) Master Cylinder (front)
(4) Master Cylinder (rear)
(5) Rear Left Wheel Cylinder
(6) Rear Right Wheel Cylinder
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—79

HU Relay Box

Removal

3. Remove 2 (two) relay box fixing bolts.

S5Lv OOS
Legend « Never loosen other bolts or nuts, If any are
(1) Solenoid Valve Connector loosened, do not reuse the hydraulic unit.

1. Remove hydraulic unit.

BS
2. Disconnect 4 (four) solenoid valve connectors.
* Pull only on connectors, not on wiring harness.

AGOLYOGS

Legend
(1) Relay Box
(2) Motor Connector

SEOL YOO
4, Pull out relay box from motor connector.
5A4—80 ANTI-LOCK BRAKE SYSTEM (ABS)
Inspection and Repair
Refer to “Chart C-2” in this Section.

instaliation
1. Install relay box to motor connector.
* Be sure dirt or foreign material is removed from
the surfaces of relay box and motor connector.
2. Tighten relay box fixing bolts.
Torque : 4.9 N-m (43 Ibin)
3. Connect solenoid valve connectors, so that
harnesses do not cross up and down.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-81

Electronic Brake Control Module (EBCM)

Removal Installation
To install, foliow the removal steps in the reverse order
noting the following points.
NOTE:
if welding work is to be performed on the vehicle
using an electric arc welder, the EBCM should be
rernoved from the vehicle before the welding
operation begins.
Do not put a radio equipment etc, that emits strong
radio wave near the EBCM.
Do not wet the control unit. If wetted, wipe off water
immediately and dry it fully.
Never loosen any screw on the control unit.
Do not paint the control unit.
Prevent possible electrostatic discharge damage.
Do not touch the control unit pin type terminal with a
metalic tip of a screwdriver or tester.
Do not apply voltage to the terminal.
‘S26L YON!
Legend
(1} Electronic Brake Control Module (EBCM)
(2) Nut
(3) Body Harness
(4) Support Bracket

1. Disconnect battery ground cable.

2. Remove glove box.
3. Disconnect body harness connectors.
4, Remove EBCM.
5A4—82 ANTI-LOCK BRAKE SYSTEM (ABS)

Front Speed Sensor

Front Speed Sensor and Associated Parts

S50LY007

Legend
(1) Speed Sensor Connector (4) Sensor Fixing Bolt
(2) Sensor Cable Fixing Bolt (5) Speed Sensor
(3) Sensor Cable Fixing Boit (6) Front

Removal Inspection and Repair

1. Remove speed sensor connector. 1. Check the speed sensor pole piece for presence of
2. Remove sensor cable fixing bolts. foreign materials; remove any dirt, etc.
3. Remove the speed sensor fixing bolt. 2. Check the pole piece for damage; replace speed
sensor if necessary.
4, Remove speed sensor.
3. Check the speed sensor cable for short or open
circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the
cable while checking for continuity.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—83

SéoLvaa7y

installation
1. Install speed sensor and take care not to hit the
speed sensor pole piece during installation.
2. Install speed sensor fixing bolt and tighten the fixing
bolt to the specified torque.
Torque : 22 N-m (16 Ibft)
3. Install soeed sensor cable fixing bolts and tighten
the fixing bolt to the specified torque.
Torque
Bolts (2) : 22 N-m (16 ibft)
Bolt (3) : 45 N-m (33 Ibft)
NOTE: Confirm that a white or yellow line marked on
the cable is not twisted when connecting the speed
sensor cable.
4. Connect speed sensor connector.
5A4—84 ANTI-LOCK BRAKE SYSTEM (ABS)

Front Speed Sensor Rotor

Front Speed Sensor Rotor and Associated Parts

s0aL 803

Legend
(1) Disc Brake Assembly (6) Hub and Disc Assembly
(2) Hub Cap (7) Speed Sensor Rotor
(3) Cotter Pin (8) Inner Bearing
(4) Hub Nut (9) Oil Seal
(5) Washer (10) Spacer

Removal
1. Remove disc brake assembly and support the
caliper assembly so that the brake hose is not
stretched or damaged.
2. Remove hub cap.
3. Remove cotter pin and hub nut.
4. Remove washer.
5. Remove hub and disc assembly.

sea yoot
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—85
6. Remove speed sensor rotor. * Hub bearing preload
7. Remove inner bearing, oil seal and spacer. New Hub Bearing 9.8-24.5 N (2.2-5.5 Ib)
Reused Hub Bearing 4.9-19.6 N (1.1-4.4 ib)

inspection and Repair

1. Check the speed sensor rotor for damage including
tooth chipping, and if damaged, replace the speed
sensor rotor.

installation
1. Using a bench press, install speed sensor rotor.
2. Install spacer onto the knuckle spindle.
3. Apply grease into the outer and inner bearings and
install bearings in the hub.
4, Install oil seat into hub and disc assembly and install
hub and disc assembly on to the knuckle spindle.

Preload Adjustment
Adjust the wheel bearing as follows:
1. Tighten the nut until you are unable to manually
rotate the hub and disc assembly.
5. Install a cotter pin through the nut and knuckle and
2. Loosen the nut. bend it over.
3. Attach a spring balancer to one stud. Gradually « \f the notch in the nut does not line up with the
retighten the nut until the hub and disc assembly cotter pin hole in the knuckle, tighten the nut until
bearing is adjusted to the specified preload. it does. Do not loosen the nut to line up a notch
and the knuckle hole.
. Apply grease into the hub cap and instail it.
3

« 40g
7. Install the disc brake assembly and tighten two bolts
to the specified torque.
* Torque : 221 N-m (163 Ib ft}
5A4—-86 ANTI-LOCK BRAKE SYSTEM (ABS)

Rear Speed Sensor

Rear Speed Sensor and Associated Parts

A20LYOO2

Legend
(1) Brake Drum (3) Speed Sensor
(2) Speed Sensor Fixing Bolt (4) Speed Sensor Bracket
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4-87

Removal inspection and Repair

1. Check the speed sensor for presence of foreign
materiais; remove any dirt, etc.
2. Gheck the speed sensor for damage, and replace
the speed sensor if necessary.
3, Check the speed sensor harness for a short or an
open, and replace with a new one if necessary. To
check for harness short or open, bend or stretch the
cable while checking for continuity.

installation
1. Install speed sensor bracket and tighten the nut to
the specified torque.
Torque
12,000 Ib and 14,500 lb model 108 N-m (80 Ibft)
17,950 Ib model 157 N-m (116 ibft)
2. Install the speed sensor and take care not to hit the
S5eLvaua

Legend speed sensor during installation.

(1) Speed Sensor Connector 3, Install the speed sensor fixing bolt and tighten it to
the specified torque.
(2) Front
(3) Speed Sensor Torque : 18 N-m (13 ibft)
(4) Rear Axle 4. install brake drum and tighten bolts to the specified
torque.
1. Disconnect speed sensor connector. Torque : 13 N-m (113 Ibin)
2. Remove brake drum. 5. Connect speed sensor connecter.
3. Remove speed sensor fixing bolt.
NOTE: Confirm that the harness is not twisted when
4. Remove speed sensor. connecting the speed sensor connector.
5, Remove speed sensor bracket.
5A4-88 ANTI-LOCK BRAKE SYSTEM (ABS)

Rear Speed Sensor Rotor

Rear Speed Sensor Rotor and Associated Parts

S20LYaat
Legend
(1) Brake Drum (6) Outer Bearing
(2) Axle Shaft (7) Rear Hub
(3) Outer Oil Seal (8) Speed Sensor Rotor
(4) Lock Washer (9) Inner Bearing
(5) Bearing Nut (10) Inner Oii Seal

Removal inspection and Repair

. Remove brake drum. 1. Check the speed sensor rotor for damage including
=

. Remove axle shait. tooth chipping. |f damaged, replace speed sensor

DOF

rotor.
OND

. Remove outer oil seal, using a screwdriver.

. Remove lock washer.
. Remove bearing nut with a hub bearing nut wrench.
Installation
. Remove hub assembly from axle case. 1. Using a bench press, install speed sensor rotor.
. Remove outer bearing from hub assembly. NOTE: Do not reuse the sensor rotor.
ON

. Remove speed sensor rotor from hub assembly. 2. install spacer on to the axle case.
. Remove inner bearing and inner oil seal from axle 3. Apply grease into the outer and inner bearings and
O

case install bearings in the hub.

4. Instali outer oil seal into hub.
 ANTI-LOCK BRAKE SYSTEM (ABS) 5A4—89
5. install hub assembly onto the axle case. 7. Measure the bearing preload a second time.

AZ0LYOOS
429.005

6. Set the lock nut with the notched line facing out. 8. Align the axle case groove with the closest
bearing nut slit.
Preload Adjustment
1. Turn the hub to the left and right several times to NOTE: if itis difficult to align the axle case and bearing
establish bearing conformity. nut, slightly tighten the bearing nut.

2, Use the bearing nut wrench to tighten the 7. install the lock washer with the lock washer tabs
bearing nut until the hub can not be manually inserted to the axle case grooves.
rotated. install the lock bolts to prevent the bearing nut from
loosening.
3. Loosen the bearing nut until hub rotates easily. Check that the lock washer tabs are inserted to the
axle case grooves.
8. Apply grease to the outer oil seal lip inner and outer
circumferences and install outer oi! seal.
9. Glean the axle shaft.
Apply gear oil to the axle shaft spline.
insert the axle shaft into the axle case.
Take care not to damage the oil seat.
10. Tighten the axle shaft nuts to the specified torque a
little at a time.
Torque : 46 N-m (34 Ib ft)
41. Install brake drum,

4. Set the spring balancer to the wheel pin in the

position shown in the illustration.
5. Measure the hub bearing preload by carefully
pulling on the spring balancer and noting the
indicator reading.
Hub Bearing Pretoad (At Wheel Pin)
42-52 N (9.5-11.7 Ib}
6. Rotate the hub several times to the right and
left.
5A4—90 ANTI-LOCK BRAKE SYSTEM (ABS)

Special Tools

TOOL NO.
ILLUSTRATION TOOL NAME

J—35616
Connector test adapter kit

SOT AWO74,

J—39200
High impedance
multimeter

(1) PCMCIA Card

(2) RS232Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) Tech—2
 PARKING BRAKE 5C-1

SECTION 5C

PARKING BRAKE
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT
De@SCription ........sccsccseressssenesecenseensnossonameraneenesererssennes SPOR AUNSR OATS OW ANA HNO RET PARA RCAN ARES T COMES RARER ADARAT ASEH O KEATON RO RTRUNH EAT OSES

On-Vehicle Service .......ccccncsccesessnsssnnossnsavensensssauensanerses Deeeernensnen one Ey

Brake Shoe AdjUStMENt .......cccsecssarseneenereneassetensansesanss seUcarnagamO Renew
Lever Adjustment........scusssesee densansutssunerevensenoasaoonsanee ANCA ARESONMORT TORONTO HT AHS SORA MAL NANAT SMH M SCS RESH SOO ROOTAGELEAMRTHUATO ASO RORHSARS

Parking Brake Disassembly NPR Manual Transmission Model

Specifications NPR Manual Transmission Model......... PON SSNAONH NAS AKKUEN NEON MOF MSR AE COST KHPA MOOKMOK TT CCCONMEOUAHTIMOKT EM OKO nsaN HATS

DESCRIPTION
The parking brake used on this vehicle is a transmission case. A control cable is routed into the
mechanically operated internal expanding-type cab and is connected to a lever at the right side of
drum brake. It is mounted on the rear of the the driver seat.

ON-VEHICLE SERVICE

Before doing any service on the parking brake, « Back off the adjuster screw the specified number
park the vehicle on a level surface, block the of notches.
wheels, and place the brake in the release or off Check the gap at the middle of the shoe lining
position. (figure 2).
Adjuster Screw Notches and Clearance
BRAKE SHOE ADJUSTMENT Model Notches | Clearance mm (in)
Excepet NPR M/T 8 9.23 (0.009)
1. Disconnect the cable at the control lever.
2. Raise the rear axle so that the tires are off the
NPR M/T 30 =|0.75 (0.029)
floor.
3. Rotate the drum to align one of the access
holes with the adjusting screw. Remove the
hole cover.
4. Move the camshaft lever side-to-side a few
times to center the shoes. (Except NPR manual
transmission model.)

Adjust
- Insert a screwdriver in the access hole and rotate
the adjuster screw until the shoes drag on the
drum (figure 1).
Rotation direction:
upward (except NPR manual transmission model)
downward (NPR manual transmission model)
Figure 1. Adjusting the Brake Shoes
5C-2 PARKING BRAKE

- 1 3
1. Screwdriver ‘I |
2. Adjuster Wheel
3. Clearance

Figure 2. Brake Shoe Clearance Figure 3. Lever Adjustment

LEVER ADJUSTMENT (NPR Manual Transmission Model)

1. Block the vehicle’s wheels. 3. Loosen the adjuster nut @ at the brake lever
2. Release the parking brake. (figure 3).

NPR Manual Transmission Model

. Parking Brake Lever 7. Adjuster Assembly

coke

Assembly 8. Adjuster Spring

. Parking Brake Cable 9. Trailing Shoe
& Gh

. Brake Drum 10. Lever

On

. Drive Coupling 11. Leading Shoe

. Hold-down Spring 12. Strut
. Return Spring 13. Support Plate

Figure 4, Parking Brake Components

 PARKING BRAKE 5C-3

5. Hold-down springs (5).

Adjust 6, Return springs (6).
- Pull the brake lever out 5-8 notches (at 147N 7, Adjuster assembly (7).
(33lbs) by turning the adjust nut. 8. Adjuster spring (8).
- Tighten the lock nut. 9. Trailing shoe with lever (9 and 10).
10. Parking brake cable from lever.
4. Check for brake-holding ability. 11. Leading shoe (11).
12. Strut (12).
PARKING BRAKE DISASSEMBLY
Measure
(NPR Manual Transmission Model)
1. Brake drum (figure 6).
[S] Disassemble (Figures 4 and 5)
Standard Limit
* Block the vehicle wheels. . . 190 mm 191 mm
» Release the parking brake. inside ae Diameter f (7.48 in) (7.52 in)
1. Parking brake lever (1) (Figure 3).
« Loosen the adjust nut @, and disconnect the 9.05 mm
front cable from the lever. QOut-of-Round (0.002 in}
» Loosen the retaining nuts @ to remove the or less
parking brake lever assembly.
2. Remove the connecting bracket and move the 2. The brake shoe lining thickness shouid not be
cover towards the vehicle front. jess than 1 mm (0.039 in) (figure 7).
Loosen and remove the nut connecting the
front cable to the rear cable. (figure 5).
. Brake drum (3).
. Drive coupling (4).
a

Refer to Manual Transmission in section 7B.

Figure 5. Disconnecting Front Cable [ oe @€ ee Oe oe Hee eee Oe

tmm (0.039 in)

Figure 7. Brake Shoe Lining Thickness

5C-4 PARKING BRAKE

3. Return springs (figure 8). 7." :

Free Length: 62.1 mm (2.44 in) Assemble (Figures 4 and 5)
Set Length: = 67.1 mm (2.64 in) 1. Parking brake cable (2) to lever (10) and trailing
Set Load: 53-65 N (11.9-14.6 Ib) shoe (9).
. Leading shoe (11).

wr
. Trailing shoe (9).
. Hold-down springs (5).

ph
. Strut (12).

on
. Return springs (6).
. Adjuster spring (8).

OOon
. Adjuster assembly (7).
. Drive coupling (4).
Refer to Manual Transmission in section 7B.
10. Drum (3).
11. Parking brake lever (1).
Free Length ———-——>+ 12. Parking brake cable through floor.
+ Connecting bracket connecting front and rear
cable (2). (figure 5).
Figure 8. Return Spring Free Length 13. Cable to parking brake lever assembly.
« Adjuster nut

SPECIFICATIONS (NPR Manual Transmission Model)

Clearance Between Brake Drum and Lining .............cccssessecsseceeesseneneaneeeceenssessusasseesusensnane 0.75 mm (0.029 in)
Brake Lever Travel ..........cccecsseeceeceetesereeaneceesecsneeeescnsersegnnseetesenseseuensuesenssavensssussaneuseseees seeeeeenen ....5-8 notches
Brake Drum
Inside Diameter ........... 2... ceeceeesceeeessseensenecseccuenecsneasanuesneseneneescceesereoraceeesusesusaecesvanenserseneenes 190 mm (7.48 in)
Inside Diameter Limit 0.0... ee eae recenneneeeeteesueeeeeeeseesoeseseuseavessuaseaseaserenertoesaueesessscsens 191 mm (7.52 in)
Out Of ROUNG ooo ce eceeeteeeeeeesencoesereetsanenssutensaassesusssuensenssiwesanasessteussesess 0.05 mm (0.002 in) or Less
Brake Lining Thickness Limit 20.0.0... cc scsascesseeeeeesouecnsueeessesneeceuereesueucussssucuesuuseeeaansaeseseverereesaa 1.0 mm (0.04 in)
Return Spring Free Length «0.0... eee eeescesssennensoneensamsacsucseeeascuseseuseeuacoesuseseseutussuecavenses 62.1 mm (2.44 in)
SeOt LONGH oo... eescecccenessssnemeceteestsecoeeusceeesesseneeneceassessusesteceesseasnassuaveaseseusetneeenecsuesssnnaees 67.1 mm (2.64 in)
Set LOAD o.ccceececsesessessessesessecsecsecsssesseseseessussecassteassvanessvaraceceneeeavereasaveavensatsvaceseeess 53-65 N (11.9-14.6lb)
 PARKING BRAKE 5C-5

smission Mode 10. Spring

41. Lever 19. Washer
20. Spring 28. Bolt
29, Flange
Except NPR Manual Transmission Model
. Pin 21. Bolt 30. O-Ring Seal
. Washer 22. Camshaft 31. Drum
14. Cover 23. Shoe 32. Nut
. Anchor Pin 25. Spring 33. Cover
. Plate 26. Brace 34, Bolt
. Nut 27. Adjuster 35. Cable

Figure 9. Parking Brake and Cable Detail

 5C-6 PARKING BRAKE

SHOE REPLACEMENT (Except [A] Adjust

NPR Manual Transmission Model) * Brake and check operation.

* Block the vehicie wheels.

« Release the parking brake.

[+9] Remove or Disconnect (Figure 9)

1. Propeller shaft. Refer to PROPELLER SHAFT

(SEC. 4B).
2. Nut (32).
3. Drum (31) and flange (29).
* O-ring seal (30) in the flange (29) bore.
Refer to Transmission in section 7.
4. Spring (19) two places (figure 10).
5. Spring (25).
6. Adjuster (27).
7. Shoes (23).

Inspect

* Return spring (19). Free length should be

specified length (figure 11).
¢ 8" Parking Brake 49.9 mm (1.96 in.)
* Shoes (23). Replace the shoes if the web at the Figure 10. Installing or Removing the Springs
point of cam (22) contact is severely worn.
* Lining. Replace if lining thickness is less than 1
mm (0.04 in.).

[oe] Install or Connect (Figure 9)

1. Shoes (23).
2. Adjuster (27).
3. Spring (25).
4. Spring (19).
* Install springs (19) to the anchor pins (15)
(figure 10).
5. Drum (31) and flange (29).
6. Nut (32).
¢ Refer to Transmission in section 7.
7. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4B).
 PARKING BRAKE 5C-7

2. Nut (32).
« Open the staking (Manual transmission
model). Be careful of the shaft threads.
. Drum (31) and flange (29).

aw
Refer to Transmission in section 7.
. Gable (35) from the lever (11).
. Pin (12) from the lever (74).
. Lever (11) from the camshaft (22).
. Washer (13).
. Bolts (21) washer (20) and nut (18).
. Plate (16).
* Leave the shoes (23) and camshaft (22) in
place.
10. Spring (10).
Figure 11. Return Spring Free Length 11. Cover (14).
* Replace parts as necessary.

DRUM REPLACEMENT (Except [oe] Install or Connect (Figure 9)

NPR Manual Transmission Model) . Gover (14).
. Spring (10) to the cover (14) bracket.
* Block the vehicle wheels. a3 Ro
. Plate (16). Be sure brake components are
« Release the parking brake.
attached.
. Washers (20) bolts (21) and nut (18).
| Remove or Disconnect (Figure 9)
&

Refer to Transmission in section 7.

1. Propeller shaft. Refer to PROPELLER SHAFT . Washer (13) on the camshaft (22).
aon

(SEC. 4B). . Camshailt (22) into the lever (11).

2. Bolts (34) and washers. * Align the holes.
3. Covers (33). 7. Pin (t2) into the lever (11) and camshaft (22)
4, Drum (31). holes.
8. Cable (35) to the lever (11).
Measure « Attach the spring (10) to the lever (11) eye.
9. Drum (31) and the flange (29).
+ Diameter. Replace if the drum (31) ID is « Be sure O-ring seal (30) is in the flange (29).
greater than maximum limit. See 10. Nut (32).
specifications. Refer to Transmission in section 7.
* Run-out. Replace if the run-out varies more 11. Propeller shaft. Refer to PROPELLER SHAFT
than 0.05 mm (0.002-inch). (SEC.4B).
-~ Check for proper brake operation and adjust
fe Install or Connect (Figure 9)
if necessary.
1. Drum (31).
2. Covers (33).
3. Bolts (34) and washers. Align the drum holes
with the flange holes.
4, Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
— Adjust the brake and check operation.

COVER REPLACEMENT (Except

NPR Manual Transmission Model)
¢ Block the vehicle wheels.
* Release the parking brake.

| Remove or Disconnect (Figure 9)

1. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4B).
5C-8 PARKING BRAKE

LEVER ADJUSTMENT BRAKE LEVER REPLACEMENT

1. Block the vehicle wheels. + Block the vehicle wheels.
2. Release the parking brake. * Release the parking brake.
3. Loosen the jam nut and adjusting nut (figure
12).
[+9] Remove or Disconnect (Figure 13)
Adjust
1. Loosen the adjust nut G@), and disconnect the
When connecting cable with cam shaft lever, use front cable.
adjust nut in order to make the clearance 0 mm (0 2. Loosen the retaining nuts @ and remove the
in) between cam and shoe, then lock adjust nut with parking brake lever assembly.
lock nut.
[oe] Install or Connect (Figure 13)

1. Install parking brake lever assembly and tighten

the retaining nuts @).
2. Install the parking brake cabie to the brake
lever.
3. Turn the adjust nut @) to adjust the lever travel
to 6-8 notches, pulling the parking brake lever
at 147N (33!b).

Figure 12. Adjusting the Cable

Figure 13. Brake Lever and Cable Deiail

 PARKING BRAKE 5C-9

SPECIFICATIONS (Except NPR Manual Transmission Model )

8" PARKING BRAKE
BRAKE DRUM
Inside Diameter Standard Maximum
203 mm (8.0-inch) 204 mm (8.03-inch)
Run-Out Maximum
0.05 mm (0.002-inch)
Clearance 0.23 mm (0.009-inch)

BRAKE LINING
Length 115 «2mm (4.53 x 2-inch)
Width 50 mm (2.0-inch)
Thickness 3.75 mm (0.15-inch) 1.0 mm (0.039-inch)
Minimum Thickness
MEMO
 AUTOMATIC TRANSMISSION 7A1-1

SECTION 7

TRANSMISSION

CONTENTS
SUBJECT
Automatic Transmission .......scssssecnene pan sana saunounonensneanvasedaeanuesesasasanocanaenasensinedonnenceunestionasaeseeenanenstan bennesaouaees
Manual Transmission (MXA).........essusescen sveusaaedapeacstesuansavenenuncnanenuanausavaes panneasesortossneasenasaedeanenescenssanensuasnouesonsan
Manual Transmission (MBP)........csscsosssescsousaseerserseanes
Clutch (For MXA Transmission)
Clutch (For MBP Transmission)

SECTION 7A

AUTOMATIC TRANSMISSION
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE

Construction and Function......... saeusnuesesuceausetauoauausansepeenessensaseanazensutaans supeuvaeaveusouscanuaanseseanenseqdapensnsuncesaassensusrannonss 7AI

DiaQnoSiS.........cssuserssessessessansanvenaseesarseres bennesueaueecaneamuanesenecanse saoneaenaanausuneueuedaneessanseunanssasanesacsdanveunsusssensasesooraneeess
On-Vehicie Service ;
| AA
Automatic Transmission Overhaul........:cscsssessssssesrescnrssesssassnsonssescnssnsorsnsenesusaoesusconsersencareonseesnavonsesnocesssecsssnces
7A1-2 CONSTRUCTION AND FUNCTION

7A1 CONSTRUCTION AND FUNCTION

CONTENTS
SUBJECT PAGE
D@SCHIPTION «2.0... :cescccsseseseessenesnsonanesersussaneeuanesoenaanenteeesesisauauredernonssueaesosonsaesuanasgeeusuauseastaneesussoeguranneanensesasacaucavess 7A1- 3
CONStrUCTION... cece ceecsstesereeetsnennsssenecententecseesatsteneseaes soneceneanvanaeuseaequausoesecuseatsenaesedausedszatesssnaneesenonenatesseasaes 7A1- 3
Transmission Serial NUMER? ......ccsceseseecsvenecenaneesesssnensentnensedtueversecsnsesesatenedssetentpansousnersnsesensntstansonanansanense TA1- 4
Number Plate Location... .cccssscsssssucecsentcenteansrssssseasenueneiedsontsusaccodeesesnaeesnenusaeensetansensuesseeetazaseneaenerrensen 7A1- 4
Component Location ............ccesserceneree canauadnendsonceescuuesssuseueesauestscennecsanedasueauéncesensensenenseetanesuanresensassaeranestaas 7A1- 5
Structure and Function of COMPONENE Q.............0.- esc sserceenseosecnaenseetansuennsnnensasuesntsescenpeneansasereonsucnounsaarecedenses 7A1- 6
Torque Converter .......occsccrerseasensenversarnessedsensueserseeutssecercncasscessuuanecuuansanesersunenssasseustepedensiseusteunnsentenstanessaes 7TA1- 6
Oi] PUMP... ce ccceeceneerenenssersenisanencaneonen buesucevedueucaneaeduecuedeattaneuesssasaueasanesenesouseaseceesuauecneesosananesusseensunnaeseasees TA1- 6
ShAft se cccccnsscsesscesessnsnsesnonseessesausessesereseuaneanesaseuteesonsoaesuacesoseouccasenenntonsenscnssensasunseaesussasnusasonsenssessaseneantesnes TA1- 7
Gear Shifting Me@CHanisin.........cccsscsnensensueeeesnssentstetesscceseesaesstersercneueonsauanennseenesuansessnueagenssuensenansenseneatanuea 7A1- 8
ACCUMUIALOS....cccssorseusessensonsassoenenennneccnaveosuscuneneuendausantanasuntuassusoonsesussannssssusaueusausseasedeuersnennenesuantaonssenseesaanaces 7A1-16
SOMO... eccnsseseenconseseresenesnvocensoeerecansessunvenneentesscsseamereries Loavanesseasacaerenuavansuesnedaaesnaqeanneceustonecaessansansaenvase 7A1-17
Automatic Transmission Fluid (ATF) ThermoSensot ...........cccccssssessscennsssenssustesnnersuosenestacesacersectanseonenans 7TA1-18
Automatic Transmission Fluid (ATF) Temperature Switch.............-..cccecssssecsnesssnsensessnsensersensessneeracessans 7A1-18
Inhibitor Switch (Neutral/Start Switch) .......00.. ccc. cecscesssssceeseneeseersneesseeesecnssasenaustneseaoesseaseneesnmesesgesusnesseas 7TA1-18
Kick-down SWitch .........::ccsessneevssneesnessosouusssenventeesanrensonnes vsnnsotuconsvssieusnesnentaapersaesnertessassenennsnenusaeeaeassassusess 7A1-19
Throttle Position SONSOL .........csssosscecssessenensesersentnensensersecuvensnsneeeneteuesaens secnesneees caavacsneneuaeaueveeresensueneee 7A1-19
Vehicle Speed Sensor 2 .........ssssscsssccensenseersnecsanseeceesonseveesanseraaserenavanesusessequesesensseesanusnerauoesantaserserennerseseas 7A1-20
Vehicle Speed Sensor 1.0 . scssvessesesmennseerssaneesseseenesseeaseconenseentecsueessnnausatscoussaesasaaieaoedsoenseseasnaatteneazessen 7A1-20
Engine Speed Sensor ......cccssscceseuecseensceesaneesessnerssenennsenouneransarsees siannevunneaenaausoavarnecesastansnesenauseaanesdeanenenens 7A1-21
Transmission Control Module (TG) ............:.ccss:sncssssscsrssssecessannsoeneesensneeenaneasesedsanseesseaensneceessunsseaeaaaas 7TA1-21
Control MeChanisM.....cccceccccceccsccntsssesesersestenssnausnaessouesuconmunecsnaesaoaeeaucounencaaecaannaesansesuaansoneasanaonetanpenussacueseaaeees 7A1-22
Content of Function and Gontiol......ccnsseseserseerseseseevesseresnreses vesansuaeusoustentensesvenmsnsentascenedsoeeeaassuneaenaness 7A1-22
Control item, Input and Output... ec cesecesnesesereeeueeeseenteunasuescausdeiuceeusesnssensensmenenseriannssuansussaensensagens 7A1-23
Major Input/Output Component FUNCtiOn.......ccccsussusssssscesnesscesnsossonescenstarsusenancoeseseneeseesoenaatsneaecaneneeanate 7A1-24
Control Circuit Block Diagrain.....ccsucsecssscscsesensnecsessesnsesirseeniseveetsesoasscuensasaneanecanscaetiensiesaadenteerarsesenanes 7A1-25
Circuit Diagram... savseuseseeuasunsuseseusocusessaucnvanusorsuacauavanoesnexeneaunauseensaseeanscouaesseusutansnersausacouseerassauaeaes 7A1-26
Valve Operation......eccsecescrssneetsssonsersssesesneesesuseusenssrsieatsouscavoenseeenvianiteneuauseoecsumnerneancatsenee cat enansseeensneaneves TA1-27
Valve FUNCTION q.0...... cee ceeeceeeteseeeneeseaueneessenedsuneccacannensanevanesensusnuaunsasdenuanneoneneaueensueessceccerssacensseenensapesaneses 7A1-27
Valve Body Construction .......cscscccssssssnstsnensessoesuresnsantonsnuacsesscunganesaanearausenonaseeenaeuaetenasadassnsaneneneoses 7A1-29
Gear Train (Transmission Mechanism) Operation.......... jaueededacoraccsnenseseasvonssanaeucauenesseununtaneanenynsesnnanesonsnaeusaes 7A1-30
Construction and Operation .........sccscssssseersenens suvcauosensousvasenussqvatesevasenseassessusansuavoeacaueayserenequseoneanteneenses 7A1-30
Component Name and FUNCHiON............seccsssscscessnessnssnsenserssascerssnnsevsnrenstieneaanaesausseateonsrsessegsaucotansenssensnears 7A1-31
Component and Their Operating Condition.......... saceeeaueasonaseusnunersensenaeuanenseecensensueseeescunassanseususeatonstensenaas 7A1-31
N Arid P range. ......cccccsescsssessscsensneneucoesostseneersausussousesseasucesecoaestatsecesnreusenarserseusuateorensaueenanneszercneoveatastensene 7A1-32
First Gear in D or 2 Range.......cccescsserecssseresseesssssessauurenersarcasee seuuevsonsansansuusarsenssasaneesansoneenensenassensensuene 7A1-33
Second Gear in D Range.....csesccsssscursssensercsseresscseeasceroceseuscuscensensscsesnsunscvasacaseecsuessaneessuessensevaeenenarsansaes 7A1-34
Third Gear in D, 2, L Range.......ecssessesesrsonsneens saenatueaennerusneene caeracdeonneusuanseerenenuauanconsesseuneeesenaeseeesanenaneotes 7A1-36
Overdrive Gear in D Range .......sscssssenees stupeuaneenonsesavauuacvoussnussnsuenssansonuaesanvonssunansenosesaususnaeaeueesuanseusaaeees wn fA1-38
Second Gear in 2 Range..........0 bvecueatceneseuseusnnenintontsensesetnenauas sonenssesusaeasaneas cractesueunssaseesnenssusaetarencarsenones 7A1-39
First Gear in L. Ramge......ccssscsesessserensessssssssuneusonsassvenuceossstcauaarsecsasuansenssunaresossaesanesuenosensaenengnsapsedinaaeuseeses 7A1-41
FL Range .....esccccnccsssesresssuensnecasnenssseuseunmennecessesoussueens sesanenneonseas donaennaunestenvenssanuaessoutesecenenscereestnnonsedsouneneepeoessean 7A1-42
 CONSTRUCTION AND FUNCTION 7A1-3

DESCRIPTION
CONSTRUCTION

12 10 11 1213 14 15 16

17 «18 19 20 21 22 23 24 25
1. Torque Converter Housing 10. Rear Clutch 19. Oj Pan
2. Torque Converter 11. Front Planetary Gear 20. Valve Body
3. Transmission Case 12. No.2 One-way Clutch 21. Input Shaft
4. Overdrive Direct Clutch 13. 1st and Reverse Brake 22. PTO Drive Gear
5. Overdrive Brake 14, Rear Planetary Gear 23. Interrnediate Shaft
6. Overdrive One-way Clutch 15. Parking Lock Gear 24, Extension Housing
7. Overdrive Planetary Gear 16. Output Shaft 25. Speedmeter Drive Gear
8. Front Clutch 17. Overdrive Input Shaft
9. 2nd Brake 18. Oil Pump

Figure 1. Construction of Automatic Transmission

The 450-43LE type automatic transmission is a TCM's self-diagnosis function allows faster
four-speed automatic gear shift that is controlled troubleshooting to enhance the vehicie’s
electronically by the Transmission Control Module serviceability.
(TCM).
The automatic transmission consists of the torque
The TCM provides smooth and powerful driving converter, oll pump, gear train, and vaive bodies.
performance by automatically selecting the
optimum transmission characteristics and gear The torque converter is of the 3-element, 1-stage,
positions according to the accelerator (throttle) and 2-phase type with a built-in lock-up clutch.
position, vehicle speed, and other conditions.
The gear train consists of 3 sets of multiple-plate
in an event of a malfunction of the vehicle speed clutches, 3 sets of multiple-plate brakes, 2 one-way
sensor, throttle position sensor, solenoid or other clutches, and 3 sets of planetary gear each
components, it shifts to fail-safe control mode to consisting of a sun gear, a pinion gear, and a ring
maintain the drivability. In an event of a malfunction gear.
of the vehicle speed sensor, throttle position
sensor, solenoid, engine rpm signal, etc., the
7A1-4 CONSTRUCTION AND FUNCTION

TRANSMISSION SERIAL NUMBER

NUMBER PLATE LOCATION

AISIN SEIKI CO., LTD.

SERIAL NO.
fA0001
ye Year, 1997
3- Month; January
EX. B; February
C; March
D; April
meneame Serial numbers

Figure 2. Number Plate Location

 CONSTRUCTION AND FUNCTION 7A1-5

COMPONENT LOCATION

co

\.

c ~
2. Pedal 7. Engine
* Throttle position sensor + Engine speed sensor
* Kick down switch * Idle signai{from PCM)
* Brake switch + FICD signal
K J ce ec ee ee cee ne ee ee
~ ——meltgoe «= w Exhaust brake cut relay
3. Speedometer
« Vehicle speed sensor-2
\ 8 Electrical source
«Ignition
rc 1. Transmission
4, Instrument panel Control Module
«Exhaust brake switch 9, Transmission
«No. 1 shift solenoid
¢ Check trans light * No. 2 shift solenoid
* ATF temperature light + Line pressure solenoid
* Engine over-run light(f equipped) « Lock-up solenoid
* Timing solenoid

5. ABS * Vehicle speed sensor-1

« ABS operating signal(from EBCM) ° ATF therrnosensor
« ATF thermo switch
¢ Inhibitor switch

6. Data link connector

* Diagnostic enable 10. Control lever
° TECH 2 « Overdrive OFF switch

~«<g—-—
ee : Signal direction

Figure 3. Component Location

7A1-6 CONSTRUCTION AND FUNCTION

STRUCTURE AND FUNCTION OF COMPONENT

TORQUE CONVERTER Oil. PUMP

(Figure 4) (Figure 5)
+ The torque converter transmits the engine torque Construction
to the transmission by way of oi! (when the lock- » The oil pump is a high performance geared oil pump
up clutch is disengaged) or the lock-up piston with a small number of teeth of a special profile.
(when the lock-up clutch is engaged).
* The torque converter is of the 3-element, 1-stage,
and 2-phase type. Viewed from Rear Side:
» “|-stage” means the output element consists of a
single turbine runner.
“2-phase” means the converter works as a torque
converter against the pump impeller when the
turbine runner speed is relatively low, and as a
fluid coupling when the speed is high.

1. Driven Gear 4. Oil Pump Body

z. Cresent 5. Delivery Port
3. Drive Gear 6. Suction Port

Figure 5. Construction of Oil Pump

Operation
« The drive gear is engaged with the extension
sleeve of the torque converter. As it rotates in the
direction of the arrow at the engine speed, the oil
ig drawn in and compressed before exiting from
the delivery port.

1. Pump Impeller 4. Lock-up Clutch

2. Turbine Runner 5. One-way Clutch
3. Stator 6. Converter Front Cover

Figure 4. Torque Converter

 CONSTRUCTION AND FUNCTION 7A1-7

SHAFT intermediate shaft

* The intermediate shaft transmits the driving force
(Figure 6) from the front clutch to the rear planetary gear.
Overdrive (0/D) input shaft The oil passage (C) inside the intermediate shaft
* The O/D input shaft (O/D planetary gear} is engaged is used to supply the oil to all parts as the
with the turbine runner and the lock-up piston inside lubricant.
the torque converter. Therefore, the driving force of
the engine reaching the torque converter is Output shaft
transmitted to the O/D planetary gear. « The output shaft transmits the driving force
The ail hole (A) inside the O/D input shaft serves as reaching the front and rear planetary gears to the
the torque converter operating pressure supply propeller shaft. The output shaft is engaged with
passage when the lock-up clutch is disengaged. it also the front planetary ring gear and the rear
serves as the lubricant supply passage to all parts. planetary carrier. The parking gear, which is used
to fix the output shaft and detect rotation, is also
Input shaft engaged by way of spline.
« The input shaft transmits the driving force from The oil passage (D) inside the output shaft is
the O/D planetary gear to the front clutch. used to supply the lubricant to all parts.
The oil hole (B) inside the input shaft is used to
supply the oil, cooled by the oil cooler, to all parts
as the lubricant.

l 1
nivit ket

Ss real
a=

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Asal
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wt o

Tak
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Tiff Oo.

1. Overdrive input Shaft

2. Input Shaft
3. Intermediate Shaft
4, Output Shaft

Figure 6. Shaft
7A1-8 CONSTRUCTION AND FUNCTION

GEAR SHIFTING MECHANISM * As shown in the figure, each planetary gear is

constructed of three elements; a sun gear, pinion
« The 450-43LE type transmission combines three gears, a ring gear, and a planetary carrier.
sets of planetary gears, three sets of multi-plate Gear shifting is achieved by conditioning two of
clutches and multi-piate brakes, and two sets of the three elements, namely the sun gear, internal
one-way clutches to achieve forward (4 speeds) gear, and the planetary carrier.
and backward (1 speed) gear shifting. * The planetary gears are locked by the clutch, brake,
and one-way clutch, according to the gear shifting.
Principle of gear shifting
* The automatic transmission uses three sets of
planetary gears unlike the parallel gears that are
used in the manual transmission.
- Planetary gears have the advantage of a compact
configuration because of the way they are
constructed with a single central shaft (one axis).
* Also, unlike the manual transmission gears that
require changing of gear mesh, the gear ratio of the
planetary gears can be changed more easily by
locking, releasing or rotating only some of their parts.
* A planetary gear is made up of a sun gear at its
center and pinion gears each of which rotates
about its own center and also along the sun gear. 1. Sun Gear
* Also, since the pinion gears are further supported 2. Pinion Gear
by the planetary carrier, they rotate as a unit in 3. Ring Gear
the same direction and at the same rate. 4. Planetary Carrier

Figure 7, Planetary Gear

 CONSTRUCTION AND FUNCTION 7A1-9

Overdrive Direct Clutch

(Figure 8)
When engaged
* The operating pressure (A), switched by the
control valve, acts on the O/D direct clutch piston
(3) to connect the clutch disk (8) and clutch plate
(7). This also connects the O/D sun gear (11) and
O/D planetary carrier (12). As the result, the
entire O/D planetary gear works as a unit to
transmit the engine torque from the O/D input
shaft (13) to the input shaft (74).

When disengaged
« Since the operating pressure is not sent to the
O/D direct clutch piston (3} when disengaging it,
the clutch piston is returned by the return spring
(5).
* The clutch plate (7) separates from the clutch disk
(8) cutting the power transmission.

O/D Direct Clutch Drum

-

O-ring
wh

O/D Direct Clutch Piston

O-ring
Oop

O/D Direct Clutch Return Spring

Snap Ring
Clutch Plate
SOSBN

Clutch Disc
Clutch Flange
Snap Ring
ek oe

1. O/D Planetary Sun Gear

=

. O/D Planetary Carrier

RD
oh

13. O/D Input Shaft

. Input Shaft
>Re

. Operating Pressure

Figure 8. Overdrive Direct Clutch

7A1-10 CONSTRUCTION AND FUNCTION

Front Clutch
(Figure 9)
When engaged
- The operating pressure (A), switched by the
control valve, acts on the front clutch piston (4) to
connect the clutch disk (9) and clutch plate (8).
As the result, the engine torque is transmitted
from the input shaft (15) to the front clutch hub
(12).

When disengaged
» Since the operating pressure is not sent to the
front clutch piston (4) when disengaging it, the
clutch piston is returned by the return spring (5).
* The clutch plate (8) separates from the clutch disk
(9) cutting the power transmission.

1.1 Front Clutch Drum

2 . O-ring
3 . O-ring
4 . Front Clutch Piston
5 . Front Clutch Return Spring
6 . Snap Ring
7 . Clutch Cushion Plate
8 . Clutch Plate
9g . Clutch Disk
10 . Thrust Bearing Race
11. Thrust Bearing
12 . Front Clutch Hub
13 . Rear Clutch Hub
14 . Snap Ring
15 . input Shaft
16 . Intermediate Shaft
A . Operating Pressure

Figure 9. Front Clutch

 CONSTRUCTION AND FUNCTION 7A1-11

Rear Clutch
(Figure 10)
When engaged
+ The operating pressure (A), switched by the
control valve, acts on the rear clutch piston (7) to
connect the clutch disk (3) and clutch plate (4).
As the result, the engine torque is transmitted
from the front clutch hub (12) to the front sun gear
(11).

When disengaged
* Since the operating pressure is not sent to the
rear clutch piston (7) when disengaging it, the
clutch piston is returned by the return spring (6).
* The clutch plate (4) separates from the clutch disk
(3) cutting the power transmission.

12 10 7 11

1. Snap Ring
2. Glutch Flange
3. Clutch Disk
4. Clutch Plate
5. Snap Ring
6. Rear Clutch Piston Return Spring
7. Rear Clutch Piston
8. O-ring
9. O-ring
10. Rear Clutch Drum
11. Front Planetary Sun Gear
12. Rear Clutch Hub
A. Operating Pressure

Figure 10. Rear Clutch

7A1-12 CONSTRUCTION AND FUNCTION

Overdrive Brake
(Figure 11)
When engaged
* The operating pressure (A), switched by the
control valve, acts on the O/D brake piston (8) to
connect the clutch disk (3) and brake plate (4 and
5). This also locks the O/D direct clutch (12) to
the O/D case (11). As the result, the O/D
planetary sun gear (13) is locked in position.

When disengaged
« Since the operating pressure is not sent to the
O/D brake piston (8) when disengaging it, the
clutch piston is returned by the return spring (7).
* The brake plate (4 and 5) separates from the
clutch disk (3) cutting the power transmission.

12 11 8

Snap Ring 13
Brake Flange
Clutch Disk
Brake Plate
Brake Plate
Snap Ring
O/D Brake Return Spring
O/D Brake Piston
O-ring
O-ring
. O/D Case
. O/D Direct Clutch
. O/D Planetary Sun Gear
. Operating Pressure

Figure 11. Overdrive Brake

 CONSTRUCTION AND FUNCTION 7A1-13

2nd Brake
(Figure 12)
When engaged
« The operating pressure (A), switched by the
control valve, acts on the brake piston No. 1 (7) to
connect the clutch disk (3) and brake plate (4).
This also locks the rear clutch (11) to the center
support (10).

When disengaged
* Since the operating pressure is not sent to the
brake piston No. 1 (7) when disengaging it, the
brake piston is returned by the return spring (6).
* The brake plate (4) separates from the clutch disk
(3) cutting the power transmission.

. Snap Ring
=

. Brake Flange
Coen & GA

. Glutch Disk
. Brake Plate
. Snap Ring
ama

. 2nd Brake Return Spring

. Brake Piston No. 1
. O-ring
. O-ring
10. Genter Support
11. Rear Clutch
A. Operating Pressure

Figure 12. 2nd Brake

7A1-14 CONSTRUCTION AND FUNCTION

ist and Reverse Brake

(Figure 13)
When engaged
* The operating pressure (A), switched by the
control valve, acts on the 1st and reverse brake
piston (8) to connect the clutch disk (3) and brake
plate (5). This also locks the 1st and reverse
brake hub (11) to the transmission case (12). As
the result, the front planetary carrier (13) is locked
in position.

When disengaged
« Since the operating pressure is not sent to the 1st
and reverse brake piston (8) when disengaging it,
the brake piston is returned by the return spring
(7).
¢ The brake plate (5) separates from the clutch disk
(3) cutting the power transmission.

Snap-Ring
CHONAAPRWON

Brake Flange
Clutch Disk
Brake Cushion Plate
Brake Plate
Snap Ring
ist and Reverse Brake Return Spring
1st and Reverse Brake Piston
O-ring
O-ring
. 1st and Reverse Brake Hub
. Transmission Case
. Front Planetary Carrier
Operating Pressure

Figure 13. 1st and Reverse Brake

 CONSTRUCTION AND FUNCTION 7A1-15

Planetary Gear
(Figure 14)
* Three sets of Simpson type planetary gears are
used to achieve the total of five gear ratios
including 4 forward and 1 backward ratios.

1. O/D Direct Clutch Drum and

O/D One-way Clutch Inner Race
2. O/D One-way Clutch Outer Race
3. O/D One-way Clutch

Figure 15 O/D One-way Clutch

One-way Clutch No.2

(Figure 16)
* The one-way clutch No.2 is locked during
acceleration in ist speed to fix the front planetary
carrier.
* It idles in 2nd, 3rd and 4th speeds.

. O/D Sun Gear

. O/D Planetary Carrier
OOONOTRWNa

. O/D Pinion Gear

ro TTT y

, O/D Ring Gear

. Front Sun Gear
. Front Planetary Carrier
. Front Pinion Gear
. Front Ring Gear
Rear Sun Gear
Rear Planetary Carrier 1. Front Planetary Carrier and
voc

. Rear Pinion Gear One-way Clutch No. 2 Inner Race

4

. Rear Ring Gear

— a

2. One-way Clutch No. 2

BO

3. One-way Clutch No. 2 Outer Race

Figure 14 Planetary Gear
Figure 16 One-way Clutch No.2

Overdrive (0/D) One-way clutch

(Figure 15)
* The O/D one-way clutch is locked during
acceleration in ist, 2nd or 3rd speed to maintain
the O/D sun gear fixed to the O/D planetary
carrier.
« The O/D one-way clutch idles in 4th speed.
7A1-16 CONSTRUCTION AND FUNCTION

ACCUMULATOR
« The accumulator helps a smooth increase of the
operating pressure in the respective friction
element to ease the gear shifting shock.
* During a gear shift, the accumulator control
Transmission
pressure regulated by the respective accumulator
control valve is applied to the back of the Case
accumulator to ease the gear shifting shock.

Transmission
Case

Figure 19. Overdrive Brake Accumulator

Transmission
Case

Figure 17. Front Clutch Accumulator

Transmission
Case

fo
Figure 20. 2nd Brake Accumulator

Figure 18. Rear Clutch Accumulator

 CONSTRUCTION AND FUNCTION 7A1-17

SOLENOID Lock-up solenoid

(Figure 22)
No.1 and No.2 Shift Solenoids « This solenoid is fitted in the lower part of the
(Figure 21) valve body. It controls the lock-up oil pressure by
* These solenoids are fitted in the lower part of the a signal from the TCM according to the duty
valve body. They are turned on or off by a signal cycle.
from the TCM to control the gear shifting.
* The ON/OFF combinations of the two solenoids
are used to control the gear position as shown
below. Upward: OFF

Gear Position | 1st 2nd 3rd Ath

Solenoid gear | gear | gear | gear

No.1 shift solenoid | ON ON | OFF | OFF

No.2 shift solenoid | OFF ON ON OFF

Timing Solenoid
Downward: ON
(Figure 21)
« This solenoid is fitted in the lower part of the
valve body. It is turned on or off by a signa! from
the TCM to control the timing during 2nd and 3rd
gear shifting. Figure 22. Lock-up Solenoid

Line Pressure Solenoid

(Figure 23)
Upward: OFF « This solenoid is fitted in the upper part of the
valve body and integrally consists of the
electromagnetic component and the pressure
reguiating valve. it controls the line pressure by a
signal from the TCM according to the electric
current.

Downward: ON
P- Out

Figure 21. No.1, No.2 Shift Solenoids and

Timing Solenoid

Downward: ON

Figure 23. Line Pressure Solenoid

7A1-18 CONSTRUCTION AND FUNCTION

AUTOMATIC TRANSMISSION FLUID AUTOMATIC TRANSMISSION FLUID

(ATF) THERMOSENSOR (ATF) TEMPERATURE SWITCH
* The sensor is fitted to the valve body in the « This switches fitted to the right side of the
transmission. It converts a change in temperature transmission case. It detects abnormal high
into a continuous electrical signal, which is sent to temperature of the ATF to protect transmission
the transmission control module (TCM) (figure 24 (figure 26).
and 25).

Figure 26. ATF Temperature Switch

Figure 24. ATF Thermosensor

INHIBITOR SWITCH (NEUTRAL/

START SWITCH)
Resistance———»

(Figure 27)
« Inhibitor switch is attached to the right side of the
transmission, and detects P, R, N, D, 2 and 1
range of selector lever.
* Inhibitor switch is set to be “ON” when selector
lever is shifted to P, R, N, D, 2 and 1 range.
« Aiso, inhibitor switch is connected to starter
switch circuit and makes engine-starting possible
when selector lever is only P or N range.

Temperature ——p

Temperature | Resistance | Temperature | Resistance

°C (°F) Q °C (°F) Q

-1

Figure 25. Output Characteristic of ATF

Thermosensor

Figure 27. Inhibitor Switch

 CONSTRUCTION AND FUNCTION 7A1-19

KICK-DOWN SWITCH
(Figure 28) ask
* The kick-down switch is fitted to the accelerator
pedal. When the pedal is fully depressed, it sends 4.0
an electrical signal to the transmission control

Output voltage (V)

module (TCM).

w
o
;
°oe
_
10 20 30 40 50 60 70 80 90 100
Throttle opening angle (%)
EEE : Allowable area
(Relating to bariation of accelerator pedal cable
stroke or adjustment of throttle position sensor)

Figure 29. Output Characteristic of Throttle

Position Sensor

Figure 28. Kick-down Switch and

Throttle Position Sensor

THROTTLE POSITION SENSOR

(Figure 28 and 29)
* The throttle position sensor is fitted to the
accelerator pedal. It converts the physical throttle
opening angle into a continuous electrical signal,
to the TCM.
* The TCM detects the throttle opening angle and
the speed at which the pedal is depressed by the
electrical signal of the throttle position sensor
having output characteristics as shown (figure
29).
7A1-20 CONSTRUCTION AND FUNCTION

VEHICLE SPEED SENSOR 2 VEHICLE SPEED SENSOR 1

(Fitted to the speedometer driven gear) (Fitted to the extension housing)
« The vehicle speed sensor 2 is fitted on the * This sensor detects the speed of revolution of the
speedometer driven gear assembly. parking gear fitted to the output shaft, and
+ The number of pulses generated is four pulses generates a pulse (AC=Alternating Current) signal
(AC) per one rotation of the pinion shaft (figure accordingly (figure 31).
32). * The pulse signal is sent to the transmission
control module (TCM) where it is converted into
the vehicle speed.
« Should the vehicle speed sensor 2 malfunction for
any reason, the vehicle speed sensor 1 takes
over control.

ie:

Figure 30. Vehicle Speed Sensor 2 Location

Figure 32. Vehicle Speed Sensor 1

Figure 31. Vehicle Speed Sensor 2

 CONSTRUCTION AND FUNCTION 7A1-21

ENGINE SPEED SENSOR TRANSMISSION CONTROL

MODULE (TCM)
(Figure 33)
« The engine speed sensor fitted on the timing gear The TCM is fitted under the meter cluster by
case. means of four stud bolts. It receives signals from
+ It detects the speed of revolution of the injection various sensors and judges the running condition
pump drive gear and generates a pulse (AC) of the vehicle accordingly. It compares the result
signal accordingly. with programmed gear shifting parameters, lock-
* The pulse signal is sent to the TCM where it is up operating parameters, etc., and sends signals
converted into the engine revolution. to solenoids and controls them accordingly.
e It controls seven different items:

1. Line pressure
2. Gear shifting (including overdrive control)
3. Lock-up
4, Exhaust brake
5, “2-3” timing
6. Self-diagnosis
7. Fail-safe function

Figure 33. Engine Speed Sensor

7A1-22 CONSTRUCTION AND FUNCTION

CONTROL MECHANISM

CONTENT OF FUNCTION AND CONTROL

Item Description
Line pressure control + The line pressure solenoid is controlled by the TCM, based on signals from inhibitor
switch and those regarding vehicle speed, throttle opening angle, etc., to automatically
control the pressure regulator.
This keeps oil pump delivery pressure at an optimal line pressure for driving condition.
Line pressure parameters including line pressure for continuous driving and that for
gear shifting are stored in the TCM’s microcomputer and appropriate parameters are
selected from time to time.

Gear shift control * No. 1 and No. 2 shift solenoids are controlled by the TCM, based on signals from
inhibitor switch and those regarding vehicle speed, throttle opening angle, etc., to
automatically shift gears to an optimal pattern.

O/D up-shift « When O/D OFF switch is turned off or when the transmission fluid temperature is iow,
inhibition contro! upshifting to Ds speed (O/D) is prohibited.

Lock-up control « When driving in Ds, Ds and Dz gear, TCM activates the lock-up solenoid based on
vehicie speed, throttle opening angle and other signals to automatically control lock-up
operation.
+ When transmission fluid temperature is low, the TCM prohibits lock-up operation.
* When ABS operation signal is supplied to TCM, the TCM prohibits coast lock-up
control.

Engine brake control * The TCM activates the solenoid based on signals from inhibitor switch, and throttle
position sensor to automatically control clutch operation. When exhaust brake is used,
it increases line pressure to ensure sufficient clutch capacity.

Fail-safe function * In case of malfunction of the vehicle speed sensor, throttle position sensor, all
solenoids or inhibitor switch, TCM automatically begins fail-safe control to minimize
effects on driving.

Self-diagnosis function * in case of malfunction (with key switch turned on) in vehicle speed sensor, throttle
position sensor, all solenoids, ATF thermosensor or engine RPM signal, check trans
light at meter panel starts blinking to warn the driver. Malfunctioning system diagnostic
trouble data is stored in the TCM and, when self-diagnosis start signal is received, the
TCM causes the check trans light to blink in a special rnanner to indicate the
diagnostic result.

Throttle learning * The varied throttle position sensor voltage is corrected within the TCM to ensure
control constant gear-shift control.

Serial data control « TCM data (such as the vehicle and engine speed) is checked and actuator test
controlled by sending signals fram “Scan Too!” to the communication program
incorporated in the TCM.

Exhaust brake control « When vehicle speed is lower than regulated speed, while shifting or while lock-up
QWS control operation, TCM cuts exhaust brake operation and QWS operation.

ATF: Automatic Transmission Fluid O/D: Overdrive TCM: Transmission Control Module
QWS: Quick Warming-up System ABS: Anti-lock Brake System
 CONSTRUCTION AND FUNCTION 7A1-23

CONTROL ITEM, INPUT AND

OUTPUT

Control tem Shift ie Timing Line | Throttle Exhaust! Engine

contrat (Exoop- solenoid | Lock-up | pressure | learning | Fail-safe wag. brake/ over-run
item Ne (Main) | io n) control control | control QWS | warning

Vehicle speed Spee o}lolololo};o;olojo

Vehicle speed |Fitedto | Oo] Of O10; 0} 0 o}| oO

Engine speed sensor O © O O OQ

Idle signal (*2) O ©

Kick-down switch (*2) Oo O

Throttle position sensor | © © © © O O @ ©

+s | ATF thermo switch © O

£ ATF thermosensor O O

Exhaust orake operation signal O O © ©

QWS operation signal O © Oo

FICD O O

O/D OFF switch © O O

Brake switch Oo O Oo

ABS operation signal O O

Inhibitor switch O O O O O O e O O O

No.1 shift solenoid O O @ O

No.2 shift solenoid O O @ O

Timing solenoid O O @ O

= Lock-up solenoid © O O

3 Exhaust brake/QWS cancel signal O O O

Line pressure solenoid @ OQ

Check trans indicator O O

O
Engine over-run indicator
(If equipped)

*1: Back-up for vehicle speed sensor 2 QWS : Quick Warming-up System
*2: Back-up for throttle position sensor FICD : First Idle Control Device
ATE : Automatic Transmission Fluid ABS : Anti-lock Brake System
O/D : Overdrive
@ : Causes “Check Trans” light to flash.
7A1-24 CONSTRUCTION AND FUNCTION

MAJOR INPUT/OUTPUT
COMPONENT FUNCTION

Component Function

Vehicle speed sensor 1 Detects output shaft revolution and sends RPM signal to TCM.
(Fitted to transmission)
In case of malfunction of vehicle speed sensor 1 fitted to the
Vehicle speed sensor 2
transmission, a signal from this sensor (spare sensor) is used for
(Fitted to speedometer driven gear)
continued control.

Engine speed sensor Detects engine revolution and sends signal to TCM.
Idle signal (from ECM) rents when accelerator pedal is fully released and sends signal to

This switch detects when the accelerator pedal is fully depressed and
Kick-down switch sends signal to TCM.
Fitted to accelerator pedal; detects throttle opening angle and pedal
Throttle position sensor operating speed and sends signal to TCM.
ATF thermo switch Detects abnormal high temperature of ATF and sends signal to TCM.
3
= ATF thermosensor Detects ATF temperature and sends signal to TCM.

Exhaust brake operation signal | Detects whether exhaust brake is in use and sends signal to TCM.

QWS operation signal Detects whether QWS is in use and sends signal to TCM.

FICD operation signal Detects whether FICD is in use and sends signal to TCM.

ABS operation signal Detect whether ABS is active and sends signal to TCM.

O/D OFF switch Detects O/D OFF switch ON or OFF position and sends signal to TCM.

Brake switch Detects when brake pedai is depressed and sends signal to TCM.

Inhibitor switch Detects select lever position and sends to TCM.

s Judges necessary line pressure, gear shifting point, lock-up

= | TCM operation and engine brake based on electrical signals from switches
& and sensors and sends appropriate signals to solenoids.
No.1 and No.2 Selects appropriate gear shifting position for current driving condition
shift solenoids based on signal from TCM.
oy . Controls the timing during 2nd and 3rd shifting based on signal from
Timing solenoid TCM.
Solenoid . Regulates (decreases) lock-up pressure to appropriate level for
Lock-up solenoid | current driving condition based on signal from TCM.
2 Line pressure Regulates (decreases) oil pump delivery pressure to the appropriate
a solenoid line pressure for current driving condition based on signal from TCM.

Exhaust brake/QWS cancel signal | Cancel exhaust brake and QWS.

Check trans light Indicates transmission malfunction.

Engine over-run warning light Indicates engine over-running.

(If equipped)
32 Self-diagnosis (such as check of vehicle input/output values and
25) Scan Tool actuator test) is performed by connecting TCM and “Scan Tool”.
 CONSTRUCTION AND FUNCTION 7A1-25

CONTROL CIRCUIT BLOCK

DIAGRAM

Learning
control

Gear shift
Throttle control
position
sensor

ate
signal Throttle
Me
solenoid
pressure
control
No. 2
FICD shift
signal solenoid

Throttle
Inhibitor pressure
switch solenoid
Lock-up
control

Kick-down Lock-up
switch solenoid

Engine
Engine over-run
warning _.
speed Timing
control
sensor solenoid

O/D OFF
switch 2-3 shift
control

ATF Exhaust
temperature brake/QWS
control .
switch Engine
over-run
wer
Brake (if equipped}
switch
Fail-safe
control
Exhaust
brake
switch

Vehicle
speed Maifunction
sensor No. 1 memory
storage
Vehicle
speed
sensor No. 2

ABS signal

Self-
diagnosis Check trans
Diagnostic control light
enable

Scan tool |< Serial data

ij

control

Figure 34. Control Circuit Block Diagram

7A1-26 CONSTRUCTION AND FUNCTION

CIRCUIT DIAGRAM

DATA
LINK
CONNECTOR
B79

879

J-19 |(3) RELAY ENG WARM CUT2

[219]4) peLaviena WARM GUT2

vsv,Fiso
[B-233](04) ecm
a
wt
3
218] (2) RELAY,EXH BRAKE LINE PABESS SOL

IB 110) (7) EBCM

F-1 9] 10A STOP | 'GHT Ol. TEMP SENSOR

STOP LIGHT

@
[Fa2 140A SW;STOP LIGHT [5-254
METER.BACK [B-233](1) ECM
JOINT CONNECTOR2

[Besq) ecm
0.58
JOINT
CONNECTOR

CONT
[e-1eo})
SW;0D OFF

[55] METER

RELAY;TAIL BACK UP LIGHT

[Bz2ke) } SW,INHIBITOR

CHECK TRANS

Hed
AT OWL TEMP OSY/G 0.5W/G

(5) RELAY,STARTER
{| FRAME

Figure 35. Circuit Diagram

 CONSTRUCTION AND FUNCTION 7A1-27

VALVE OPERATION
VALVE FUNCTION
Upper Vaive Body
(figure 36)

Valve name Function

(1) 2-3 shift valve Shifts between the 2nd and the 3rd gears.

When the gear is shifted to the R range when the vehicie is

(2) | « Reverse inhibitor valve running forward at high speed, this valve provides the necessary
solenoid output to prevent shifting to the reverse gear.

» Regulates the line pressure before it is supplied to the lock-up

(3) Modulator valve
signal valve, orifice control valve, etc.

Regulates the signal pressure (throttle pressure) to regulate the

(4) Throttie valve
line pressure to the optimum level for the driving conditions.

Controls the oil pressure being sent from the primary regulator
Secondary regulator valve valve to the torque converter, and controls the pressure of the
es
&

lubricant being supplied to all parts.

(6) Reducing valve » Reduces the line pressure before it is supplied to the throttle valve.

(7) Lock-up signal valve Activates or deactivates the lock-up function.

Lowers the back pressure of the accumulator to the low throttle

(8) Accumulator control valve opening angle, and acquires from line pressure the necessary
accumulator control pressure for easing the gear shifting shock.

Regulates pressure from the line pressure to a low pressure to

(9) Low coast modulator valve
ease the gear shifting shock when shifting to the L range.
°

(10) | + Orifice control valve Switches the orifices to reduce the shock.

When the gear is shifted to the L range when driving at high

(11) | « Low inhibitor valve speed, this valve shifts to the 3rd gear at the timing solenoid
output.
Switches the oil passage to the rear clutch (C2) between the D
(12) Check valve range and the R range.
7A1-28 CONSTRUCTION AND FUNCTION

Lower Vaive Body

(Figure 36)

Valve name Function

Switches the oil passage to the P, R, N, D, 2, or L range according

(1) *« Manual valve
to the select lever action.

(2) 1-2 shift valve Switches between the 1st and the 2nd gears.

(3) « 3-4 shift valve Switches between the 3rd and the O/D gears.

(4) « Pressure relief valve Regulates the supply pressure to the cooler to the low pressure.

Controls the oil pressure (line pressure) reaching respective

* Primary regulator valve
elements.

* Lock-up contro! valve Switches the flow of fluid being sent to the torque converter.

Eases the gear shifting shock when shifting from the 3rd to 2nd
* CO exhaust valve
gears.

Optimizes the oil pressure switching timing to ease the shock

(8) 2-3 timing valve
when shifting from 2nd to the 3rd gears.

Causes the cut-back pressure to act upon the throttle vaive to

(9) Cut-back valve
lower the line pressure.
 CONSTRUCTION AND FUNCTION 7A1-29

VALVE BODY CONSTRUCTION

Upper Valve Body:

. 2-3 Shift Valve
=

. Reverse Inhibitor Valve

COON

. Modulator Valve
OA BWND

. Throttle Valve
. Secondary Regulator Valve
. Reducing Vaive
. Lock-up Signal Valve
. Accumulator Contro! Valve
. Low Coast Modulator Valve
10. Orifice Control Valve
11. Low Inhibitor Valve
. Check Valve

Lower Valve Body:

. Manual Vaive
=

. 1-2 Shift Valve

h®N

. 3-4 Shift Valve

. Pressure Relief Vaive
. Primary Regulator Valve
an

. Lock-up Control Valve

. CO Exhaust Valve
OOanN

. 2-3 Timing Valve

. Cut-back Valve

x ;
O
| jlof Xo) [Tro eS ‘|
\

Figure 36. Valve Body Construction

7A1-30 CONSTRUCTION AND FUNCTION

GEAR TRAIN (TRANSMISSION MECHANISM) OPERATION

CONSTRUCTION AND OPERATION gears, three pairs of multi-plate clutches, three

pairs of multi-plate brakes and two pairs of one-way
The gear train consists of three pairs of planetary clutches.

12 34 6 7 8 9 10 11 1213

poo Vv q

|
- CE
as
[a inpat Stat input Shae | _ ems _Loutputsnat
|
145 15 16 17

1. O/D Direct Clutch (CO) 7. 2nd Brake (B1) 13. Rear Pinion Gear
2. O/D Brake (BO) 8. Rear Clutch (C2) 14. O/D One-way Clutch (FO)
3. O/D Ring Gear 9, No. 2 One-way Ciutch (F1) 15. Front Sun Gear
4, O/D Pinion Gear 10. Front Ring Gear 16. Front Pinion Gear
5. O/D Sun Gear 11. ist and Reverse Brake (B2) 17. Rear Sun Gear
6. Front Clutch (C1) 12. Rear Ring Gear

Figure 37. Construction of Automatic Transmission

 CONSTRUCTION AND FUNCTION 7A1-31

COMPONENT NAME AND FUNCTION

Component name Symbol Function
O/D direct clutch Co Connects ©/D sun gear and O/D carrier.
Front clutch C1 Transmit the engine torque from the input shaft to the
intermediate shaft.
Rear clutch C2 Transmit the engine torque fram the front clutch hub to the front
and rear planetary sun gear.
O/D brake BO Locks the ©O/D planetary sun gear.
2nd brake Bt Locks the front and rear planetary sun gear.
1st & Rev. brake B2 Locks the front planetary carrier.
0/D one-way clutch FQ Locks the O/D sun gear and O/D planetary carrier during
acceleration in 1st, 2nd or 3rd gear.
One-way clutch No.2 Fi Locks the front planetary carrier during acceleration in 1st gear.
No.1 shift solenoid $1 The ON/OFF combinations of the two solenoids are used to
No.2 shift solenoid S2 control the gear position.

COMPONENT AND THEIR OPERATING CONDITION

Shift
position co Ci C2 BO B1 ye
Be ro
FO cr
Fi $1 $2 Remarks

P © ©

R oO © © ®
N O ©

ist © O @ @ ©)

2nd O O ® oO; oO Automatic

shift control
D
3rd O O O @ O lee2e3ead
oO/D oO O O

{st O 0 © ® O Automatic
2 | 2nd O O QO € O Q shift contro!
" lo2e3
3rd O O O @ O

ist O Oo © ® 8 O
- ~ Fixed at 1st speed
L | 2nd © O © @ © © 1o—263(')

3rd O O © ® ©

© - Engaged
@ - Operative when accelerating
* . 3rd gear engaged when the timing solenoid is active
7A1-32 CONSTRUCTION AND FUNCTION

N AND P RANGES P range

* As in the case of the N range above, the torque
N range from the input shaft is not transmitted to the
* The front clutch (C1) and the rear clutch (C2) are output shaft. The parking lock pawl, which is
released. The torque from the input shaft is not linked to the select lever, is engaged with the
transmitted to the output shaft. parking lock gear, which is directly coupled with
the output shaft. The vehicle is locked as the
result.

_ C1

b G2

IL] L— mes
c. ___O/D Input Shalt Input Shaft [ __lntermediate Shaft . _ . _ | Output Shaft_

1. Parking Lock Gear

2. Parking Lock Pawl

Figure 38. N and P Range

 CONSTRUCTION AND FUNCTION 7A1-33

FIRST GEAR IN D OR 2 RANGE The clockwise rotational force of the input shaft is
transmitted, by the front clutch (C1), from the
The O/D direct clutch (CQ), front clutch (C1), O/D intermediate shaft to the rear planetary ring gear
one-way clutch (FO) and No.2 one-way clutch (F1) and to the rear planetary pinion gear. Since the
are activated to form the ist gear. In the O/D rear planetary carrier is stopped at this time due to
planetary gear, the O/D direct clutch (CO) connects the vehicle load, the rear sun gear receives the
the O/D planetary carrier (O/D input shaft) to the counterclockwise rotational force and transmits it to
O/D sun gear. This prevents the O/D pinion gear the front planetary pinion gear. This causes the
from turning so that the O/D planetary carrier front planetary carrier to turn counterclockwise.
transmits the driving force to the input shaft along However, since the front planetary carrier is
with the O/D ring gear as a unit (direct coupling). prevented from turning counterclockwise by the
When the O/D planetary carrier turns clockwise the one-way clutch No.2 (F1), the pinion gear causes
O/D pinion gear tends to turn counterclockwise the front ring gear and the rear planetary carrier to
causing the O/D sun gear to turn clockwise. turn clockwise so that the driving force is
However, since it turns faster than the O/D transmitted to the output shaft.
planetary carrier, the O/D one-way clutch (FO) locks (Rotational direction is viewed from torque
the O/D planetary carrier with the O/D sun gear. converter side)
This prevents the O/D pinion gear from turning, as
in the case when the O/D direct clutch (CO) is
activated, so that the O/D planetary carrier transmit
the driving force to the input shaft along with the
O/D ring gear as a unit (direct coupling). The two-
way transmission of the power helps to ease the
load being applied to the O/D direct clutch (CO).

Path of power transmission

O/D input shaft

¥
O/D planetary carrier

O/D planetary pinion gear

¥
O/D planetary ring gear
¥
Input shaft
¥
Front clutch

¥
Intermediate shaft

¥
Rear planetary ring gear

¥
Rear planetary pinion gear ACCES Front and rear planetary sun gear

¥ ¥
Front planetary pinion gear
Rear planetary carrier

4%
Output shaft rl Front planetary ring gear
7A1-34 CONSTRUCTION AND FUNCTION

Cc. . O/D Input Shaft _ [_ input Shaft | _ | Output shat |

iv =,

Output

a a

Pianetary gear rotate Locked by one-way

as @ unit (direct coupling) clutch {Ft}

Figure 39. First Gear in D or 2 Range

SECOND GEAR IN D RANGE gear. At this time, the rear sun gear which is
engaged with the pinion gear receives a
The front clutch (C1), 2nd brake (B1), and O/D one- counterclockwise rotational force. However, since it
way clutch (FO) are activated to form the 2nd gear. is prevented from turning by the 2nd brake (B1), the
In the 2nd gear, the rotational force of the input rotational force is not transmitted to the front
shaft caused by the O/D one-way clutch (FO) is planetary gear. It is transmitted via the rear pinion
transmitted from the intermediate shaft to the rear gear to the rear planetary carrier and to the output
planetary ring gear and to the rear planetary pinion shaft.

Path of power transmission

O/D input shaft

¥
O/D planetary carrier Intermediate shaft

¥ ¥
O/D planetary pinion gear Rear planetary ring gear
¥ ¥
O/D planetary ring gear Rear planetary pinion gear
+ ¥
Input shaft Rear planetary carrier

% ¥
Front clutch Output shaft
 CONSTRUCTION AND FUNCTION 7A1-35

C .. O/D Input Shaft

—

input Shaft
__,
~ | outputshat
|

|
a
Planetary gear rotate Front planetary sun Rear planetary sun
as a unit (direct coupling) gear is locked gear is locked

Figure 40. Second Gear In D Range

7A1-36 CONSTRUCTION AND FUNCTION

THIRD GEAR IN D, 2, L RANGE the front clutch (C1) and the rear clutch (C2).
Therefore, the front and rear planetary pinion gears
The O/D direct clutch (CO), front clutch (C1), rear are locked so that the pianetary gear turns as a
clutch (C2), and O/D one-way clutch (FO) are unit. As the result, the rotational force of the input
activated to form the 3rd gear. In the 3rd gear, the shaft is transmitted directly to the output shaft
intermediate shat and the front and rear sun gears without being reduced.
rotate in the same direction as a unit because of

Path of power transmission

O/D input shaft

¥
O/D planetary carrier
¥
O/D planetary pinion gear
%
O/D planetary ring gear
ya

Input shat ____) Rear clutch

Front clutch Front and rear planetary sun gear

¥ v
Intermediate shaft Rear planetary pinion gear Front planetary pinion gear

¥ Front planetary ring gear

Rear planetary ring gear

¥
Rear planetary pinion gear

¥
Rear planetary carrier

Output shaft
 CONSTRUCTION AND FUNCTION 7A1-37

_ Ti] y

C2 i
|

— eee
_input Shaft __ intermediate Shaft \. . . _| Output Shaft |

Planetary gear rotate Planetary gear rotate Planetary gear rotate

as a unit (direct coupling) as a unit (direct coupling) as a unit (direct coupling)

Figure 41. Third Gear in D, 2, L Range

7A1-38 CONSTRUCTION AND FUNCTION

OVERDRIVE GEAR IN D RANGE rotational force which is transmitted from the O/D
input shaft to the O/D planetary carrier causes the
When the overdrive conditions (shown in the table O/D planetary pinion gear to turn about itself and
below) are met in the 3rd gear condition, the O/D revolve at the same time. This increases the speed
direct clutch (CO) is released. At the same time, the of the O/D planetary ring gear (input shaft) and, as
O/D brake (BO) is activated to form the overdrive in the case of the 3rd gear, the rotational force of
gear. In the overdrive gear, the O/D sun gear is the input shaft is transmitted directly to the output
locked by the O/D brake (BO). Therefore, the shaft.

Path of power transmission

O/D input shaft

¥
O/D planetary carrier Overdrive condition
s Shift position D
O/D planetary pinion gear O/D OFF switch OFF
§ ATF temperature (at the cil pan) above 40°C (104°F)

O/D planetary ring gear

Input shdt Oc_,| > Rear clutch

Front clutch Front and rear planetary sun gear

Intermediate shaft Rear planetary pinion gear Front planetary pinion gear

Rear planetary ring gear Front planetary ring gear

4
Rear planetary pinion gear

4
Rear planetary carrier

Output shaft
 CONSTRUCTION AND FUNCTION 7A1-39

Ci

Cc a O/D input Shaft _ _|_tpput Shaft |

& —Output

O/D planetary sun gear Planetary gear rotate Planetary gear rotate
as a unit (direct coupling) as a unit (direct coupling}

Figure 42. Overdrive Gear in D Range

SECOND GEAR IN 2 RANGE driven by the second gear in the D range. When the
engine brake is applied, the counterclockwise
The rotational force is transmitted in the same way rotational force of the O/D sun gear deactivates the
as in the case of the 2nd gear in the D range with a O/D one-way clutch. The engine brake takes no
few exceptions. The clockwise rotation of the O/D effect as the O/D sun gear idles in this condition.
sun gear during the engine brake is prevented by For this reason, the O/D direct clutch (CO) is
the O/D direct clutch (CO). In other words, the activated in the 2nd range to engage the O/D sun
rotational force is transmitted to the input shaft by gear and the O/D planetary carrier so that the
the O/D one-way clutch (FO) when the vehicle is engine brake is effective.

Path of power transmission

O/D input shaft

¥
O/D planetary carrier intermediate shaft

4% v
O/D planetary pinion gear Rear planetary ring gear
v 4%
O/D planetary ring gear Rear planetary pinion gear

4 %
Input shaft Fiear planetary carrier

4 v
Front clutch Output shaft
7A1-40 CONSTRUCTION AND FUNCTION

81

Gi

C2

ect,

Cc . O/D input Shaft | Input Shatt | ___intermediate Shaft _ ~ | output shatt_|}

Output

Planetary gear rotate Front planetary sun Rear planetary sun

as a unit (direct coupling) gear is locked gear is locked

Figure 43. Second Gear in 2 Range

 CONSTRUCTION AND FUNCTION 7A1-41

FIRST GEAR IN L RANGE carrier is locked by the one-way clutch No.2 (F1} so
that the rotational force is transmitted to the output
The rotational force is transmitted in the same way shaft. When the engine brake is applied, however,
as in the case of the ist gear in the D and 2nd a counter force deactivates the one-way clutch
ranges with a few exceptions. When the engine No.2 (F1). This causes the front planetary carrier to
brake is applied, the clockwise rotation of the front idle and the engine brake takes no effect. In the L
planetary carrier is prevented by the 1st and range, the 1st and reverse brake (B2) is activated
reverse brake (B2). When the vehicle is driven by to lock the front planetary carrier so that the engine
the 1st gear in the D or 2nd range, the brake is effective.
counterclockwise rotation of the front planetary

Path of power transmission

O/D input shaft

¥
O/D planetary carrier
¥
O/D planetary pinion gear
4%
O/D planetary ring gear
¥
Input shaft
¥
Front clutch

4
Intermediate shaft

v
Rear planetary ring gear

Rear planetary pinion gear > Front and rear planetary sun gear

4% 4
Rear planetary carrier Front planetary pinion gear

Output shaft EEE Front planetary ring gear

7A1-42 CONSTRUCTION AND FUNCTION

B1

[or
__Intermediate Shaft 1 a . “| . | Output Shaft

Output

Planetary gear rotate Front planetary carrier

as a unit (direct coupling) is locked

Figure 44. First Gear in 1 Range

R RANGE rotational force of the input shaft is transmitted to

the pinion gear of the front planetary gear as the
In the R range, the O/D direct clutch (CO), O/D one- rear Clutch (C2) is active. However, since the front
way clutch (FO), rear clutch (C2) and 1st and planetary carrier is locked by the 1st and reverse
reverse brake (B2) are activated to form the brake (B2), the rotational force of the sun gear is
reverse gear. The rotational force of the O/D input transmitted to the ring gear via the pinion gear so
shaft is transmitted directly to the input shaft as that the counterclockwise rotational force is
does the 1st gear in the D or 2nd range. The transmitted to the output shaft.

Path of power transmission

©/D input shaft

¥
O/D planetary carrier Rear clutch

¥ ¥
O/D planetary pinion gear Front planetary ring gear

¥ ¥
O/D planetary ring gear Front planetary pinion gear

¥ ¥
Input shaft Front planetary carrier
4
Output shaft
 CONSTRUCTION AND FUNCTION 7A1-43

Bo

C2

Cc Y. O/D input Shaft _ __input Shaft | __intermediate Shait i _ _ | Output shat | _

tigre, | 7

Planetary gear rotate Front planetary carrie:

as a unit (direct coupling) is locked

Figure 45. R Range

 AUTOMATIC TRANSMISSION 7A2-1

7A2 DIAGNOSIS

CONTENTS
SUBJECT PAGE

De@SCIiption.........ccccseseceseaseesconensusnonuscaseaueuacvanesessdansontaenecneueaesossusaesaussuucaussurdousesuenssusususeueasunesieueedsuantusnsserscessanss TA2- 2
Diagnosis Procedure ........ccsssssesseeee sneuneens asaenateorsodeorenssenusauserienusoussedvanseuuseusensnsdeueaaseneeenieveetes cneventeusenecuess TA2- 2
Self Diagnosis. ...........cccesecesseesssusessessnerensssssasennersesnose ; 7A2- 3
Self Diagnosis Information TA2- 3
Clearing Memory of the Diagnostic Trouble Code (DTC) ........cscsnssescorsessessonsseseocssnsensuenssesansusvssnssenneaase TA2- 6
Identification of Transmission Control Module (TCM) ...ccusscsssesssccssnseenssssnanesoonsanenentensuurtaresaaensentatsssneeanes TA2- 7
Diagnosis Based on Diagnostic Trouble Code (DTC) .....cneuorsscsensertusrsensusensoeniescenensronneenersaenereevearenneerey 7A2- 8
DTC 11 Vehicle Speed SeMSOr 1.........cscssesesssserrenssescsenssansscsonaeensassenessussuvausesasusansasveesecaaneedsonsegntenseueeaned TA2- 9
DTC 13 Engine Speed Sensor.......ccsenssenssnerssesneriesenevensssaveennsensnnsnuns TA2-14
DTC 15 Automatic Transmission Fluid (ATF) Thermosensor...... 7A2-13
DTC 17 Inhibitor SWitch «0.02... scoceesesstssesaesessserverseenesseesuansaomuesenes 7TA2-15
DTC 19 ABS Operation Signal ........ccsscsscssersssensessnersscnscessaue TA2-17
DTC 21 Throttle Position Sensor ........ eeueuanuensenentueeueetenenaueddereenusuuadsanenenineesusannoceserteuedeedaswaccndacscauenseardenenans 7A2-19
DTC 24 Vehicle Speed Sensor 2........cccscsssceesessesesserscsssaussnmarsvossoncuessnssncenaranseeusesseunssseanseneesasenesenvasssunsenen TA2-22
DTC 31 No.1 Shift SOlOMOI........ cc ccsecncesursetssareneuseusenustenssnrsentiacsnessasuesetorsasensersnesssnereneansuesonteateneenaes sasoere 1 A2-24
DTC 32 No.2 Shift Solenoid. ...........sscsssessessenrsarenssesnenssseseussansosconsnecssvenwesiausdensuoussessuaaiusausecnenuseuasmessuaeauenaes TA2-26
DTC 33 Timing Solenold.............ccssssssescessesssanisccoseessenaseessumnscenuenessnnmessnensantaeesseneuontarsnnasaneaseannenesesntenreren TA2-28
DTC 34 Lock-up SOlemoid.........cssccconsesnerecssnsscensensersussrsessnssssnanrsersusprneonneauneenausensuateaneaessnneauaneonsssenseneracssents 7A2-30
DTC 35 Line Pressure Solenoid .........csscoussecseassnsnsmeseotsnsnsenersusseaceraenerenaaseasueesnscsddsoesuauananseciusuaemumendsuoenes 7A2-32
DTC 37 Exhaust Brake Cut Systerm .......ccccssscsssscsaccranasceneneeceuseveneaunans ieussnsateedenseanensnaveeuneusansonsavesense TA2-34
DTC 38 Engine Warming Up Cut System TA2-36
Diagnosis Based on Vehicle Conditions.........cecsssonercnsesecaveunas
Inspection Based on Faulty SyMptorm ......ccssseccnsseresnerecesennes TA2-40
Wiring Diagra...........cccsssssucssenssssseorrsesneestoresersersesrarnnessennuenvansnrsuesnnenaenuuensanaeninsausuesasarseneneraurnanssarenssavaneseaan TA2-56
Parts Location ........0ccceccuserssseersnes eenucesnuutennieevonsanesniuaesudsesenesunesnansnumeconauesseeenutesenessesaussntenssuaauesaa weauaenasuersoee TA2-57
Connector Configurations........ccusersscceenseseersnenessonsnnecneenee ss uevensvaevauneyaaneeouseueunesevsoonsuanuaneaeuesierssanars TA2-58
Control Signal Inspection 7
Line Pressure TeSt .......:ssesssrssessonrssenenaes
Stall TeSt........---ccecnssoneestnenneurssossascocesnens pbaneeaaucesaueenteceauanagues
Rad TeSt .....ccscccccsssseneneecsseruasssnscsaanscussusucensessoctenceusseesennrens sun eoaenuensencauassedeaueeoaussunsenuenuensansuetenautaene
Shift Point Diagram and Lookup FPoint Diagram. seeasanenusuenneneanaceaaedanvnsne sunanennansaanauosunnucesesnsnnensaerereneneacdenta 7TA2-68
Diagnosis by Using Scan Tool... snsuensseuaeenuenseacdsnenadsusnasauusuecanseutueusqaneuseseaeconsnsnasessunvensenssontnsnasransmenstanocess AQT
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7A2-2 AUTOMATIC TRANSMISSION

DESCRIPTION
DIAGNOSIS PROCEDURE function, a stall test, a line pressure test or a road test
to reproduce such abnormal phenomena so as to fully
When the automatic transmission is out of order, understand what is out of order before starting
something is wrong with the mechanical system or the inspection, adjustment or overhaul.
electrical system such as the hydraulic circuit, friction
element and Transmission Control Module (TCM), and
complicated phenomena may occur sometimes. So,
at the time of diagnosis, perform the self-diagnosis

Occurrence of fault

|
Warehousing io service shop

inspection pene w nner enna See the “ON-VEHICLE SERVICE.”

Ai . Sectional inspection, adjustment

Self-diagnosis (Scan Tool} pO overhaul

| See the “ON-VEHICLE SERVICE.”

» Diagnosis based on diagnostic
trouble code
« Diagnosis based on vehicle
condition
» Inspection based on faulty symptom
«Line pressure test
« Stall test
» Road test

Figure 1. Diagnosis Procedure

 AUTOMATIC TRANSMISSION 7A2-3

SELF DIAGNOSIS
SELF DIAGNOSIS INFORMATION Indication of the Check Trans Light with
the Key Switch Turned On (User Mode)
The transmission control module of this system When the throttle position sensor, vehicle speed
has the function of self diagnosis. lf any trouble sensor, solenoids, etc., starts to malfunction when
occurs in this system, the check trans light the vehicle is running (the key switch turned on),
functions to inform operator of possible troubles the check trans light blinks to warn the driver (figure
related to the following 13 components. 3).
1. Vehicle speed sensor-1 » The check trans light begins to blink as soon as a
{Installed on the Transmission) problem occurs during driving, and keeps blinking
2. Engine speed sensor until it is corrected.
3. Automatic transmission fluid therrnosensor
4. Inhibitor switch
5. ABS operation signal Key switch ON
6. Throttle position sensor
7. Vehicle speed sensor-2
(Fitted on the speedometer driven gear) Normal
8. No.1 shift solenoid
9. No.2 shift solenoid
10. Timing solenoid
11. Lock-up solenoid
2. Line pressure solenoid Trouble occur
13. Exhaust brake cut 4
l
14, Engine warming up cut ON 4 Constant
Abnormal | | | | | | “ ‘lashings
orr— hepnmnnanrnmnifontoabectactee}e-
32 04 04 04

Fo
04 04 (sec.)

Figure 2b. Check Trans Light Display

Figure 2a. Check Trans Light

7A2-4 AUTOMATIC TRANSMISSION

Indication of the Check Trans Light Indication of Self-Diagnostic Results

During Self-Diagnosis (Dealer Mode) A diagnostic trouble code (DTC) registered in
To help the mechanic locate the problem more memory can be displayed by the connection of
easily, the check trans light blinks in different terminal 11 and terminal 4 or 5 of the data link
cycles. Each cycle represents one of the eleven connecter (DLC).
possible sources of problem. The DLC is the black 16pin connector and it is tied
to the support bracket locating under the brake and
clutch fluid tank.

fy
eetelsisrelrle)
Aas
fo hop ihiziai]

ee

Figure 3. DLC Location

« When no problem exists, the display flashes “1”

repeatedly (figure 4-A).
» When a malfunction exists, the appropriate DTC
is displayed three times repeatedly (figure 4-B).
» When two or more DTCs are registered, they are
all displayed three times repeatedly, one at a
time, starting with the lowest code number (figure
4-C).

A. NORMAL

Self diagnosis start

{
ON |
| we ee
OFF 0

04 0.4 0.4
0.4 0.4 (sec.)

B. DIAGNOSTIC TROUBLE CODE “32” C. DIAGNOSTIC TROUBLE CODE “11” AND “32”

Self diagnosis start Self diagnosis start

i
i 10 20 30 1 2 10
ON |
I

OFF
op 3294
eee
04 04
Tre bd
0404 32
hl04
04°04 1.2 0.4 (sec.)

Figure 4. Self Diagnosis Display

 AUTOMATIC TRANSMISSION 7A2-5

Diagnostic Trouble Codes (DTC)

DTC No. DISPLAY PATTERN DIAGNOSED CONTENT REFERENCE

ore SL IL | cult open or |

Yehiclé speed sensor 72
13 i UL Engine speed sensor circuit open or 7A2-11

15 _ [ Lf. Automatic transmission fluid thermosensor 7AD-13

an FL FLPUPLILSLIL. | inntatorswicn ecu open ormatitex | ap.4g

pen or] apo.yy
system circuit ke
19 | []_SUPLPLPILILILITIL. | Attelagebre
a LIL Spcoteg Position sensor circuit open or 7A2-19
2 | ALS Yericls speed sensor 2 crcutepen or |r ap.09
s ) ALL. Not shit solenoic ($1) circuit open or |p ng
2) TLS No. ait slenis (Scheu opener | aa a
33 | [IAFL FIST. _| timing solenoid ($7) circuit open or shorted | 7a2-28
34 mio _ PU ._ Lock-up solenoid circuit open or shorted TA2~30

5 | FUPTL_SUPLILILL. | stoweeouesmionetsreutoven or) ra a.3e

st | PILL FLPLSLILILILIL.. | Extaustraxe cut system oircutopen or |
open or shorted

Figure 5. Diagnostic Trouble Gade

7A2-6 AUTOMATIC TRANSMISSION

CLEARING MEMORY OF THE

DIAGNOSTIC TROUBLE CODE (DTC)
0.2 sec.

1) To clear the memory in TCM, use Tech-2 (Scan em

Tool).
2) To clear the memory in TCM without Tech-2, ON
perform the following operation at once and
keep more than 5 seconds.
- Turn the key switch to ON position, but do not
start the engine.
(= No engine RPM/No vehicle speed)
+ Connect terminal 11 and terminal 4or 5 of the OFF —~ -
DLC. g—-——- 1 Sec. —»
{= Self-diagnosis is started)
* Select “N” (Neutral) range.
{= “N” range signal is sent) Figure 6. First Flashing Pattern After Clearing
* Depress brake pedal fully. Memory
(= Brake switch is ON)
+ Depress accelerator pedai fully.
{= Kick-down switch is ON)
if the memory is cleared normally in this
procedure, the check trans light flashes rapidly
(“ON’-0.2 sec, “OFF’-0.2 sec) for 10 seconds.
 AUTOMATIC TRANSMISSION 7A2-7

IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM)

ISUZU part No. : 8972060411
OOP

AISIN part No. : 86410-0469

Manufactured date
Ex. : fy 14
CONTROL UNIT;
y Year; 1998
AIT
-» Month; June c
A: January
B: February
‘| 897206 0411
AISIN 86410-0469
L: December 12V No 8F14
ij» Day .
AISIN SEIKI CO. LTD.
MADE IN JAPAN

Figure 7. Identification of TOM

7A2-8 AUTOMATIC TRANSMISSION

DIAGNOSIS BASED ON DIAGNOSTIC TROUBLE CODE (DTC)

B229 3280
ss _— | B231
CT

13/12]11)10) 918 | 7} 6)5,)4/)3] 2115817; 6'5)4)3)2)11/615)413) 241

26| 25 24/23} 22] 21) 20, 1911817) 16) 15) 144] 16) 15] 14/13/12) 11/10 9 1/12) 11}10) 9 | 8} 7
(26 pin) (16 pin) (12 pin)
Pin No. Function Pin No. Function
B231-1 ignition signal 229-1 Engine speed sensor
B231-2 Battery ground B229-2 Not used
B231-3 — Shift position; P range signal 8229-3 Vehicle speed sensor (Transmission/+)
B231-4 Shift position; N range signal B229-4 Vehicle speed sensor (Speedometer)
B231-5 Not used B229-5 Throttle position sensor
B231-6 Shift position; 1 range signal B229-6 ATF thermosensor (+)
B231-7 Not used B229-7 Not used
B231-8 Battery ground B229-8 Engine over-running light
B231-9 Shift position; R range signal B229-9 Check trans indicator light
B231-10 Shift position; D range signal B229-10 Not used
B231-11 Shift position; 2 range signal B229-11 Timing solenoid (ST)
B231-12 Brake switch B229-12 No.2 shift solenoid (S2)
B229-13 No.1 shift solenoid (S1)
B230-1 Exhaust brake signal B229-14 Not used
B230-2 Not used 8229-15 Shield for No. B229-3
B230-3 Not used H229-16 Vehicle soeed sensor (Transmission/—)
B230-4 — idle up signal B229-17 Not used
B230-5 Not used 6229-18 Throttle position sensor voltage
B230-6 O/D OFF switch B229-19 Throttle position sensor ground
B230-7 Kick-down switch B229-20 ATF thermosensor (—)
B230-8 Diagnostic enable signal B229-21 Serial data (Scan tool)
B230-9 Not used B229-22 Exhaust brake cut signal
B230-10 Not used B229-23 QWS (Engine warming up system) cut signal
B230-11 ABS (Anti-lock brake system) signal B229-24 Lock-up solenoid
B230-12 QWS (Engine warming up system) signai B229-25 Line pressure solenoid (-)
B230-13 Not used B229-26 Line pressure solenoid (+)
B230-14 Not used
B230-15 ATF temperature switch
B230-16 idie signal

Figure 8. TCM Connector Pin Layout

1. Test Probe 1. Test Probe

Figure 9. Connector Inspection Figure 10, Connector Inspection

Connector Inspection CAUTION: Never insert the circuit tester test

Use circuit tester to check the connector for probes (1) into the connector open side to test the
continuity. Insert the test probes (1) from the continuity (figure 10).
connector wire side (figure 9). Broken or open connector terminals will result.
 AUTOMATIC TRANSMISSION 7A2-9

DIAGNOSTIC TROUBLE CODE (DTC) 11

VEHICLE SPEED SENSOR 1
(Wire Breaking/Short Circuit)
Explanation of Circuit: Vehicle speed information is input from the vehicle speed sensor 1 into the
sent from the vehicle speed sensor 1 to the TCM.
Transmission Control Module (TCM). This sensor is (2) At this test, the continuity of circuit wiring and the
provided in the transmission rear cover. vehicle speed sensor 1 is checked.
The vehicle speed sensor 1 is an electromagnetic
pulse pickup type that generates a speed signal Diagnostic Aids: A temporary failure may be caused
according to the revolution of the transmission output by faulty connection, worn-away wire insulator or
shaft (18 pulses at a single revolution of the output internal wire breaking of insulator. Check if any of the
shaft). As a result, the sensor sends a sine wave following conditions is provided in the TCM harness
signal to the TCM, which converts this sine wave connector: Terminal positional shift, improper
signal (pulse voltage) into a km/h (mph) signal. junction, lock damage, improper terminal shape or
damage, faulty wire connection of terminal, and
Explanation of Test: The following numbers harness damage.
correspond to the numbers enclosed with a circle in
the diagnosis chart. TGM Voltage Gheck: Refer to page 7A2-60.
() When the vehicle is running, a speed signal is

H4 o J73
107" 2.y
i
I . \
* ><
Ss \/ 1
«
oft =

Vehicle speed sensor 1

(installed in the transmission)

TCM

H-4

tj2/afe|5h erm | s}7} 8/9

0} 142313114)15 gm 16 9711
=
7A2-10 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 11

VEHICLE SPEED SENSOR 1
(Wire Breaking/Short Circuit)

@)} - Litt the driving wheels.

+ Set the vehicle into gear and put the engine into an idling status. Connect a
voltmeter to the TCM connector terminal (B229-3) and (B229-16).
* Is the displayed voltage 0 V (at a stop) or 1 V (AC) or more (when the vehicte runs

4
ai 24 km/h / 15 mph)? (The voltage increases in proportion to the speed.)

[yes]
* DTC 11 was temporarily stored @|. Key switch “OFF”
into memory. » Disconnect the TCM 26-pin connector (B229).
When other DTCs are not stored « Connect an ohmmeter to the terminals
into memory, refer to “Diagnostic (B229-3) and (B229-16) of the TCM 26-pin connector.
Aids”. * Is the displayed resistance 500 to 1000 22?

bes] [ No

« Replace the TCM with a new one. @® * Disconnect the connector (J73) of the vehicle
» Make a road running test for the vehicte. speed sensor 1 on the transmission side.
*is DTC 11 displayed? * Measure the resistance between the
terminals of the connector (J73) on the vehicle
speed sensor 1 side with an ohmmeter.
+ Is the displayed resistance 500 to 1000 Q?

cs [re
ves | NO
The vehicle speed The TCM is faulty
sensor 1 is faulty. (TCM before
replacement)
The wire between The vehicle
the vehicle speed speed sensor 1 is
sensor and TCM faulty.
is broken or
shorted.

AC: Alternating Current

TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-11

DIAGNOSTIC TROUBLE CODE (DTC) 13

ENGINE SPEED SENSOR
(Wire Breaking/Short Circuit)

Explanation of Circuit: Engine speed (RPM) signals intermittently).

are sent from the engine speed sensor to the The voltage increases in proportion to engine
Transmission Control Module (TCM). revolution speed.
The engine speed sensor is an electromagnetic pulse
pickup type that generates signals when the fuel Diagnostic Aids: A temporary failure may be caused
timing gear revolves (35 pulses at a single revolution by faulty connection, worn-away wire insulator or
of the timing gear). internal wire breaking of insulator. Check if any of the
The TCM converts these sine wave signals into following conditions is provided in the TCM harness
engine speed (RPM) signals. connector: Terminal positional shift, improper
junction, lock damage, improper terminal shape or
Explanation of Test: The following numbers damage, faulty wire connection of terminal, and
correspond to the numbers enclosed with a circle in harness damage.
the diagnosis chart.
@ Engine speed signals are input from the engine TCM Voltage Check: Refer to page 7A2-60.
speed sensor into the TCM.
(2) When the engine speed is 2000 RPM, the voltage
varies within the range of 0 to 1 V (AC

Engine ECU
2 i

Penrose
B229
1
14
Uo 9 Ba82
Tod
LG Hi4 |
“
\ ts
. 13,
Joint i
Connector 1 Vv
meen ett oon
12) se
\
—
B23t vn
14
9 L Engine speed sensor
TCM

8-229 H-4

—)
ajafala/s el7[si9
Tote asiard igi

B282
wale

ela
ale

AG
7A2-12 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 13

ENGINE SPEED SENSOR
(Wire Breaking/Short Circuit)

+ Key switch “ON” and engine “ON”

+ Start the engine.
* Drive the vehicle in “D” range, higher than 20 mph, 2 minutes or more.
Try this procedure twice (2 trips).
+ Key switch “ON” and engine “OFF”
«ls DTC 13 displayed by self-diagnosis?

[ otc 13 is displayed. | DTC 13 is not displayed.

@}. Engine “OFF” and Key switch “ON” DTC 13 was temporarily
« Connect a voltmeter to the TCM connector terminals (B229-1} stored into memory.
and (B231-2)}. is the voltage 0 V? Refer to "Diagnostic Aids”.

[ves | 0)
@). Key switch “ON” and engine “ON” Wire breaking or voltage short circuit
* Connect a voltmeter to the TCM connector terminals (8229-1) and (B231-2).
Is the voltage under the range of 0 - 1 V (AC intermittently) when the engine speed is
about 2,000 RPM? Does the voitage increase as the engine speed is increased?

YES | *NO |
The TCM connection is The wire is ground-shorted or the
faulty or the TCM is faulty. engine speed sensor is faulty.

AC: Alternating Current

TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-13

DIAGNOSTIC TROUBLE CODE (DTC) 15

AUTOMATIC TRANSMISSION FLUID (ATF) THERMOSENSOR
(Wire Breaking/Short Circuit or Voltage Drop)

Explanation of Circuit: Tne ATF thermosensor is a the diagnosis chart.

thermistor sensor that is installed in the transmission i } Check that the voltage of the ATF thermosensor
valve body and converts temperature changes into varies with ATF temperatures.
continuous electric signals, then outputs them to the @) Check that the resistance of the ATF
Transmission Control Module (TCM). When the ATF thermosensor varies with ATF temperatures.
temperature is low, the resistance of the sensor
(thermistor) goes up, so that the voltage of the TCM Diagnostic Aids: A temporary failure may be caused
signal becomes high. by faulty connection, worn-away wire insulator or
As the ATF is gradually warmed, the resistance of the internal wire breaking of insulator. Check if any of the
sensor goes down and the voltage becomes low. At following conditions is provided in the TCM harness
the normal operating ATF temperature (80°C/176°F) connector: Terminal positional shift, improper
of the transmission, the voltage of the TCM is about junction, iock damage, improper terminal shape or
0.4 V. damage, faulty wire connection of terminal, and
harness damage.
Explanation of Test: The foliowing numbers
correspond to the numbers enclosed with a circle in TCM Voltage Check: Refer to pages 7A2-60.

H4

cc
L/Y’

J=
5" ok

3f% 7}
' t
6
Sy
wt
Y 6°
éé M

ATF thermosensor
(installed in the transmission)
— oo

TCM

[B-229 H-4 |

enplmageiceelie ry rt "

AAHOOOBDOLIDS fer si7iaie [9|s|7\s &)4jal2i4

rf salsatzofe sfzzpeape ates
Tafusfvel 1a igiadease] [arasatedas
7A2-14 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 15

AUTOMATIC TRANSMISSION FLUID (ATF) THERMOSENSOR OR
BATTERY BACK-UP VOLTAGE
(Wire Breaking/Short Circuit or Voltage Drop)

* Key switch “ON” and engine “ON”

+ Connect a voltmeter to the TCM connector terminals (B231-1)
and (B231-2) or (B231-8).
Is the voltage 10 to 16 V?

Power supply voltage drop |

@| . Engine “OFF” and Key switch “ON”

* Connect a voltmeter to the ATF thermosensor connector terminals (B229-6) and (B229-20).
Does the voitage change as the ATF temperature changes as shown in the table?

YES NO

* Replace the TCM. * Disconnect the TCM connector (B229).

* Make a running test (8 trip). + Measure the resistance between terminals (B229-6) and (B229-20).
«is DTC 15 displayed byself- is the resistance value as shown in the table?
diagnosis?

es] "NO NO|

The wiring or connector The TCM is faulty. * The TCM is « Disconnect the A/T 8-pin
connection between the faulty or the connector (J71).
TCM and ATF continuity of * Measure the resistance between
thermosensor is faulty. wiring is (J71-6) and (J71-7). Is the resistance
temporarily value as shown in table?
faulty.
Refer to
“Diagnostic
Aids”,

The wiring The ATF

between the thermosensor
[Table] TCM and ATF is faulty.
Resistance thermosensor
1 connector is
40/104 1 ground-shorted.

A/T: Automatic Transmission

TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-15

DIAGNOSTIC TROUBLE CODE (DTC) 17

INHIBITOR SWITCH
(Wire Breaking or Multiplex Signal)

Explanation of Circuit: The inhibitor switch gives the solenoid are checked.
signals related to the selector lever position
(PRND21) to the Transmission Control Module Diagnostic Aids: A temporary failure may be caused
(TCM). The inhibitor switch turns on when the select by faulty connection, worn-away wire insulator,
lever is shifted to the P, R, N, D, 2 or 1 range. The internal wire breaking of insulator. Check if any of the
inhibitor switch, which is connected to the starter following conditions is provided in the TCM harness
switch circuit, is available only when the select lever connector: Terminal positional shift, improper
is in the P or N range. junction, lock damage, improper terminal shape or
The inhibitor switch is connected to the transmission damage, faulty wire connection of terminal, and
manual shaft and installed in the transmission case. harness damage.

Explanation of Test: The following numbers GAUTION: Before continuing checking, adjust the
correspond to the numbers enclosed with a circle in shift linkage. After completion of the adjustment,
the diagnosis chart. clear DTCs and make a running test for the
@) Itis judged whether the input signal received from vehicle. Check that the trouble has been repaired
the inhibitor switch by the TCM is proper or net. by self-diagnosis.
@) The power status of the inhibitor switch is
checked. TGM Voltage Check: Refer to pages 7A2-60.
@) The continuity between inhibitor switch terminals
and the continuity of the wire connected to the

To starter relay eR12 vg t

9
[ oe B KE

Fuse #12 HS : J69

To key switch <¢———-O--_0- Biy > BY <€
10A 22 8}
wasae WR ns
qf ot
t !
5 R.{| i R/L <é

i pa
wiR WIR As WIR ee
We 6.)
WO S) LO xe
7 ay
LR 5 UR vg
161" au
mi SS L/W te
; aes
Ba —
_
Inhibitor switch
B ¥ (installed in the transmission)

TCM

{hf oom P
ao
Wily Say" Ui pare
tals] als 2
si7/el9
ol qiziiaiia ica trates
i nnd
7A2-16 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 17

INHIBITOR SWITCH
(Wire Breaking or Multiplex Signal)

C F
O * Engine “OFF” and key switch “ON” (Table 1) Q e Voltage (V)
* Connect a voltmeter to the each terminal of the TCM minal | minal
connectors (B231) and grounding terminal 10 - 16: P range
(B231-2 or B231-8). B2S1-3 | 4 or less: Others than P range
» Measure the voltage shifting the select lever to every 10 - 16: R range
position. (Comparison with Table 1) a re Others than R range
+ Is the displayed voltage at every position normal? B231-2
or B231-4 10- 16: N: range
B231-8 1 or less: Others than N range
_ip| 10-16: D range
B231-10 1 or less: Others than D range

[yes | [ No | p231-11| 10- 16: 2 range

1 or less: Others than 2 range
. _q| 10-16:1 range
B231-6 1 or less: Others than1 range
* Clear the memory.
* Make a running test.
(greater than 30 sec}

the displayed voltage at every position abnormal? |

a

ls DTC 17 displayed [ ves | re]

by self-diagnosis? J ens

[te @ + Check if there is any wire breaking in

| the fuse and wire connected to the
ee | ™ connector terminal (J69-8} of the inhibitor
[ves No | switch.
_| * Check the adjusted condition of the inhibitor
The TCM is faulty or The continuity of switch. ae
the continuity of wiring wiring is temporarily * If no fault is found, repiace the inhibitor switch.
is temporarily faulty. faulty. Refer to ®
Refer to "Diagnostic “Diagnostic Aids”. + Disconnect the connectors (J69) of the inhibitor switch.
Aids”. * Make a continuity check between inhibitor switch terminals
with an ohmmeter. (Table 2) Is the result OK?

(Table 2)

. 213)4'51 6]
a 7| 8| 9/12
[ves
ves
[No >|
1
Wire breaking or a Replace the inhibitor
short circuit switch.
between the TCM
connector and the
inhibitor switch TCM: Transmission Control Module
connecter.
O-C© Continuity
 AUTOMATIC TRANSMISSION 7A2-17

DIAGNOSTIC TROUBLE CODE (DTC) 19

ABS OPERATION SIGNAL
(Wire Breaking/Short Circuit)

Explanation of Circuit: When the signal from Diagnostic Aids: A temporary failure may be caused
Electronic Brake Control Module (EBCM) is supplied by faulty connection, worn-away wire insulator or
to the Transmission Control Module (TCM), the TCM internal wire breaking of insulator.
judges the operating condition of the ABS. Check if any of the following conditions is provided in
The ABS operation signal is output from the EBCM to the EBCM and TCM harness connector: Terminal
the TCM, the TCM inhibits the coast lock-up control. positional shift, improper junction, lock damage,
improper terminal shape or damage, faulty wire
Explanation of Test: The following numbers connection of terminal, and harness damage.
correspond to the numbers enclosed with a circle in
the diagnosis chart. TCM Voltage Check: Refer to pages 7A2-60.
@) When the ABS is INACTIVE, the voltage between
the TCM terminal (B230-11) and ground (B231-2
or B231-8) is 10 to 16V.
@) When the exhaust brake cut relay is removed, the
TGM terminal (B230-11) and ground (B231-2 or
B231-8) is OV.

Fuse3 LGAW é
ON dr
3

B230 «#BR/B . BAB,

1 ” §
Exhaust brake cut relay

B110
18

TCM
7A2-18 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 19

ABS OPERATION SIGNAL
(Wire Breaking/Short Circuit)

a
| ‘Is DTC 25 (for ABS) displayed by self-diagnosis?

YES

Malfunction of the ABS system. Refer to ABS system * Key switch "ON" and engine "ON".
diagnosis. * Connect a voltmeter to the TCM connector terminal
(B230-11) and gronding terminal (B231-2 or B231-8).
Is the voitge 10 to i6V?

ca
Ql - Remove the exhaust brake cut relay. * Check the continuity between TCM connector terminal
* Connect a voltmeter to the TCM connector terminal (B230-11) and exhaust brake cut relay (B34-5).
(B230-11) and gronding terminal (B231-2 or B231-8). ‘Is the continuity OK?
Is the voltge OV?

YES
| The continuity of wiring is faulty.
| The TCM is faulty. | The wiring between the TCM
and exhaust brake relay is
shorted. * Check the continuity between fuse-3 and exhaust brake
cut relay (B34-3}.
‘Is the continuity OK?

Is the fuse-3 OK? | The continuity of wiring is faulty.

| YES | NO

The L terminal of Replace fuse.

generator is faulty.

TCM : Transmission Control Module

 AUTOMATIC TRANSMISSION 7A2-19

DIAGNOSTIC TROUBLE CODE (DTC) 21

THROTTLE POSITION (TP) SENSOR
(Wire Breaking/Short Circuit)

Explanation of Circuit: When the signal of the TP grounding terminal.

sensor installed in the accel pedal is supplied to the &) Check the resistance (Idle: 9.6 - 11.7 kQ,
Transmission Control Module (TCM), the TCM judges Wide open throttle: 1 - 42kQ) between the TP
the opening condition of the throttie. sensor input terminal and grounding terminal.
The shift point of the transmission is determined by © Check that the kick down switch input voltage is
this opening condition of the throttle. 10 to 16 V.
@) Check that the idle signal input voltage is 10 to 16 V.
Explanation of Test: The following numbers
correspond to the numbers enclosed with a circle in Diagnostic Aids: A temporary failure may be caused
the diagnosis chart. by faulty connection, worn-away wire insulator or
@ Check that the throttle input voltage is 3.8 to 4.5 V. internal wire breaking of insulator.
@) At this test, check that as the throttle opens, the Check if any of the following conditions is provided in
voltage goes down and that the voltage reaches the TP sensor and TCM harness connector: Terminal
1.0 to 2.2 V at the full open status. positional shift, improper junction, lock damage,
@) Check the power supply voltage (4.5 - 5.5 V) of improper terminal shape or damage, faulty wire
the TP sensor. connection of terminal, and harness damage.
@ Check the resistance (about 12 kQ) between the
TP sensor power supply voltage terminal and TCM Voltage Check: Refer to pages 7A2-60.

Throttle Position sensor

GRIL
Qo
N
9
fo SS
7A2-20 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 21

THROTTLE POSITION (TP) SENSOR
(Wire Breaking/Short Circuit)

* Engine “OFF” and key switch “ON”

* Connect a voltmeter to the TCM connector
terminal (B229-5) and grounding terminal (B229-19).
Is the voltage 3.8 to 4.5 V?

YES

* Open the throttle completely.

is the voltage 0.5 to 1.8V?
ca aL

+ Is the voltage between TCM connector terminals

(B229-18) and (B229-19) 4.5 to 5.5 V?

[ves ca
Continue to next page. The TP
@)] « Key switch “OFF”. The TCM is faulty or
sensor is « Disconnect the TCM connectors (B229, B230 wire breaking / short
faulty. and B231). circuit between
« Connect an ohmmeter to the TCM connector terminals (B229-18)
terminals (B229-18) and (B229-19). and (B80-1), or (B229-
[Table] 19) and (B80-3).
is the resistance about 12 kQ?
Throttle position sensor resistance values
between terminals (B80-2) and (B80-3) eee one enn <4
Idle 9.6 - 11.7 kQ [ ves | NO |
wor i - 42kQ0 | | _
OF Is the resistance value (4)| - Disconnect the TP sensor connector (B80)
between TCM connector of the accel pedal. Is the resistance
terminals (B229-5) and (B229-19) as value between terminals (B80-1) and
shown in the table? (B80-3) about 12 kQ?

[ves| No | [ves | | No |

The TCM is | ©)|. Disconnect the TP sensor connector * Wire breaking or short The TP.
faulty. (B80) of the accel pedal. Is the resistance circuit between terminals Sensor Is
value between terminals (B80-2) and (B229-18) and (B80-1) or faulty.
(B80-3} as shown in the table? terminals (B229-19) and
(B80-3)

[ne|
* Wire breaking or short circuit The TP TCM: Transmission Control Module
between terminals (B229-5) and sensor is WOT: Wide Open Throttle
(880-2) or terminals (B229-19) faulty.
and (880-3)
 AUTOMATIC TRANSMISSION 7A2-21

Continued

© |- Connect a voltmeter to the TCM connector terminal

(B230-7) and grounding terminal (B231-2 or B231-8).
Is the voltage 10 to 16 V?

Gs ni]
@ |+ Connect a voltmeter to the TCM connector * Wire breaking or short circuit between
terminal (B230-16) and grounding terminal terminals (B230-7) and (B76-1).
(B231-2 or B231-8). * Kick down switch is faulty.
\s the voltage 10 to 16 V?

[ves [No|
* Engine “ON”
« Is the voltage 0 V?
And 10 to 16 V with depressed accel pedal?

[ves cs
Temporary failure. [The engine ECU is faulty. |
Refer to “Diagnostic Aids”
7A2-22 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 24

VEHICLE SPEED SENSOR 2
(Wire Breaking/Short Circuit)

Explanation of Circuit: Vehicle speed information is @) Speed signals are output from the speedometer.
provided by the vehicle speed sensor 2 to the The sensor power supply is given from the TCM.
speedometer.
In the speedometer, the pulses of the speed sensor Diagnostic Aids: A temporary failure may be caused
are converted to speed signals (pulses), and these by faulty connection, worn-away wire insulator or
signals are output to the Transmission Control internal wire breaking of insulator. Check if any of the
Module (TCM). The TCM converts these pulse following conditions is provided in the output of the
voltages to km/h (MPH) signals. speedometer and the harness connector: Terminal
positional shift, improper junction, lock damage,
Explanation of Test: The following numbers improper terminal shape or damage, faulty wire
correspond to the numbers enclosed with a circle in connection of terminal, and harness damage.
the diagnosis chart.
@) The cause of DTC 24 setting is due to the TCM Voltage Check: Refer to page 7A2-60.
operation fault of the speedometer.

Speedometer

TCM =

F{2iDL
AIS [Ol 7 Eel ores tai
tafistial t7tialistzeietafzai2
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Mey
 AUTOMATIC TRANSMISSION 7A2-23

DIAGNOSTIC TROUBLE CODE (DTC) 24

VEHICLE SPEED SENSOR 2
(Wire Breaking/Short Circuit)

* Lift the driving wheels.

« Set the gear to the D range and drive the engine into an idling status.
ts the displayed speed 0 km/h (0 mph) in the “Scan Tool’?

YES NO

®] does the speedometer operate? DTC 24 represents a

temporary failure. When
other DTCs are not stored
in memory, refer to
“Diagnostic Aids”.
YES [No

@) - Open the throttle and increase the revolution speed « The speedometer is faulty.
of the driving wheels. * The vehicle speed sensor 2 is faulty.
« Measure the voltage between the TCM connector
terminals (8229-4) and grounding terminal (B231-2 or
B231-8) with a voltmeter. Does the voltage vary
intermittently in the range of 1 V to 5 V (AC)?

YES NO

The TCM The wire between the speed

connection is output of the speedometer and
faulty or the TCM the TCM is broken or the vehicle AC: Alternating Current
is faulty. speed sensor 2 is faulty. TCM: Transmission Control Module
7A2-24 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 31

No.1 SHIFT SOLENOID (S1)
(Wire Breaking/Short Circuit)
Explanation of Circuit: The No.1 shift solenoid (S1) measured with a voltmeter.
changes the hydraulic route with the signals from the @) When the driving wheels revolve with the 3rd
Transmission Control Module (TCM) according to the gear, the voltage is 1 V or less.
vehicle speed and the opening of the throttle in order @) The solenoid resistance is within the range of 10
to exert shift control. When the No.1 or No.2 shift to 20 Q.
solenoid (S1 or S2) fails, the hydraulic circuit is
mechanically operated as a backup. Diagnostic Aids: In case of faulty wire connection to
the TCM terminal (B229-13), wire breaking or short
Explanation of Test: The following numbers circuit, DTC 31 is displayed.
correspond to the numbers enclosed with a circle in A temporary failure may be cause by faulty
the diagnosis chart. connection, worn-away wire insulator or internal wire
@) When the key switch has been turned on, the breaking of insulator.
voltage between the TCM terminals (B229-13)
and (B231-2 or B231-8) is 10 to 16 V when itis TCM Voltage Check: Refer io page 7A2-60.

Transmission valve body

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 AUTOMATIC TRANSMISSION 7A2-25

DIAGNOSTIC TROUBLE CODE (DTC) 31

No.1 SHIFT SOLENOID (S1)
(Wire Breaking/Short Circuit)

Operating solenoid
Gear Si $2
ist ON OFF
2nd ON ON
- Engine “OFF” and key switch “ON” 3rd OFF ON
¢ Connect between the TCM connector terminal (B229-13) and
4th OFF OFF
grounding terminal (B231-2 or B231-8) with a voltmeter.
«Is the voltage 10 to 16 V?

[ves] C01[
+ Lift the driving wheels. ()| + Key switch “OFF”
* Key switch “ON” and engine “ON” * Disconnect the TCM connector (B229).
+ Is the shift up normally by acceleration in the D range? + Measure the resistance between the
terminal (B229-13} and grounding.
is the resistance 10 to 20 Q?

oo |
[ves| [No
[ ves| [xo
@ ° At the 3rd gear.
« Is the voltage between the TCM connector The TCM is faulty @ Disconnect the A/T connector (J71). Is
terminal (B229-13) and grounding terminal or the continuity the resistance between the No.1 shift
(B231-2 or B231-8) 1 V or less? of wiring is solenoid (J71-4} and grounding
temporarily faulty. 10 to 20 2?
| Refer to
a “Diagnostic Aids”. lt t”t”™~™~™~—C— L
YES Lae} [Yes cs
* Clear the memory. (D| + Key switch “OFF” The wiring The No.1 shift
Refer to page 7A2-6 for + Disconnect the TCM connector (B229). between jerminals solenoid ($1)
clearing DTC. » Measure the resistance between the (B229-13) and is faulty.
° Make a road test. terminal (B229-13) and grounding. (J7 1-4) is ground-
is the resistance 10 to 20 0? shorted.

is DTC 31 displayed
by self-diagnosis?
too OL
[yes| Le]
NO | The TOM is fauity] @ + Disconnect the A/T connector (J7 1).
or the continuity « Is the resistance between the No.1 shift solenoid
en of wiring is (81) (J71-4) and grounding 10 to 20 Q?
The TCM is faulty The continuity of temporarily faulty.
or the continuity wiring 's Refer to
of wiring is temporarily faulty. “Diagnostic Aids”.
an
temporarily faulty. Refer to
[ves| LNo_]
i |
Refer to “Diagnostic Aids”.
“Diagnostic Aids”.
The wiring between The No.1 shift
terminals (B229-13) solenoid (S14)
and (J71-4) is faulty. is faulty.

A/T: Automatic Transmission

TCM: Transmission Control Module
7A2-26 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 32

No.2 SHIFT SOLENOID (S2)
(Wire Breaking/Short Circuit)

Explanation of Circuit: The No.2 shift solenoid ($2) measured with a voltmeter.
changes the hydraulic route with the signals from the @) When the driving wheels revolve with the 2nd
Transmission Control Module (TCM) according to the gear, the voltage is 1 V or less.
vehicle speed and the opening of the throttle in order to @) The resistance of the solenoid is in the range of
exert shift control. 10 to 20Q.
When the No.1 or No.2 shift solenoid ($1 or S2) fails, the
hydraulic circuit is mechanically operated as a backup. Diagnostic Aids: in case of faulty wire connection to
the TCM terminal (B229-12), wire breaking or short
Explanation of Test: The following numbers circuit, DTC 32 is displayed.
correspond to the numbers enclosed in a circle in the A temporary failure may is caused by faulty
diagnosis chart. connection, worn-away wire insulator, or internal wire
@) When the key switch has been turned on, the breaking of insulator.
voltage between the TCM terminals (B229-12)
and (B231-2 or B231-8) is 1V or less when it is TCM Voltage Check: Refer to page 7A2-60.

Transmission valve body

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 AUTOMATIC TRANSMISSION 7A2-27

DIAGNOSTIC TROUBLE CODE (DTC) 32

No.2 SHIFT SOLENOID (S2)
(Wire Breaking/Short Circuit)

Operating solenoid
Gear Si $2
ist ON OFF
end ON ON
+ Engine “OFF” and key switch “ON” ord OFF ON
* Connect a voltmeter to the TCM connector terminal (B229-12)
4th OFF OFF
and grounding terminal (B231-2 or B231-8).
+ Is the voltage 1V or less?

YES
« Lift the driving wheels. * Key switch “OFF”
* Key switch “ON” and engine “ON” « Disconnect the TCM connector (B229).
« Is the shift up normally by acceleration * Measure the resistance between the terminal (B229-12)
in the D range? and grounding. Is the resistance vaiue 10 to 20 Q?

Les a
@ * At the 2nd gear The TCM is faulty or
the continuity of
* Disconnect the A/T connector (J7 1).
» Is the voltage between the TCM connector terminal « Is the resistance between the No.2 shift
(B229-12) and grounding terminal (B231-2 or B231 wiring is temporarily solenoid (S2) (J71-3) and grounding 10 to 20 Q?
-8) 10 to 16 V? faulty. Refer to
“Diagnostic Aids”.

lL
[YES
, =|
[vo [ ves|
The wiring
(a)
The No.2
+ Clear the memory. @ * Key switch “OFF”
—

between terminals shift solenoid

Refer to page 7A2-6 for « Disconnect the TCM connector
(B229-12) and (S2) is fauity.
clearing DTC. (B229).
(J71-3) is ground-
+ Make a road test. * Measure the resistance between the
shorted.
terminal (B229-12) and grounding.
« {s the resistance 10 - 20 07
Is DTC 32 displayed
by self-diagnosis?

[ves]
[
The TCM is faulty or the @ * Disconnect the A/T connector (J71).

[Yes [vo] continuity of wiring is ternporarily

faulty. Refer to “Diagnostic Aids”.
is the resistance between the No.2 shift
solenoid (S2) (J71-3) and grounding 10 to 20 Q?

The TCM is The continuity of wiring is

faulty or the temporarily faulty. Reter to
continuity of “Diagnostic Aids”.
wiring is
temporarily The wiring between The No.2
faulty. Refer terminals (B229-12) shift solenoid
to “Diagnostic and (J71-3) is faulty. {82} is faulty
Aids”. (Wire breaking)

A/T: Automatic Transmission

TCM: Transmission Control Module
7A2-28 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 33

TIMING SOLENOID (ST)
(Wire Breaking/Short Circuit)

Explanation of Circuit: When shifting 1st to 2nd, @) The resistance of the timing solenoid is 10 to 20
2nd to 3rd, or 3rd to 2nd, timing solenoid (ST) turns Q.
on. It controls the orifice of the 2nd brake (BO) and
reduces the shift shock. Diagnostic Aids: In case of faulty wire connection to
the TCM terminal (B229-11), wire breaking or short
Explanation of Test: The following numbers circuit, DTC 33 is displayed.
correspond to the numbers enclosed with a circle in A temporary failure may be caused by faulty
the diagnosis chart. connection, worn-away wire insulator or internal wire
@) When the timing solenoid (ST) is ON, the voltage breaking of insulator.
between the TCM terminals (B229-11) and (B48-
13 or B48-14) is 10 to 16 V. TCM Voitage Check: Refer to page 7A2-60.
@) When the timing solenoid (ST) is OFF, the voltage
between the TCM terminals (B229-11) and
(B231-2 or B231-8) is 1 V or jess.

Transmission valve bod

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 AUTOMATIC TRANSMISSION 7A2-29

DIAGNOSTIC TROUBLE CODE (DTC) 33

TIMING SOLENOID (ST)
(Wire Breaking/Short Circuit)

@ * 2 range
* Measure the voltage when shift up from 2nd to 3rd between the TCM connector
terminal (B229-11) and grounding terminal (6231-2 or B231-8) with a voltmeter. Is the
voltage 10 to 16 V?

YES
se
@| - D range, O/D switch “ON"
* Key switch “OFF”
¢ Is the voltage between the TCM connector terminal * Disconnect the TCM connector (B229).
(B229-1 1) and ground terminal (B231-2 or B231-8) * Measure the resistance between
1V or less? the terminal (B229-11) and grounding.
is the resistance 10 to 20 Q7

YES [No [ves | [no|

*Clear the TCM memory. @|- Key switch “OFF” The TCM is faulty + Disconnect the A/T 8-pin
Refer to page 7A2-6 for * Disconnect the TCM connector or the continuity connector (J7 1).
clearing DTC. (B229). of wiring is + Is the resistance of the
» Make a road test. + Measure the resistance between temporarily faulty. timing solenoid (ST)
the terminal (8229-11) and grounding. Refer to (J71-2) 10 to 20 0°?
+ Is the resistance 10 to 20 Q? “Diagnostic Aids”.
[1s DTC 33 displayed by self-diagnosis?)

a] | ee
LL=a ae ~ _
The TCM is fauity The continuity of The TCM is faulty * Disconnect the A/T 8-pin | | The wiring The timing
or the continuity wiring is temporarily |_| or the continuity connector (J7 1). between solenoid (ST)
of wiring is faulty. Refer to of wiring is + Is the resistance of the terminal (B229- | | js faulty.
temporarily faulty. “Diagnostic Aids”. temporarily faulty. timing solenoid (ST) terminal] | 11) and (J71-2)
Refer to Refer to (J71-2} 10 to 20 Q? is ground-
“Diagnostic Aids”. “Diagnostic Aids”. shorted,

The wiring The timing solenoid

between terminais } | (ST) is faulty.
(B229-11) and
(J71-2) is faulty. AIT. Automatic Transmission
(Wire breaking) TCM: Transmisson Control Module
7A2-30 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 34

LOCK-UP SOLENOID
(Wire Breaking/Short Circuit)

Explanation of Circuit: The lock-up solenoid of the @) When the 3rd gear in the D range and the
Torque Converter Clutch (TCC) aims at controlling Throttle Position (TP) sensor is about 50% at a
the lock-up clutch when the vehicle runs. higher speed than about 65 km/h (41 mph) at the
This function can improve the fuel cost to almost the final gear ratio 5.857, the TCM supplies 10 to 16
same extent as the manual transmission. The lock-up V, so that the lock-up duty solenoid is actuated
solenoid is put into battery voltage by the with the result of lock-up.
Transmission Contro! Module (TCM), so that the @) The resistance of the lock-up duty solenoid is 10
solenoid is actuated with the result of lock-up. to 20 QQ.

Explanation of Test: The following numbers Diagnostic Aids: In case of faulty wire connection to
correspond to the numbers enclosed with a circle in the TCM terminal (B229-24), wire breaking or short
the diagnosis chart. circuit, DTC 34 is displayed. A temporary failure may
G@) When the key switch is ON, the voltage between be caused by faulty connection, worn-away wire
the TCM connector terminals (B229-24) and insulator or internal wire breaking of insulator.
(B231-2 or B231-8) is 1.0 V or less. TCM Voltage Check: Refer to page 7A2-60.

Transmission valve body

meet

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4
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 AUTOMATIC TRANSMISSION 7A2-31

DIAGNOSTIC TROUBLE CODE (DTC) 34

LOCK-UP SOLENOID
(Wire Breaking/Short Circuit)

OF Engine “OFF” and key switch “ON after warming up

* Connect a voltmeter to the TCM connector terminal (B229-24) and grounding terminal (B231-2 or B231-8).
Is the voltage 1 V or less?

YES

@)| - Lift the driving wheels and support them. * Key switch “OFF”
- Drange, 3rd gear * Disconnect the TCM connector (B229).
« Make a test at a specified speed (shown in the table) ¢ Measure the resistance between the
or more with 50% opening of the throttie. terminal (B229-24) and grounding.
+ Is the voltage between the terminal (B229-24) and is the resistance 10 to 20 Q?
grounding terminal (B231-2 or B231-8) 10 to 16 V?

| tL
Ls Ae Lvs NO
* Clear the TCM memory. @}. Key switch “OFF” The TCM is faulty @}. Disconnect the A/T connector
Refer to page 7A2-6 for « Disconnect the TCM connector or the continuity (J71)
clearing DTC. (B229). of wiring is + Is the resistance between the
« Make a road test. * Measure the resistance temporarily faulty. lock-up duty solenoid
between the terminal (B229-24) || Reter to (J71-8) and grounding
and grounding. Is the resistance || “Diagnostic Aids”. 10 to 20 Q?
| is DTC 34 displayed by self-diagnosis? 10 to 20 Q?

YES NO [Yes | [_ no | | Yes | | NO

| [ @ | | |
The TCM is faulty The continuity of The TCM is faulty || ° Disconnect on wT The wiring The lock-up
or the continuity wiring is or the continuity Is the resi stance between between duty solenoid
of wiring is temporarily faulty. of wiring is the lock-up duty solenoid terminals is faulty.
temporarily faulty. Refer to temporarily faulty. (J71-8) and grounding (B229-24) and
Refer to “Diagnostic Aids”. Refer to 10 to 20 Q? (J71-8) is faulty.
“Diagnostic Aids”. “Diagnostic Aids”. (Wire breaking)

YES ] [ NO |
Table al ~~ ae
. _ | Lock-up point km/h (mph) The wiring between terminals The lock-up duty
Final gear ratio | a+ throttle opening 50% (B229-24) and (J71-8) is solenoid is faulty.
ground-shorted.
5.376 64 (40)
5.857 62 (39) A/T; Automatic Transmission
TCM: Transmission Control Module
7A2-32 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 35

LINE PRESSURE SOLENOID
(Wire Breaking/Short Circuit)

Explanation of Circuit: The Transmission Control @) As the throttle opens gradually, the voltage
Module (TCM) outputs signals to the line pressure between TCM terminals (B229-26) and (B229-25)
duty solenoid to control the line pressure of the goes down. (When the throttle is completely
transmission. With the operation of this solenoid, the open, the voltage is 1.0 to 1.7 V)
operation and shift of the hydraulic circuit in the @) The resistance of the line pressure solenoid is 3.5
transmission can be performed smoothiy. The line to 6.5 Q.
pressure solenoid is controlled according to the
inhibitor switch, vehicle speed and throttle position Diagnostic Aids: in case of faulty wire connection to
sensor signal. the TCM terminal (B229-26 or B229-25), wire
breaking or short circuit, DTC 35 is displayed.
Explanation of Test: The following numbers A temporary failure may be caused by faulty
correspond to the numbers enclosed with a circle in connection, worn-away wire insulator or internal wire
the diagnosis chart. breaking of insulator.
@ When the key switch is ON, the voltage between
TCM terminals (B229-26) and (B229-25) is 3.3 to TCM Voltage Check: Refer to page 7A2-60.
5.5 V.

Transmission valve body

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ag
4
BRIB A
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BRAV ' BRAW
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 AUTOMATIC TRANSMISSION 7A2-33

DIAGNOSTIC TROUBLE CODE (DTC) 35

LINE PRESSURE SOLENOID
(Wire Breaking/Short Circuit)

@M) - Engine “OFF” and key switch “ON” after warming up

+ Measure the voltage between the TCM connector terminal (B229-26) and (B229-25) with a
voltmeter. Is the voltage 3.3 to 5.5 V (AC)?

YES [ NO |

@ * Depress the accel completely. * Key switch “OFF”

« Is the displayed voltage between ithe TCM connector terminal « Disconnect the TCM connector (B229).

(B229-26) and (B229-25) 1.0 to 1.7 V (AC)? « Measure the resistance between
the terminals (8229-26) and (B229-25).
is the resistance 3.5 to 5.5 Q?

YES

* Clear the TCM memory. * Key switch “OFF” The TCM is faulty * Disconnect the A/T
Refer to page 7A2-6 for * Disconnect the TCM or the continuity 8-pin connector (J71).
clearing DTC. connector (B229). of wiring is - Is the resistance of the line
+ Measure the resistance temporarily faulty. pressure solenoid between
between the terminal Refer to (J71-1) and (J71-5) 3.5 to
(B229-26) and (B229-25). “Diagnostic Aids”. 5.5 Q7
ls DTC 35 displayed by selt-diagnosis?| + Is the resistance 3.5 to 5.5 Q?

YES | [ NO ‘| YES | | NO

The TCM is fauity The continuity of The TCM is faulty | Disconnect the A/T 8-pin || The wiring The line pressure
or the continuity wiring is temporarily or the continuity connector (71). between the solenoid is faulty.
of wiring is faulty. Refer to of wiring is ls the resistance of the line pressure
temporarily faulty. “Diagnostic Aids”. temporarily faulty. line pressure solenoid solenoid and
Refer to Refer to between (J71-1) and TCM is broken
“Diagnostic Aids”. “Diagnostic Aids”. (J71-5) 3.5 to 5.5 Q. or shorted.

The wiring between The line pressure

the line pressure solenoid is faulty.
solenoid and TCM is
broken or shorted.
A/T: Automatic Transmission
TCM: Transmission Controi Module
7A2-34 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 37

EXHAUST BRAKE CUT SYSTEM
(Wire Breaking/Short Circuit)

Explanation of Circuit: The TCM sends the exhaust (@) When the exhaust brake cut relay is ACTIVE, the
brake cut signal, the exhaust brake cut relay acts on voltage between the TCM terminal (B230-1) and
the exhaust brake magnetic valve to OFF when the grounding is 1V or less.
selector position is “P”, “N” range or when the vehicle
speed is slow. Diagnostic Aids: A temporary failure may be caused
In addition, when the lock-up (ON-+OFF) is activate, the by faulty connection, worn-away wire insulator or
TCM sends the exhaust brake cut signal instantaneously. internal wire breaking of insulator.
Check if any of the following conditions is provided in
Explanation of Test: The following numbers the TCM harness connector: Terminal positional shift,
correspond to the numbers enclosed with a circle in improper junction, jock damage, improper terminal
the diagnosis chart. shape or damage, faulty wire connection of terminal,
@ When the exhaust brake cut relay is INACTIVE, and harness damage.
the voltage between the TCM terminal (B229-22)
and (B231-2 or B231-8) is 10 to 16 V. TCM Voliage Check: Refer to pages 7A2-60.

LG

| Accelerator pedal switch

J31
LG “vHS LG
SS 32
LG/B /7ts Gia _'! GW
Exhaust brake cut relays \7 i t 2
"Exhaust brake,switch
Ji8 Fuse 15
pC ex yes
“oP
~
use

one
 AUTOMATIC TRANSMISSION 7A2-35

DIAGNOSTIC TROUBLE CODE (DTC) 37

EXHAUST BRAKE CUT SYSTEM
(Wire Breaking/Short Circuit)

@] + Vehicle is running in “D” range at a speed of 6km/h (10 mph) or more.

+ Exhaust brake switch is “ON”.
* Measure the voltage between the TCM connector terminal (B229-22) and grounding terminal
{B231-2 or B231-8) with a voltmeter. Is the voltage 10 to 16 V?

YES [ NO |
ne oo

@Q). Key switch “OFF” * Key switch “OFF”

¢ Connect a wire between the TCM connector terminal (B229 * Disconnect the exhaust brake cut relay.
-22) and (B23 1-2 or B231-8) » Key switch “ON”
» Shift “P” range. Engine “ON” + Measure the voitage between
* Exhaust brake switch “ON” the terminal (J18-4) and grounding.
¢ Measure the voltage between the TCM connector terminal Is the voltage 10 to 16V?
(B230-1) and grounding. Is the voltage 1V or less?

YES | NO ‘|

The TCM is faulty or the * Key switch “OFF” The exhaust brake Wire breaking or a short
continuity of wiring is » Disconnect the exhaust brake cut relay | | cut relay is faulty or circuit between the fuse-12
hea ined Aids” * Key switch “ON” the continuity of — and the terminal (J18-4) or
Refer to “Diagnostic Aids’. » Measure the voltage between the terminal wiring is temporarily the fuse-12 blow out.
f faulty. Refer to
(J18-3) and grounding. “Diagnostic Aids”.
Is the voltage 1V or less?

The exhaust The wiring between the

brake cut relay is terminal (J18-3) and
faulty. (B230-1) or magnetic valve
is shorted to valtaged wire.
A/T: Automatic Transmission
TCM: Transmission Control Module
7A2-36 AUTOMATIC TRANSMISSION

DIAGNOSTIC TROUBLE CODE (DTC) 38

ENGINE WARMING UP CUT SYSTEM
(Wire Breaking/Short Circuit)

Explanation of Circuit: When the vehicle is running in Diagnostic Aids: A temporary failure may be caused
“D” range and lock-up (OFF—ON) is activate, the TCM by faulty connection, worn-away wire insulator or
sends the engine warming up cut signal instantaneously, internal wire breaking of insulator. Check if any of the
cause the warming up cut relay-2 to turn off the magnetic following conditions is provided in the output of the
valve. speedometer and the harness connector: Terminal
Explanation of Test: The following numbers positional shift, improper junction, lock damage,
correspond to the numbers enclosed with a circle in improper terminal shape or damage, faulty wire
the diagnosis chart. connection of terminal, and harness damage.
@) When the warming up cut relay is INACTIVE, the
valtage between the TCM terminal (B229-23) and TCM Voitage Check: Refer to page 7A2-60.
(B231-2 or B231-8) is 10 to 16V.
@) When the warming up cut relay is ACTIVE the
voltage between the TCM terminal (B230-12) and
grounding is 1V or less.

LGW

Magnetic valve

20 To accelerator
\ LG switch
errr RY
3
To warming up
. BRR Cut relay - 1

1 Fuse 12
oN Pp
 AUTOMATIC TRANSMISSION 7A2-37

DIAGNOSTIC TROUBLE CODE (DTC) 38

ENGINE WARMING UP CUT SYSTEM
(Wire Breaking/Short Circuit)

@I - Engine “OFF” and key switch “ON” before warming up

» Measure the voltage between the TCM connecior terminal (B229-23) and grounding terminal
(B231-2 or B231-8) with a voltmeter. Is the voltage 10 to 16 V?

YES

| « Key switch “OFF” + Key switch “OFF”

* Connect a wire between the TCM connector terminal (B229 :
« Disconnect the warmin.
-23) and (B231-2 or B231-8) Koy eaiten “ONY 9 UP cul t relay relay-2.
+ Key switch “ON”. Engine “ON”. Warming up switch “ON”. ey swite
+ Drive the vehicle in “D” range at a speed of 18km/h (30 mph) » Measure the voltage between
or More (throttle opening: 20 to 30 %). At this time, lock-up the terrninal (J19-2) and grounding.
function (OFF-ON) activates, and the TCM sends output is the voltage 10 to 16 V?
signal.
* Measure the voltage between the TCM connector terminal
{B230-12) and grounding. is the voltage 1V or less?

nn — een
YES - a — —
The TCM is faulty or the + Key switch “OFF” The warming up cut Wire breaking or a short
continuity of wiring is + Disconnect the warming up cut relay-2. | | relay-2 is faulty or citcult between the fuse-12
temporarily faulty. + Key switch “ON” the continuity of and the terminal (J19-2) or
Refer to “Diagnostic Aids”. « Measure the voltage between the terminal wiring is temporarily the fuse-12 blow out.
; faulty. Reter to
(J19-3) and grounding. “Diagnostic Aids”.
Is the voltage 1V or less?

[ves]
The warming up The wiring between the
relay-2 is faulty. terminal (J19-3) and
(B230-12) or magnetic
valve is shorted lo voltaged
wire.

AT: Automatic Transmission

TCM: Transmission Control Module
7A2-38 AUTOMATIC TRANSMISSION

DIAGNOSIS BASED ON VEHICLE CONDITION

ON-VEHICLE SERVICE ITEM

UOIPUOS pUe OAs} 4 IV

jeuBis oip)
uonnjoaes Guyjpt euribuz
plougjos eunsseud aur]

(ZS) plousjos ylys Z’ON

(1S) plousjos Buiwiy

Ja}9AU0S aNbioy
YOWMS JOVQIYL|

YOUMs 440 G/O

Y Noo JeWeYS
Check position

plousjos dn-4907]
(1S) plougjos WiYs LON
Josues peads eulbuy

YOUMS UMOP-H01y
aBeyuy jou05

YOUMS eyeiq jsneyxy

WOL
Josuas peeds aja,
Josues uogisod emory
Faulty symptom

VEHICLE MOVEMENT
Vehicle does not run at “R”

_
Vehicle does not move at every range

colin | ama | me | me
Vehicle moves at “P”
Parking gear does not release when selector is moved from “P”
Vehicle moves at “N”
ABNORMAL GEAR CHANGE
Does not upshift from 1st to 2nd

ent

9] G91 N3] Nd] Go] No] ca] Na] Na] pa] col co] co
Gat cord
ROPROERS]
Does not upshift from 2nd to 3rd
Does not upshift from 3rd to 4th
Does not downshift from 4th to 3rd
Does not downshift from 3rd to 2nd
Does not downshift from 2nd to ist
Engine overruns when shifting from 2nd to 3rd
All shift points extremly high or low
Crh

Kick-down fails

RO] =i) ND
Engine brake does not function at “L’ range
Engine brake does not function at “2” range
—s
Lock-up device does noi function
Lock-up point extremly high or low
EXCESSIVE SHOCK WHEN CHANGING GEARS
Excessive shock when selector is moved to “R” from “N”, or

Po

Po
“ry from “Ny”

Ra} Go} Ga;

RO] Ra LG} Go}
Excessive shock when upshifting from ist to 2nd

Go} Co
GCOPPOERST
Excessive shock when upshifting from 2nd to 3rd

GIRL
Excessive shock when upshifting from 3rd to 4th
Excessive shock when upshifting (all gear)
Excessive shock when downshift from 4th to 3rd
Excessive shock when downshift from 3rd to 2nd
When lock-up
SLIPPAGE
When going forward and backward
ak

When in reverse gear

| a] a

When in 1st gear

When in 2nd gear
werk | wee f

When in 3nd gear

When in 4th gear
OTHERS
Engine will not srart in either “P” or “N”
hr

Engine can start in other than “P” or “N”

Engine stalls when selector is moved from “P” or “N” to one
of drive ranges
Automatic transmission unit overheating/ATF blows off from
1
air breather pipe
Note: The numbers in the table denote the order of inspection.
1. Moveable parts that are dislocated easily or are hard to adjust.
2. Parts that are turned on and off.
3. Other parts that are controlled by electrical circuit.
4, Others.
 AUTOMATIC TRANSMISSION 7A2-39

OVERHAUL ITEM

1.9
1g

plougjos ainssaud oury

ZD
Ajquiasse Apog aajen
duind {Io

(14) yoinjo Aem-auo 2 ‘ON

Og
Aseyouryd yuosy
(04) yoynjo Aem-ou0 W/O
(2g) S42 “AOE 8 IS}
(Lq@) exeiq pug

(09) Yon yep G/O

JOSUBSOLLIOU} 4 LY

(og) a421q G/O

(4.0) YoIn|D quod

Aseyourd sey
Check position

(29) yoinpo wey

abeyuy Supe

Joyejnuinooe
JoyEINUINDDe
Joyejnunooe
JoyEjnuNDVB
Faulty symptom

VEHICLE MOVEMENT
Vehicle does not run at “D”, “2”, “L”

OQ
Vehicle does not run at “R”

O
Vehicle does not move at every range

O
O
Vehicle moves at “P”

ele
Parking gear does not release when selector is moved from “P”
Vehicle moves at “N” O
ABNORMAL GEAR CHANGE
Does not upshift from ist to 2nd O

OOOO COO
Does not upshift from 2nd to 3rd
Does not upshift from 3rd to 4th O
Does not downshift from 4th to 3rd

O
Does not downshift from 3rd to 2nd
Does not downshift from 2nd to ist
Engine overruns when shifting from 2nd to 3rd ©
All shift points extremly high or low
Kick-down fails

OO
Engine brake does not function at “L' range
Engine brake does not function al “2” range
Lock-up device does not function

ele
Lock-up point extremly high or low
EXCESSIVE SHOCK WHEN CHANGING GEARS
Excessive shock when selector is moved to “R” from “N”
O

Excessive shock when selector is moved to “D” from “N”

O
Excessive shock when selector is moved to “R” from “N”, or

jOQOOO|OOL ©
ary from “AY?

Excessive shock when upshifting from 1st to 2nd

Excessive shock when upshifting from 2nd to 3rd O
Excessive shock when upshifting from 3rd to 4th
Excessive shock when upshifting (all gear)
Excessive shock when downshift from 4th to 3rd O
Excessive shock when downshift from 3rd to 2nd
When lock-up
SLIPPAGE
When going forward and backward QO
QaQqgogge,

When in reverse gear LO

When in ist gear
OOOO

When in 2nd gear

When in 3nd gear
Q}O

When in 4th gear O

OTHERS
Engine will not srart in either “P” or “N”
Engine can start in other than “P” or “N”
Engine stalis when selector is moved from “P” or “N” to one
of drive ranges
‘Automatic transmission unit overheating/ATF blows off from OO O
air breather pipe
7A2-40 AUTOMATIC TRANSMISSION

INSPECTION BASED ON FAULTY SYMPTOM

This section details how to inspect or repair the . At acceleration, the engine races and slippage
following phenomena found in fault reproducing tests: occurs.
1. The vehicle does not move at every range. . The engine stalls when the selector lever is
2. The vehicle moves at the “N” range. moved from the “P” or “N” to one of the drive
3. The gear cannot be changed. ranges.
4. Does not upshift from the 3rd to 4th. . The ATF blows off from the air breather pipe
5. The gear change is abnormal. during driving.
. Engine brake does not function.
 AUTOMATIC TRANSMISSION 7A2-41

1 The vehicle does not move at every range.

When the accelerator is depressed while the selector lever is set in the drive range, the vehicle does not move, but
iSituations| the engine comes to rotate faster.

@ The ATF is not sufficient. ® The powertrain slippage.

@® The selector lever has not been assembled nor © The control valve does not slide correctly.
Causes adjusted correctly. @ The line pressure solenoid is defective.
@ The throttle position sensor is defective or is not ®) The parking mechanism is defective.
adjusted correcily.
@ The line pressure has cropped.

Steps Inspection Corrective Measures

1-1 is the ATF sufficient and in good order? YES | Proceed to the next step.
(See Page 7A3-2)
NO <Reference>
<Reference> * It is finally required to replace the
* When the ATF is cloudy (pinkish), it contains some transmission. The inside of the
water. transmission is considered to be damaged,
and the causes will be traced in the
following step. Ifthe ATF has become
cloudy, replace the A/T and check the
route (radiator, etc.) through which water
has entered the A/T.

1-2 is the self-diagnosis satisfactory? (See Page 7A2-3) YES | Proceed to the next step.

NO When a DTC is shown, check the relevant

section of the DTC. When the trouble cannot
be fixed, replace the transmission.

1-3 Is the line pressure sufficient? (See Page 7A2-65) YES | Proceed to the next step.
kPa (PS)

Range idling pressure Stall pressure

D 529-784 (77-114) 990-1480 (144-215)

NO Proceed to the Step 1-5.
R 755-1127 (110-164) 1401-2107 (203-306)

1-4 Is the parking mechanism in good order? | YES | The powertrain inside the A/T is considered
* The tires are locked when the selector leverissetin | to be out of order. Replace the transmission.
the “P” range.
+ When the brake is released with the selector lever set
in other range than “P”, the vehicle can be moved by NO The parking mechanism is considered to be
being pushed. out of order. Replace the transmission.

i-8 Does the selector lever move well? YES | Proceed to the next step.

NO | Adjust the selector lever.

A/T: Automatic Transmission ATF: Automatic Transmission Fluid DTC: Diagnostic Trouble Code
 7A2-42 AUTOMATIC TRANSMISSION

Steps Inspection Corrective Measures

1-6 Does the line pressure solenoid of the TCM output YES | Replace the transmission.
correct voltage? (See Page 7A2-60)

Terminal | Voltage (V) Measuring Conditions NO Measure the resistance values.

(See Page 7A3-14)
3.3-5.5 | When the throttle is completely closed. OK -» Proceed to the next step.
B229-26 NG -+ Check defective parts or the harness.
1.0-1.7 | When the throttle is fully open.

1-7 Are signais properly input to the throtile position sensor YES {| Replace the TCM.
of the TCM? (See Page 7A2-60) Check the ATF, and when a sign of “Burn” or
“Damage” is found inside the A/T, replace the
Terminal | Voltage (V) Measuring Conditions A/T as well.

a 38-45 Release the accelerator (to close the NO Proceed to the next step.
B229-56 | throttle completely).
I
-) Depress the accelerator fully (ta
0.5-1.8 ,
B229-19 open the throttle fully).

1-8 Is the supply voltage of the throttle position sensor YES | Check the throttle position sensor and the
satisfactory? (See Page 7A2-60) harness.
As the inside of the A/T is considered to be
Terminal Voltage (V) damaged, replace the transmission.

Oo © .
B229-18 «+ B229-19 45-55 NO Check the power circuit of the throttle position
sensor.
When it is in order, replace the TCM.

A/T: Automatic Transmission ATF: Automatic Transmission Fluid TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-43

2 |The vehicle moves at the “N” range.

* The vehicle moves at the time of idling and accelerates when the accelerator is depressed with the selector lever
Situations) set in the “N” range.
* The vehicle does not drive with the selector lever set in the “R” range.

@ The selector lever has not been assembled nor

adjusted correctly.
c @) The front clutch or the rear clutch has seized.
auses @) The manual valve has malfunctioned (the linkage has
come off).

Steps inspection Corrective Measures

2-1 Does the selector lever work well? YES | Proceed to the next step.

NO Adjust the selector lever, then proceed to the

next step.

2-2 Can the trouble be fixed by conducting a road test? Do YES | Proceed to the next step.
you recognize no abnormal phenomenon like
“Slippage”? NO The inside of the A/T is considered to be
damaged, so replace the A/T.

2-3 Is the stall revolution normal in a stall test? YES | The control linkage is defective, but the inside
Stall revolution 1600-1900 RPM oe A/T is considered to be free of any

NO Replace the A/T.

A/T: Automatic Transmission

 7A2-44 AUTOMATIC TRANSMISSION

3 | The gear cannot be changed.

* Gear changes from 1st to 2nd, from 2nd to 3rd and from 3rd to 4th are not possible, and the shift gear is fixed.
Situations| « The gear changes at a time but not at other time.

@ The shift solenoids (No.1 and 2) are defective.

@) The control valve does not slide properly.
Causes @ The vehicie speed sensor 1 is defective.
@ Grounding is not correct.
(©) The TCM is defective.

Steps Inspection Corrective Measures

3-1 is the self-diagnosis satisfactory? (See Page 7A2-3) YES | Proceed to the next step.

NO | ADTC appears
Check the relevant DTC section.

3-2 Is the gear set to the 1st when the vehicle starts? YES | Proceed ta the Step 3-4.

NO Proceed to the next step.

3-3 Are the output voltages from the TCM to the No.1 and 2 YES | Proceed to the next step.
shift solenoids ($1 and S2) satisfactory in the “4th
(O/D)” range? NO Measure the resistances of the shift solenoids
(See Page 7A2-60) No.1 and 2. (See Page 7A3-14)
OK ~» Proceed to the Step 3-7.
Solenoid | Terminal Voltage (V) NG — Check the shift solenoids No.1, 2 and
the harness.
No.1 12: When driving at the D1 or D2 gear.
(st) | 82213) gq When driving at the D3 or D4 gear.
No.2 f2 — : When driving at the D2 or D3 gear.
(82) Be2e-12 0 — : When driving at the Di or D4 gear.

3-4 is the resistance of the vehicle speed sensor 1 YES | Check wiring from the TCM to the vehicle
satisfactory? speed sensor 1 and connection of the
connector. Proceed next step.
Resistance (Q) 560-680 (at 20°C)

NO Replace the vehicle speed sensor 1.

Proceed to the next step.

3-5 Is the trouble is fixed when the TCM is replaced with a YES | Replace the TCM.
non-defective one?
NO Replace the A/T.

A/T: Automatic Transmission ATF: Automatic Transmission Fluid DTC: Diagnostic Trouble Code O/D: Overdrive
TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-45

4 Does not upshift from the 3rd to 4th.

- Even though the engine is accelerated and rotates faster, ihe gear does not shift to the 4th.
Situations! * When the accelerator is released at the vehicle speed is over 6Okm/h (38mph) with the selector lever set in the
s “D2” range, the gear is not set to 4th.
% When the engine is cold (the ATF temperature is below 40°C/104°F), the gear is not set to the 4th (O/D).
@ The ATF thermosensor is defective. ) The vehicle speed sensor 1 is defective.
@) The No.1 and 2 shift solenoids are defective. @ The O/D OFF switch is defective.
Causes | @ The control valve does not slide well. @ The grounding is not correct.
@ The inhibitor switch is defective or is not adjusted (8) The TCM is defective.
correctly.

Steps Inspection Corrective Measures

4-1 is the self-diagnosis satisfactory? (See Page 7A2-3) YES | Proceed to the next step.

NO A DTC appears.
Check the relevant DTC section.

4-2 Are the output voltages from the TCM to the No.1 and 2 YES | The inside of the A/T is considered to be
shift solenoids (S1 and $2) satisfactory in the “4th (O/D)” defective.
range? Check the ATF, and if internal parts have
(See Page 7A2-60) been burnt, replace the A/T.

Solenoid | Terminal Voltage (V)

No.1 | poogtg | 12 ‘When driving at the D1 or D2 gear. NO | Measure the resistances of the shift solenoids
(Si) Q —_ ; When driving at the DS or D4 gear. No.1 and 2.
OK — Proceed to the next step.
No.2 8209-12 12: When driving at the D2 or D3 gear. NG —» Check defective parts and the
(S2) 0 : When driving at the D1 or D4 gear. harness.

ATF: Automatic Transmission Fluid DTC: Diagnostic Trouble Code O/D: Overdrive
AVT: Automatic Transmission
TCM: Transmission Control Module
7A2-46 AUTOMATIC TRANSMISSION

Steps Inspection Corrective Measures

4-3 Are the voltages at the inhibitor switch and O/D OFF YES | Proceed to the next step.
switch terminal of the TCM satisfactory?
(See Pages 7A2-60) NO Check defective parts and the harness.
When the trouble is not fixed, return to the
Terminal | Voltages (V) Measuring Conditions Step 4-2,

10-16 “P" range

B231-3
1 max. Other than “P” range

10-16 “R” range

B231-9
1 max. Other than “R” range

10-16 “N” range

B231-4
1 max. Other than “N” range

10-16 “D” range

B231-10
7 max. Other than “D” range

10-16 “2” range

B231-11
1 max. Other than “2” range

10-16 “4” range

B231-6
1 max. Other than “1” range

10-16 O/D OFF switch “OFF”

B230-6
1 max. O/D OFF switch “ON”

4-4 is the resistance of the vehicle speed sensor 1 YES | Check wiring from the TCM to the vehicle
satisfactory? speed sensor 1 and connection of the
connector.
Resistance (Q) 560-680 {at 20°C) Proceed next step

NO Replace the vehicle speed sensor 1.

Proceed next step.

4-5 Is the potential difference between the ground terminal YES | Replace the TCM.
B231-2 or B231-8 of the TCM and the transmission
case correct? NO | The grounding is considered not to be
correct.
Potential difference | OV (when it is normal)
Check the grounding point.

O/D: Overdrive TCM: Transmission Control Module

 AUTOMATIC TRANSMISSION 7A2-47

5 | The gear change is abnormal.

+ The gear change pattern is different from the drive pattern.
Situations; | Example) When the engine is accelerated by depress on the accelerator slowly, the ist gear abruptly changes
to the 4th gear.

@ The ATF is not sufficient. () The TCM is defective.

@® The grounding is not correct. ® The control valve does not slide well.
Causes @ The throttle position sensor is defective or has not
been adjusted correctly.
@ The vehicle speed sensor 1 is defective.

Steps Inspection Corrective Measures

5-1 Is the ATF sufficient and in good order? YES |} Proceed to the next step.
(See Page 7A3-2)
NO <Reference>
<Reference> » tis finally required to disassemble and
« When the ATF is cloudy (pinkish), if contains water. repair the A/T.
The inside of the A/T is considered to be
damaged.
Proceed to the next step, and find causes
of the trouble.
When the ATF is cloudy, replace the A/T
and check the route (radiator, etc.) through
which water has entered the A/T.

5-2 Is the self-diagnosis satisfactory? (See Page 7A2-3) YES | Proceed to the next step.

NO A DTC appears.
Check the relevant DTC section.

5-3 Is the line pressure sufficient? (See Page 7A2-65) YES | Replace the A/T.
kPa (PSI
” NO Proceed to the next step.
Range Idling pressure Stall pressure

D 529-784 (77-114) 990-1480 (144-215)

R 755-1127 (110-164) | 1401-2107 (203-306)

5-4 Does the selector lever work well? YES | Proceed to the next step.

NO Adjust the selecior lever.

A/T: Automatic Transmission ATF: Automatic Transmission Fluid OTC: Diagnostic Trouble Code
TCM: Transmission Control Module
7A2-48 AUTOMATIC TRANSMISSION

Steps Inspection Corrective Measures

5-5 Does the line pressure solenoid of the TCM output YES | Replace the A/T.
correct voltages? (See Page 7A2-60)
NO Proceed to the next step.
Terminal | Voltage (V) Measuring Conditions

3.3-5.5 | When the throttle is completely closed.

B229-26
1.0-1.7 | When the throttle is fully open.

5-6 Are signals properly input to the throttle position sensor YES | Replace the TCM.
of the TCM? (See Page 7A2-60) Check the ATF, and when a sign of “Burn” or
“Damage” is found inside the A/T, replace the
Terminal | Voltage (V) Measuring Conditions A/T as well.

ab 38-45 Release the accelerator (to close the NO Proceed to the next step.
B229-5 ~~ throttle completely).
I
© Depress the accelerator fully (to
0.5-1.8
B220-19 open the throttle fully).

5-7 Is the supply voltage of the throttle position sensor YES | As the inside of the A/T is considered to be
satisfactory? (See Page 7A2-60) damaged, replace the A/T.
Terminal Voltage (V) Measuring Condition NO Check the power circuit of the throttle position
~ sensor.
) © 45-55 Key switch “ON” When it is in order, replace the TCM.
B229-18<> B229-19

F
J

A/T: Automatic Transmission ATF: Automatic Transmission Fluid TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-49

6 At acceleration, the engine races and slippage occurs.

e When the accelerator is depressed to start driving, the engine rotates faster, bui the speed does not increase.
Situations| ° Even if the accelerator is depressed for acceleration during a drive, only the engine rotates faster but the speed
does not increase.

@ The ATF is not sufficient. S) The powertrain slips.

@) The selector lever has not been assembled or ©) The control valve does not slide well.
Causes adjusted correctly. @) The tine pressure solenoid is defective.
@®) The throttle position sensor is defective or has not
been adjusted correctly.
@) The line pressure has dropped.

Steps inspection Corrective Measures

6-1 is the ATF sufficient and in good order? YES | Proceed to the next step.
(See Page 7A3-2)
NO <Reference>
<Reference> » It is finally required to disassemble and
+ When the ATF is cloudy (pinkish), water is contained repair the A/T.
in the ATF. The inside of the A/T is considered to be
damaged.
Proceed to the next step, and find causes
of the trouble.
When the ATF is cloudy, replace the A/T
and check the route (radiator, etc.) through
which water has entered the A/T.

6-2 is the self-diagnosis satisfactory? (See Page 7A2-3) YES | Proceed to the next step.

NO A DTC appears.
Check the relevant DTC section.

6-3 is the line pressure sufficient? YES | Replace the A/T.

kPa (PSI)
; NO Replace the selector lever.
Range idling pressure Stall pressure OK -+ Proceed to the next step.
NG —+ Adjust or replace the selector lever.
D 529-784 (77-114) 990-1480 (144-215)

R 785-1127 (110-164) | 1401-2107 (203-306)

64 Is the output voltage of the line pressure solenoid of the YES | Replace the A/T.
TCM satisfactory? (See Page 7A2-60)
. a: NO | Proceed io the next step.
Terminal | Voltage (V) Measuring Conditions

3.3-5.5 | When the throttle is completely closed.

B229-26
1.0-1.7 | When the throttle is fully open.

A/T: Automatic Transmission ATF: Automatic Transmission Fluid DTC: Diagnostic Trouble Code
TCM: Transmission Control Module
7A2-50 AUTOMATIC TRANSMISSION

Steps Inspection Corrective Measures

6-5 Are signals properly input to the throttle position sensor YES | Replace the TCM.
of the TCM? (See Page 7A2-60) Check the ATF, and when a sign of “Burn” or
“Damage” is found inside the A/T, replace the
Terminal | Voltage (V) Measuring Conditions A/T as well.

4 38-4 Release the accelerator (to close the NO Proceed to the next step.
B229-5 B45 throttle completely).
t
= Depress the accelerator fully (to
ee 0.5-1.8 open the throttle fully).

6-6 Is the supply voltage of the throttle position sensor YES | As the inside of the A/T is considered to be
satisfactory? (See Page 7A2-60) damaged, replace the A/T.

Terminal Voltage (V) NO Check the power circuit of the throttle position
sensor.
When it is in order, replace the TCM.
® © 4.5-5.5 P
B229-18<+ B229-19

A/T: Automatic Transmission ATF: Automatic Transmission Fluid TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-51

The engine stalls when the selector lever is moved from the “P” or “N” to one of
7 :
the drive ranges.
teat « When the selector lever is changed frorn the “N” or “P” range to the drive range while the engine is idling, the
Situations : : :
engine stops immediately.

@) The idling speed of the engine is slow. (4) The vehicle speed sensor 1 is defective.
() The control valve does not slide well. (5) The engine speed sensor is defective.
Causes @) The inhibitor switch is defective or has not been
adjusted correctly.

Steps Inspection Corrective Measures

7-1 Is the idling speed satisfactory? YES | Proceed to the next step.
Idling speed : 775 - 825RPM
NO Adjust the idling speed.

7~2 is the trouble fixed when the connectors of Pin 12, Pin YES | Proceed to the next step.
16 and Pin 26 of the TCM are disconnected? Be sure
to reset the connectors. NO Replace the A/T.

7-3 Are the voltages at the inhibitor switch and the vehicle YES | Proceed to the next step.
speed sensor 1 of the TCM satisfactory?
(See Pages 7A2-60} NO Check defeclive parts and the harness.

Terminal | Voltages (V} Measuring Conditions

10-16 “P” range

B231-3
71 max. Other than “P” range

10-16 “RY range

B231-9
1 max. Other than “F" range

10-16 “N” range

B231-4
1 max. Other than “N” range

10-16 “Dy” range

B231-10
1 max. Other than “D” range

10-16 “2” range

B231-711
1 max. Other than “2” range

10-16 “4” range

8231-6
1 max. Other than “1” range
on
® 0.35 (AC) | Vehicle speed of over 24km/h
B229-3 min. (15mph)
i (As the speed increases, the
— voltage increases continuously.)
B229-16

AC: Alternating Current A/T: Autornatic Transmission TCM: Transmission Control Module
7A2-52 AUTOMATIC TRANSMISSION

Steps Inspection Corrective Measures

7-4 Are the voltage at the engine speed sensor terminal YES | Proceed to the next step.
satisfactory? (See Page 7A2-60)
NO Check defective parts and the harness.

Terminal Voltage (V) Measuring conditions

oe The engine speed is

B229-1 | T min. 4O000RPM approx.

7-5 Is the potential difference between the ground terminal YES | Replace the TCM.
B229-3 or B229-16 of the TCM and the transrnission
case correct? NO The grounding is considered not to be
correct.
Potential difference | OV (when it is normal)
Check the grounding point.

TCM: Transmission Control Module

 AUTOMATIC TRANSMISSION 7A2-53

8 | The ATF blows off from the air breather pipe during driving.
- During a drive, ATF blows off from the air breather pipe.
Situations|

@ The ATF is too much.

@) Water enters the A/T from the outside.
Causes

Steps Inspection Corrective Measures

8-1 Is the ATF at the proper level and in good order? YES | Proceed to the next step.
(See Page 7A3-2)
NO Adjust the ATF level when its condition is
<Reference> satisfactory but the level is too high.
« When the ATF is cloudy (pinkish), water is contained When its level is satisfactory but the condition
in the ATF. is not, the inside of the A/T is considered to
be damaged, so replace the A/T.
When the ATF is cloudy, replace the A/T and
check the route (radiator, etc.) through which
water enters it.

8-2 is the phenomenon improved during a drive after the YES | Check the ATF while keeping it at the “Low”
ATF is adjusted to the “Low” level? level.
If the level rises, water is considered to have
entered the A/T.

NO Replace the A/T.

A/T: Automatic Transmission ATF: Automatic Transmission Fiuid

7A2-54 AUTOMATIC TRANSMISSION

9 | Engine brake does not function.

* When the accelerator is released during a drive at an intermediate or high speed, the engine rotates at the idling
Situations speed and the vehicle drives free.
* Also, when the accelerator is released during a drive at a low speed with the selector lever set in “2” or “1” range,
the vehicle drives free.
@) The ATF is not sufficient. © The O/D OFF switch is defective.
@) The powertrain slips. © The inhibitor switch is defective or has not been
Causes | @) The control valve does not slide well. adjusted correctly.
@ The throttle position sensor is defective or has not @ The vehicle speed sensor 1 is defective.
been adjusted correctly.
Steps inspection Corrective Measures
9-1 is the ATF sufficient or in good order? YES | Proceed to the next step.
(See Page 7A3-2)
NO <Reference>
<Reference> * tis finally required to disassemble and
» When the ATF is cloudy (pinkish), water is contained repair the A/T.
in the ATF. The inside of the A/T is considered to be
damaged.
Proceed to the next step, and find causes
of the trouble.
When the ATF is cloudy, check the route
(radiator, etc.) through which water enter
the ATF.

9-2 Is the self-diagnosis satisfactory? (See Page 7A2-3) YES | Proceed to the next step.

NO A DTC appears.
Check the relevant DTC section.

9-3 Does such a phenomenon occur as “At the time of YES | The powertrain is considered to slip.
acceleration, the engine races or the clutch slips”? Proceed to the Abnormal Phenomena 6 “At
acceleration, the engine races and slippage
occurs.”

NO Proceed to the next step.

9-4 Is engine braking effective with the selector lever set in YES | Proceed to the next step.
the “1” range?
NO The inside of the A/T is considered to be
defective. Check the ATF, and if internal parts
seem to be burnt, replace the A/T.

A/T: Automatic Transmission ATF: Automatic Transmission Fluid DTC: Diagnostic Trouble Code O/D: Overdrive
TCM: Transmission Control Module
 AUTOMATIC TRANSMISSION 7A2-55

Steps inspection Corrective Measures

9-5 Are voltages at the inhibitor switch, O/D OFF switch, YES | Replace the TCM.
throttle position sensor and vehicle speed sensor 1
terminal of the TCM are satisfactory? NO Check defective parts and the harness.
(See Pages 7A2-60)

Terminal | Voltages (V} Measuring Conditions

10-16 “P" range

B231-3
1 max. Other than “P” range

10-16 “R” range

B231-9
1 max. Other than “R” range

10-16 “N” range

B231-4
1 max. Other than “N” range

10-16 “O° range

B231-10
1 max. Other than "D” range

10-16 “2” range

B231-11
1 max. Other than “2” range

10-16 “1” range

B23 1-6
1 max. Other than “1” range

10-16 O/D OFF switch “OFF”

B230-6
1 max. O/D OFF switch “ON”

® Release the accelerator

8229-5 3.8-4.5 (to close the throttle completely).
t
eS Depress the accelerator fully
B229-19 0.5-1.8 (to fully open the throttle).

oO Vehicle speed of over 24km/h

B229-3 (15mph)
! 098 (AC) (As the speed increases, the
min. voltage increases continuously.)
B229-16

AC: Alternating Current O/D: Overdrive TCM: Transmission Control Module

7A2-56 AUTOMATIC TRANSMISSION

WIRING DIAGRAM

DATA BS
LINK
CONNEC TOR By

B-79

[ v-19 (9) RELAV:ENG WARM CUT2

[9] pevay.ena WARM cUT2

[v2] vevrisp

fe-2as](14) ecm
R
@1 [318]@) RELAY-EXH BRAKE LINE PBRESS SOL

(7 EBC
[Ea] 100 STOP LIGHT OIL TEMP SENSOR

STOP LIGHT

Qo

31104 SW:STOP LIGHT

[Ee] O.3LG
MITER BACK [B-20q() ECM ~
JOINT GONNECTOR2
=
8 B2oqt7)
asa?) ECM
EC
0.58
JOINT
CONNECTOR

THROTTLE
SENSOR

ARTER
SWITCH
SW;OD OFF

[B-55}@) METER

BACK UP LIGHT
SW,INHIBITOR

CHECK TRANS

H-4
AT OI TEMP O5Y/G O.5Y/G

(5) RELAY,STARTER
}} FRAME

Figure 11. Wiring Diagram

 B-52 OD OFF INDICATOR LIGHT & CHECK
TRANS LIGHT (METER)

N-7 OD OFF SW STARTER SW

\ |
oa J-129 ATF SW
PARTS LOCATION

A \ ~~ ~ J-71
FUSE BOX ASM \ leo ~
=| ~S« / 478 VEHICLE SPEED
f { i
FIP \ oN /
/ \ | INHIBITOR SENSOR
\ | |
; sw | | AN, too
\ \ /f B66STOP “>~_| | Ee y Ue
V LIGHTSW ss \ | |
7\ Ge
B-110 A SN ) // AS
EBCMS. [co~~ B84 \ Va
{
Aa — .

" eS
B-29 JOINT

p
CONNECTOR~_|_

Figure 72. Parts Location

\ -FL-1, FL-2 FUSIBLE LINK

RELAY BOX ASM

J-21 DIODE

B-76 KICK DOWN SW B-229

B-80 THROTTLE POSITION SENSOR = =—-_--79 DATA LINK CONNECTOR

AUTOMATIC TRANSMISSION 7A2-57
7A2-58 AUTOMATIC TRANSMISSION

CONNECTOR CONFIGURATIONS (1)

“TH
alo
win
—,

le sit
J~J

Whe
A
f

t2jale
rasta

a aie
tl2[3 4) 5i6
71 8/3) 40} 19) 12
13/4 [15 19 | 17| 10
19 | 2o(20 22| 23| 24
[afar aa 29
37| 32133 | 24 | 35 | 36] 37 | 38] 39] 40

Figure 13. Connector Configurations (1)

 AUTOMATIC TRANSMISSION 7A2-59

CONNECTOR CONFIGURATIONS (2)

J-71

T
anna
s baslel2 (s[ef7te
ze ‘see
ra
i

[Na] [eelrs} [ra]

es

Figure 14. Connector Configurations (2)

7A2-60 AUTOMATIC TRANSMISSION

CONTROL SIGNAL INSPECTION

Control signal inspection is done to check for
transmission and transmission contro! module
(TCM) problems which cannot be detected by self
diagnosis.
21 | SERIAL DATA LOCK-UP reer? Additionally, it serves as a back-up check for self
B229| (SCAN TOOL} SOLENOID - 8229 diagnosis.
TIMING say oo
9 ENGINE SOLENOIDIST) (23314 Measure the voltage drop and make a continuity
| B229 O¥ER RUNNING test for each of the sensors, solenoids, and
: No.2SHIFT | [B29 L switches.
12-3590 HATING UP SOLENOID(S2) If the voltage is within the specified range and
SYSTEM No.1 SHIFT
SOLENOID(S?) [B229= |=13 inui exists, that particular area of the TCM
continuity
ENGINE LINE and automatic transmission assembly is normal.
Ef 8208 | WARMING UP PRESSURE (e220? ‘|f voltage deviation or lack of continuity is
SOLENOID(- discovered, disconnect the applicable parts and
4 — | SIGNAL
IDLE UP LINE
PRESSURE [aa29 ]2°. check each of them indivi
individually.
—~{'B230
SOLENOID(+)-—— This will allow you to determine the trouble
—raps0
J BAKE
EXHAUST A RMO- __
ATF location
i (TCM, automaticj transmission
igsi unit,j or
-— SIGNAL SENSOR(-} another area of the vehicle).
29 EXHAUST SHE RMO
=-{"B229 [BRAKESIGNAL
B29 | GUT SENSOR(+)- [B2209 }*
SHIELD
27 591 BRAKE FOR 8229-31 82292 }'*
SWITCH
VEHICLE SPEED | ag 1 2
ENGINE SENSOR [ B229 }—
B22 29 | SPEED (TRANSMISSION )
~~! SENSOR
VEHICLE SPEED _
SENSOR p229 }*
8/5950 | OE a SENSOR ssionsa) E229 [(
BATTERY -— 8
1 peat IGNITION GROUND [_B231 }-- me
231 | SIGNAL
BATTERY ae
OVER DRIVE
—8F p30 | OFF ROUND 8231. 1. Thin wire
SWITCH 2. Probe
CHECK TRANS SWITCH YL 8280
—2(B229] INDICATOR THROTTLE pt i
Figure i Tool
16. Inspection
7 LIGHT sOSiTION
SENSOR (8229 ['?-
15 | ATE GROUND Inspection Tool
B230 | TEMPERATURE
r—~ SWITCH THROTTLE
POSITION [6229 P~ Use a circuit tester to measure voltage and circuit
_, DIAGNOSTIC SENSOR continuity.
~—={ B230| ENABLE , og:
mo" SIGNAL THROTTLE Refer to the following table for the specified
POSITION Monn
8231 | P RANGE SENSOR [229 fe voltage ranges.
9
| B231| R RANGE VOLTAGE TCM terminals are extremely small.
Wrap a piece of thin wire (1) around the probe of
“18237 ] N RANGE VEHICLE
10 B231| D RANGE SPEEDSENSOR [ 8229 [~~ tester (2) (figure 16).
(SPEEDOMETER) This will make measurement easier.
ma
B231| 2 RANGE
ABS OPERATION “5200
55237
a | 1 4 RANGE SIGNAL

B229 8230, B231

|
fishaiiifiol ofs[7[e.5|4[3l2tsielz]els eR EERET
[2 29 24l23} 291 Sad ahahaha shal idishatshalniidal waltiholg [3] 7

Figure 15. TCM Gonnector Pin

 AUTOMATIC TRANSMISSION 7A2-61

TCM Terminal No.

(Wire Color) Standard . a: Signal oo
Voltage Inspection Condition Type Circuit
Tester (~) | Tester (+)

. B229-1 More than 1.0 | At an engine speed of Engine speed

8231-2 (B)) “(L/O) | (Intermitent AC) | approx. 1,000 RPM Input | sensor
B231-8 (B)| 229.2 | Notused — -— —
Vehicle speed 24 km/h (15 mph)
B229-16 B229-3 More than 0.35 (Voltage increases in proportion to Vehicle speed
(P) - ( '9- (AC) the speed) input | sensor
(Transmission)
0 Vehicle stopped
B231-2 (B)) B009-4 0-5 Vehicle moved at slowest possible input Vehicle speed sensor
B231-8 (B) (L/G) speed at least 1 meter (SPEEDOMETER)
B229-19 3229-5 3.5-4.7 Accelerator pedal fully closed Input Throttle position

(UY) (RW) 0.5-1.9 Accelerator pedal fully opened sensor

B229-20 3229-6 0.9 ATF temp. approx. 10 °C (60 °F)

(Y) (UY) input | ATF thermosensor
0.3 ATF temp. approx. 40 °G (104 °F)

B229-7 Not used ~— — —

B229-8 10-16 Engine speed more than 3,800 RPM Engine overrunning
(BIW) Output | light
Less than 1.0 | Engine speed less than 3,700 RPM (If equipped)

10-16 Normally state

B229-9 fi
(O/B) Less than 3.0 In order to 2 seconds when after Output | Check trans light
, the key switch “ON”

8231-2 (8) | B229-10 | Notused ~ _~ _

B231-8 (B) 10-16 | Shift up to 2nd or 3rd kick down to
B229-11 ‘st Output | Timing solenoid (ST)
(R/B)
Less than 1.0 | Normally state

10-16 Driving at “D2” and “D3”

B229-12 (No.2 shift solenoid (S2) “ON’) No.2 shift solenoid
(
BRR) Less than 1.0 Driving at “D1” and “D4”
Output | (g2)
, (No.2 shift solenoid (S2) “OFF”)

AC: Alternating Current ATF: Automatic Transmission Fluid TCM: Transmission Control Module
7A2-62 AUTOMATIC TRANSMISSION

TCM Terminal No.

(Wire Color) Standard Signal
Voltage Inspection Condition Type Circuit
Tester (-) | Tester (+)

10-16 Driving at “D1” and “D2”

B229-13 (No.1 shift solenoid (S1) “ON’) No.1 shift solenoid
(BR/Y) Less than 1.0
—
Driving at “D3” and “D4”
Output | (g1)
B231-2 (B) , (No.1 shift solenoid ($1) “OFF”’)
or
B231-8 (B)| B229-14 Not used _ —_ —

B229-15 _ — _ Shield

B229-17 Not used —_ —_ _

B229-19 | 8229-18 ; Throttle position

(LY) (RIG) 4.5~5
. 5
Key switch a6,
“ON th
Source sensor supply voltage

B229-21 “ ,
(B/R) _ _ — Scan Tool

10-16 Vehicle speed 16 km/h (10 mph)

rBG) selector “1” range Output | Exhaust brake cut
B231-2 (B) Less than 3.0 | Selector “P” or “N” range
or
B231-8 (B) 3229-23 10-16 Key switch “ON”, Selector “P” range Output Engine warming up

(B/R) Less than 3.0 | Lock-up “OFF” to “ON” cut

10-16 Lock-up “ON”

BAW) Output | Lock-up solenoid
Less than 1.0 | Lock-up “OFF”

3.3-5.5 Engine warmed up and stopped,

( AC) Throttle fullly closed, key switch

B229-25 | B229-26 ON Output Line pressure duty

(BR/G) (BR) 1.0-1.7 Engine warmed up and stopped, solenoid

rN Throttle fullly opened, key switch
(AC) | cone
B230-1 10-16 Exhaust brake switch “ON”
(LG) Input | Exhaust brake
B231-2 (B) Less than 1.0 | Exhaust brake switch “OFF”
or
B231-8 (B)| 8230-2 Not used _ —_ —_

B230-3 Not used _ _ _—

TCM: Transmission Control Module

 AUTOMATIC TRANSMISSION 7A2-63

TCM Terminal No.

(Wire Color) Standard Signal
Voltage Inspection Gondition Type Circuit
Tester (-) | Tester (+)

10-16 Air conditioner copmressor “ON”

UG) Input | Engine idle up
Less than 1.0 | Air conditioner copmressor “OFF”

B230-5 Not used — — —

10-16 O/D OFF switch “OFF”

eo) input O/D OFF switch
Less than 1.0 | O/D OFF switch “ON”

B230-7 10-16 Accelerator pedal “released”

(GRIL) input Kick down switch
Less than 1.0 | Accelerator pedal “depressed”

10-16 Self diagnosis “OFF”

BM) Input Data link connector
Less than 1.0 | Self diagnosis “ON”

B230-9 Not used _— _ -_

B231-2 (B)| B230-10 Not used _ _ >

or
B231-8 (B)) 3530-14 10-16 ABS “Inactive” at engine running
(BR/B) Input ABS signal
Less than 1.0 | ABS “Active”

10-16 QWS switch “ON”

nee Input | Engine warming up
(LGW) | Less than 1.0 | QWS switch “OFF”
B230-13 Not used ~— _ —

B230-14 Not used —_ — —_

10-16 Normally state

ay Input | ATF thermo switch
(Yi) Less than 1.0 | ATF temperature more than 147 °C

10-16 Engine speed more than 880 RPM

B230-16 on
(B/G) Less than 1.0 Accelerator pedal full closed. Input | Idle signal
, Engine speed 400-880 RPM

O/D: Overdrive TCM: Transmission Control Module

7A2-64 AUTOMATIC TRANSMISSION

TCM Terminal No.

(Wire Color) Standard . ye Signal ae
Voltage Inspection Condition Type Circuit
Tester (—) | Tester (+)

B231-1 (BY) 10-16 Key switch “ON” Source | Battery voltage

B231-3 10~16 Selector “P” range

(WIR) input | “P” range switch
Less than 1.0 | Selector other than except “P” range

10-16 Selector “N” range

B231-4 unin Input | “N” range switch
(W/R) Less than 1.0 Selector other than except “N
, range

B231-5 Not used _ — _

B231-6 10-16 Selector “1” range

(LW) Input | “1” range switch
B231-2 (B) Less than 1.0 | Selector other than except “1” range
or _ _ —_—
B231-8 (B) B231-7 Not used

10-16 Selector “R” range

vA). Input | “R” range switch
Less than 1.0 | Selector other than except “R” range

10-16 Selector “D” range

UO) Input | “D” range switch
Less than 1.0 | Selector other than except “D” range

10-16 Selector “2” range

OUR). Input | “2” range switch
Less than 1.0 | Selector other than except “2” range

10-16 Stop light “ON”

ma) 12 Input | Stop light
Less than 1.0 | Stop light “OFF”

TCM: Transmission Control Module

 AUTOMATIC TRANSMISSION 7A2-65

LINE PRESSURE TEST

The line pressure test checks oil pump and 6. Start the engine and allow it to idle until the ATF
control valve pressure regulator valve function. ft temperature reaches 50-80°C (122-176°F) and
will also detect oil leakage. check the idling rpm.
7. Hold the brake pedal down as far as it will go.
CAUTION: The line pressure test always requires 8. Place the selector in the “D” range.
two persons with the first person checking the tire 9. Note the pressure gauge reading with the
and tire stopper off the vehicle while the second engine idling.
person performs testing. 10. While depressing the accelerator pedal to the
floor, quickly read the oil pressure at stalling
Line Pressure Test Procedure rpm.
1. Check the level of the engine coolant, the
engine oil, and the automatic transmission fluid. CAUTION: Release the accelerator pedal and stop
Replenish if required. the test if the rear wheels start to turn before the
2. Set the parking brake. engine reaches the stalling rpm.
3. Place chocks at the front and rear of each tire.
4, Remove the pressure detection plug at the left 11. Repeat the test in the “R” range.
side of the transmission.
5. Set a pressure gauge to the pressure detection Measure
plug hole.
« Line Pressure kPa (PSI)
Tools Required:
J-29770-A Pressure Gauge Engine Speed
J-43407 Adapter Range
Idling Stalling

D 529-784 990-1480
(77-114) (144-215)

A 755-1127 1401-2107
(110-164) (203-306)

12. install pressure detection plug to the

transmission.
13. Tighten the pressure detection plug.

Tighten

* Detection Plug 27 N-m (20 lb-in)

Figure 17. Detection Plug Hole

7A2-66 AUTOMATIC TRANSMISSION

Line Pressure Test Results Probable Trouble Area

* Defective or poorly adjusted throttle position sensor

* Sticking or short throttle pressure solenoid
Line pressure is above the specified
* Sticking regulator vaive
limit in all ranges
* Defective idle switch
* Defective kick-down switch

* Poorly adjusted throttle position sensor

¢ Sticking or short throttle pressure solenoid
Line pressure is below the specified
* Sticking regulator valve
limit in all ranges
* Worn oil pump
* Defective O/D direct clutch
Line pressure is below the specified * Oil leakage in “D” range line
limit in “D” ranges * Defective front clutch
° Oil leakage in “R” range line
Line pressure is below the specified
* Defective rear clutch
limit in “R” ranges « 1st and reverse brake malfunction
 AUTOMATIC TRANSMISSION 7A2-67

STALL TEST
The stall test allows you to check the 5. Set a tachometer to the engine.
transmission for internal abrasion and the one-way 6. Hold the brake pedal down as far as it will go.
clutch for slippage. Torque converter performance 7. Place the selector in the “D” range.
can also be evaluated. 8. Gradually push the accelerator pedal to the
The stall test results together with the road test floor.
results will identify transmission components The throttle will fully open.
requiring servicing or adjustment. Note the engine speed at which the tachometer
needle stabilizes.
CAUTION: When the clutch appears to be slipping
in a road test, etc., or when the line pressure does Measure
not reach a preset value in a line pressure test, do
* Stall speed 1,600-1,900 RPM
not proceed to a stall test.
9. Release the accelerator pedal.
Stall Test Procedure
10. Place the selector in the “N” range.
1. Set the parking brake.
11. Run the engine at 1,200 RPM for one minute.
2. Place chocks at the front and rear of each tire.
This will cool the transmission fluid.
3. Check the level of the engine coolant, the
12. Repeat Steps 6-11 for the “2”, “1 “, and “R”
engine oil, and the automatic transmission fluid.
ranges.
Replenish if required.
4. Start the engine and allow it to idle until the
CAUTION: Do not continuously run this test
engine coolant temperature reaches 70-80°C
longer than 5 seconds so the transmission
(158-176°F).
does not become overheated.
7A2-68 AUTOMATIC TRANSMISSION

ROAD TEST

The road test should be performed by two people SHIFT POINT DIAGRAM AND LOCK-UP
(one to drive and the other to note the required POINT DIAGRAM
data) on a lightly traveled ordinary public road.
in the shift point diagram and the lock-up point
General Test Items diagram, figures indicate vehicle speeds (in km/h)
1. Compare the actual automatic shift speeds with for the final gear ratio of 5.375 and for the tire
the fixed shift schedule. radius of 0.373m (215/85R16). And vehicle speeds
a. Perform the diagnosis procedures. (in km/h) for other final ratios can be obtained by
b. Note the actual shift up, shift down, and lock multiplying figures in this diagram by following
up speeds on the fixed shift schedule. coefficients.
2. Check for shock or drag when the transmission
shifts from one gear to another. Final Gear
Ratio Tire Radius | Coefficient
3. Check that the engine brake functions in the "2"
and "1" ranges.
4. Check for abnormal noise or vibration. 5.375 (43/8) | 215/85R16 | 0.373m | —-1.000
After completing the road test, make the
necessary adjustments and repairs to the 5.857 (41/7) |225/70R19.5| 0.394m 0.970
automatic transmission and related parts.
The tolerance to measured values is £3km/h.
 AUTOMATIC TRANSMISSION 7A2-69

Diagram : . .
Shift Point Diagram
g
Range

8/8

78 |

6/8 |-
2
> 5/6
eo

2
6 4/8
Q

2
o 3b
"bp" Ee

2/8

1/8b

08 i
(6)(7) (12) (17) (20)
Output shaft . 10 20 . 30 . 40
rev. x 100rpm
Velocity
Final gear km/h 20 . 40 . 60 . 80 . 190
ratio=5.375
Radius of 0 10 20 30 40 50 60
tire=0.373m (mph) + + + + + +
(14.7in)

Diagram . .
agra Lock-up Point Diagram
Range

32 2 50 58 76 82
8/6 (31) (47)
! /
7/8 . !
1
&/ é

1 7-4? (36) ¥,' 61)

6/8 ' |
li 4 t
& Ww! F

2% 68t a1 t
2 ' ;
c 4/8 + | t

"5" 2
3 ' iL

. £ 3/Bb ' 5
O/D off switch Fe a
4 t

“ON” 26 :
i
Te !
I J
1 i

ve (20ya3) (29) 33) (36)

7 i.

Output shaft 0 20 30 49
rev. x 100rpm
Velocity
Finalgear kmh 20 . 40 . 80 ' 80 : 190
ratio=5.375
Radius of 0 10 20 30 40 50 60
tire=0.373m (Ph) + + +
(14.7in)
7A2-70 AUTOMATIC TRANSMISSION

Diagram ‘ .
Lock-up
OCcK-Up Point Diagram
agra
Range

88 32
1
4

f- ;
7/6
'
1

6/8 F
uw i

Bost Q
|
aD
a 9

£2 i
4/8F
5
"Dp"
& 1

; 2 set |
O/D off switch =
“a OFF” 2a

' r
t t

1/8F i '
$ L
i t
' '
o/8 1 L
(20,22) (28) (36)
Output shaft 0 10 20
rev. x 100rpm
Velocity 100
Finalgear knyvh 20 40 60
ratio=5.375
0 40 20 30
Radius of
tire=0.373m (Mh), t ; ;
(14,7in)

Diagram . . .
9 Shift Point Diagram
Range

543
8/8 (13)

7B
i
1

678 | !
@
> 5r
® 9
= asl o
¢
E< a8 !
© .
2
deepal

278+
'

8Fr
'
'

0/8 33)L

Output shaft 20
rev. x 100rpm
Velocity
Final gear kmh © 2 . 40 . 80 190
ratio=5.375
Radius of GQ 20 30
tire=0.373m = (™Mph) ;
(14.7in)
 AUTOMATIC TRANSMISSION 7A2-71

Diagram : :
Lock-up p Point Diagram
g
Range

ae 2 58
'
'

7/8 | ;
i
i

68 |
i

B 56
8
§
we!us|
§ 48 |
8 2
6
£
at 9
“gu

I
2/8
F
f

1/8/-
t
E

oe (20%22) —« (29) (36)

Output shaft 8 . 20 30 : 40
sev. x 100rpm
Velocity :
Final gear kivh ° 20 40 : 60 . 80 . 100
tatio=5.375
Radius of a 10 20 30: 40‘ 50 60
tire=0.373m (Mh) -—
(14.7in)

. .
Diagra
i mi Shift: Point Diagram
Range

22 54
8/6 ‘ 1
i 1
1 t

7/8 +
t '
t t

6/8 + ' '

4 i
' 1

2
coy
sel “| $ I
!
> é | o!
& 4b ;
a 4

s ‘ '
2 i
2 3/8 i \
mae &
1 t

2Br ,
4 f
1 t

18 /-
f U
' 1
if 4

oe (13) (33)
Output shaft a 10 20 30 40
rev. x 100rpm ,
Velocity
Finalgear km/h © 20 40 80 80 100
ration5.375
Radius of
tire=0.373m — (Mph) +
0 10
' 20 30 49 50 60
(14.7in)
7A2-72 AUTOMATIC TRANSMISSION

DIAGNOSIS BY USING SCAN TOOL

TECH 2 SCAN TOOL

In this 450-43LE transmission, diagnosis can be

perfomed for electrical faults by using the diagnosis
equipment called "TECH 2".
When the check trans light blinks or when an
electrical fault in the transmission may probably
exist, check diagnostic trouble codes by using the
“TECH 2".
For the operations of "TECH 2", refer to following
instruction and the User Guide in the "TECH 2" kit.

PCMCIA card eT nas

Wulzlslsisisi7|a}
i rl
fo ey

Figure 19. DLC Location

6. The vehicle ignition turns on.

7. Power up the Tech 2.
8. Verity the Tech 2 power up display (Figure 20).

SAE 16/19 adapter

Figure 18. TECH 2 Scan Tool

CONNECTING THE TECH 2

Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed.
Tech
1. The Isuzu PCMCIA card inserts into the Tech 2.
2. Connect the SAE 16/19 adapter to the DLC
cable. Press (ENTER) To Continue
3. Connect the DLC cable to the Tech 2.
4. Make sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC connector (Figure 19).

Figure 20. TECH 2 Display

 AUTOMATIC TRANSMISSION 7A2-73

5. Follow the operating procedure below.

@ Press "ENTER" key.

Tech
Press (ENTER) To Continue

@ Press "FO" key, or

'
select "FO Diagnostics" Main Menu
with selection key and ee
press "ENTER" key. [FOF1 : Diagnostics
View Capture Data
F2 : Tool Options
F3 : Download/Upload Help

@ Select "(W) 1998”

Y
Vehicle Identification
with selection key and Select one of the following
press "ENTER" key. Model Year(S)
(W) 1996

(W) 1998

@ Select "(N*) ELF, NPR, NQR" Vehicle Ident

; ‘ ehicie identification
with selection key and Select one of the following
press "ENTER" key. Vehicle Type(S)
(UB) Trooper, Bighorn
(UE} Rodeo/Amigo, Wizard
[(N) ELF, NPA, NOR
(N*} ELF, NPR, NOR

® Press "Fi" key, or

Y
System Selection Menu
select "F1 Transmission"
with selection key and (W) 1998 (N*) ELF, NPR, NOR
press "ENTER" key.
FO : Engine
[F1 : Transmission

Continue to next page.

Figure 21. TECH 2 Display (2)

7A2-74 AUTOMATIC TRANSMISSION

Continued

Select "A445 AT"

Y
Vehicle Identification
with selection key and
Select one of the following
press "ENTER" key. Transmission

Other

A445 AT

Press "ENTER" key.

Y
System Identification
(W) 1998 (N*) ELF, NPR, NOR
Electronic System : AT A445

Turn On Ignition!

Confirm

Press the "Soft key”

'
System Identification
under the "Confirm" box. (W) 1998(N*) ELF, NPR, NOR
Electronic System : AT A445

PartNumber : 8971880060
Aipha Code : ZA

Confirm More

Select required item from

Y
application menu.
Application Menu

FO : Diagnosis
F1 : Data Display
F2 : Actuator Test

Figure 22. TECH 2 Display (3)

 AUTOMATIC TRANSMISSION 7A2-75

MODE F1: DATA DISPLAY

{tem Key switch ON Engine running
Engine OFF at idle

Current Gear 1 |

Selector Position P P

Vehicle Speed Sensor 1 (AT side) O km/h 0 km/h

Vehicle Speed Sensor 2 (Meter side) O km/h Okm/h

Engine Speed 0 RPM 700-850 RPM

PC (Line Pressure) Solenoid Desired Current 1.00 A 1.00 A

PC (Line Pressure) Solenoid Actual Current 1.00 A 1.00 A

Engine Runtime * ok ok sec * & sec

TPS (Throttle Position Sensor) Voltage 3.80-4.50V 3.80-4.50V

TPS (Throttle Position Sensor) Angle 0% 0%

ATF Temperature * OC * OC

ATF Temperature Sensor Voltage # KY * KY

Battery Voltage 10-16V 10-16V

Inhibitor Switch P ON 12V ON 12V

Inhibitor Switch R OFF OV OFF OV
Inhibitor Switch N OFF OV OFF OV
Inhibitor Switch D OFF OV OFF OV

Inhibitor Switch 2 OFF OV OFF 0V

Inhibitor Switch 4 OFF 0V OFF 0V

OD OFF Switch OFF 12V OFF 12V

PTO Switch OFF OV OFF OV
Lock Up Duty (Solenoid) 0% 0%

Idle Signal OFF 12V ON OV

Kick Down Switch OFF 12V OFF 12V

BTS Switch (Oil temp. Switch) OFF 12V OFF 12V

EXH. Brake Switch OFF OV OFF OV

Brake Switch OFF OV OFF OV

Diagnosis Switch OPEN OPEN

First Idle Control OFF OV OFF 0V

QWS Switch OFF OV OFF OV

Shift Solenoid $1 ACTIVE 12V ACTIVE 12V
Shift Solenoid $2 INACTIVE OV INACTIVE OV
Shift Timing Solenoid ST INACTIVE 0V INACTIVE OV
PTO Solencid INACTIVE 0V INACTIVE OV
OFF 12V OFF 12V
Engine Overrun Warning
Transmission Check Light OFF 12V OFF 12V

Exhaust Brake Cut ON OV ON OV

Qws Cut OFF 12V OFF 12V

7A2-76 AUTOMATIC TRANSMISSION

SPECIAL TOOLS
TOOL NO.
ILLUSTRATION TOOL NAME

TECH 2 Scan Tool Kit

J-29770-A
Pressure Gauge

J-43407
Adapter
 ON-VEHICLE SERVICE 7A3-1

7A3 ON-VEHICLE SERVICE

CONTENTS

SUBJECT PAGE

DeSCHiption......-scssesesssssssssessenssssassesseneessnraeecenssnenentocseaieacsentencanensnssusssaneusensnmesesasaeneasonsneanenseunecnsacauonesenesonanaany 7A3- 2
Automatic Transmission Fluid (ATP).........:::sscsssessssscessnsesnsenseasenseenssaneeauneneusenenenscessssenasonseseaneeenssszagnaees TAS 2
ATE LeVEI ..ccccccccscccecscserssrscscvsnccnnscesceusnssnnsnrscensansaneusensdsaneectuaoeensanuronsesesussceseatssnenssnessesenueesnensauesnanseanseesoessaas TAZ 2
ATE Change .......ccccsssssessessersssnnseensrsnsesneeseenscusenseusuninnsoersessensasazansee raven suevunansenoessensennacsacsnsuneecouncouseuassecenseneensess 7TA3- 3
Transmission Control Module (TCM)......:csesscsssssncssreseerseonsescsssenenssensuiseeetssavsntstususssoraquanscnsessenseecenasnanens TAZ 3
Throttle Position Sensor and Kick-DOWN SWItCH .........:ccsssssssersssssesssenunssseuseausenesuunnerssanseseseuaeusensennoense TAS 4
Inhibitor Switch.............. den vantensassocnaeccecsauseouesgaceaventanseeauanensesauateonssnauessusenensenseataeneeussseusseusesasnaneseagenenons venseeee TA3- 6
Vehicle Speed SENSOF-2.......scsrcssccccsersenssssnsensensunsuersnsusarseracsoseueceatuatantssnscntunanensenenesatenenteanusacenencuunnansonseenrans TA3- 8
Vehicle Speed SENSOM-1 .........sesscecsseneseeesseeeseeneveansesnanseensensensesnnennanenenrsunnensensenscsaaanaessrasonsseanenes suenacuaesoneea 7TA3- 9
Automatic Transmission Fluid (ATF) Temperature Switch gevavesuausensusesvoeeasavanseaueceauecsussnsessneuessonssnencasaresee TA3-10
Engine Speed Sensol........sssssssecsessssnessesseasermeeanssucusentssceatensarssssasenesrscaseneneronsnonstansentanssousenseneanuenneanentens TA3-11
Overdrive OFF SWItGH .......:cscccseccsssesrsesceseesssoncesersnusaersensonsnpeocsesonsnsasannoasanenaasarenseenoeuansosesanenaacaneresstseseuesenees TAS-11
Oil Pan.........008 seoeaanaeaeuaes sadactnneesenscetscesensuecaranpeasecunsansepedqusanensaeeqauanesessumecsuraeuanausnesaned resensensensecansanedsaneaaansnnasezene 7A3-12
Oil Filler TUbD@.........::sscccssceccssssesscossesessscocsnecsensssesonnesunoessusasneeeasnatsarecesorsensaueaeneenaesiseaennenseeneusnesusatenoacneousnsenues 7TA3-13
Oil Strainer ....cccsccsccsscsecccssecscsscensossnssessesssecnnsnsenssecanseeesensueseeusuasneussrenesnaceaeessansandausenscanennseseeontvoccsnanansesesdsecaneees 7A3-14
SOMOS ......ecccssessceesesecconsecscrncencoenessevesansnrasaseaneanentaeontonsuusesucansonssenensenstaacurnnesssnsoanaraneussassansencossueuspesesensensass TAS-14
Rear Cover Oil Seal ........:cs.cccsssseneessesneesccnnnorscossanseneneaneneaneseneens suengespnecussuaeeadaneauadnanauansesssecacseusssasenzsnessacds TA3-15
Vehicle Speed (Speedometer) Sensor Driven Gea ...........:.ssessnsssesssnenennnerteorsmnansnereceneneunsnsanrasncansensenns TA3-16
Control Lever ASSOMDILy ..........ccccccrscssssssenserssessnsarersensensersnensesencanieonsnscsenenstenesuecsssonanonatasasoesensusonuauumeoeanenss TA-17
Control Cable .....csccsscscceccssssssssssescseccssesscosssnsersesuerssoesssusseusunsenszrscnseesnsnssnuseaestaeeanranssusraneauseussusinvassananateoennesnens 7A3-18
Transmission ASSOMDIy ...........:.:eccsssssseseenesevncarsstseesrssesnsecesseusrensecaunennanenenenenensseguaranensnseasaeanneneszezauenecanen 7A3-20
Torque CONVerterr ......-.sccssceseccseesernenesnnsaronsnee sttscesseacanesonseazenses daeasancentaaseuensossenorsseusesoeseansonsnengeensensenaucesenense 7A3-22
Specifications .......scsssesscscsseersessnensecseennenensseneeneisseesnsiacesesnsessssrausavecserearasaeensunsasnatsseuronsnacanecacersssasoecsansnacey TA3-23
Special Tools .......::cceesee sauausuacausneconsnssonsneatanecauenensossnnsussennasecanseivensseucousteverstenseaoseneaonaneaneseucausnuuvenszeanenancene 7TA3-23
7A3-2 ON-VEHICLE SERVICE

DESCRIPTION

Before performing on-vehicle service on the

automatic transmission, check that the engine idling
speed and generai engine condition are normal.

AUTOMATIC TRANSMISSION FLUID (ATF)

Inspect

Remove the transmission dipstick to check the

condition of the ATF.
Clean the dipstick and look for gum or varnish.
Gum or varnish indicate scorching of the clutch
and other parts.
The transmission control module, the transmission
unit, and the vehicle must be carefully checked if
gum or varnish is present.
Figure 1. Moving Gear Selector
ATF LEVEL
Inspect

CAUTION:
Steady the vehicle level on a flat road. Apply the
parking brake and block the wheel.
* An improper oil level (too high or too low) can
cause trouble.
* Check the idle rpm before starting the level
check.
* Keep the transmission fully warmed (ATF
temperature: 70 - 80°C/ 150 - 176°F) during the
check.

1. Depress the brake pedal and start the engine.

2. With the engine idling, shift the gear slowly in Figure 2. Hot ATF Level
every range from "P" to "L" ranges, and return to
the "P" range (figure 1).
3. With the engine idling, remove the level gauge
and apply compressed air to remove threads or
other foreign items. Insert the level gauge,
remove it again, and confirm that the oil level is
within the "HOT" range (figure 2).

CAUTION:
* When checking the oil level at low ATF
temperatures ( 20 - 30°C/ 68 - 86°F) during oii
change, etc., adjust the oil level so that it is
within the "COLD" range (figure 3). Then,
recheck the oil level in the fully warmed
condition (70 - 80°C/ 150 - 176°F).
* Use the lower level if the oil level varies Figure 3. Cold ATF Level
between the front and back of the level gauge.

4. If the oil level is low, suspect oil leakage.

 ON-VEHICLE SERVICE 7A3-3

AUTOMATIC TRANSMISSION FLUID (ATF) TRANSMISSION CONTROL MODULE

CHANGE (TCM)
1. Start the engine and allow it to idle until the ATF The TCM is located under the meter cluster
reaches a temperature of 40-50°C (104-122°F). (figure 4).
2. Park the vehicle on level ground and block the
wheels. [+9] Remove or Disconnect
3. Stop the engine. 1. Block the wheels.
4. Raise vehicle and support with suitable safety 2, Negative battery cable.
stands. 3. Harness connectors (26 pin, 16 pin and 12 pin
5. Remove the drain plug from the oil pan and
connectors).
drain the ATF (approximately 4 liters). 4, Fixing nuts (1).
. Remove the oil pan. 5. TCM (2).
ono

. Inspect the oil pan (details written below).

. Install the oil pan. [oe] install or Connect

NOTICE: Use new gasket. Clean the oil pan 1. TCM.

and magnet. 2. Fixing nuts .
3. Harness Connectors.
fA] Tighten 4, Negative battery cable.
5. Remove the wheel biocks.
+ Oil pan bolts 7 N-m (61 ib-in)

9. Replace the gasket and install the drain plug.

Tighten
* Drain plug 27 N-m (20 Ib-ft)

NOTICE: Do not reuse old washer (gasket).

Clean the drain plug (especially the threaded
section).

10. Remove the ATF filter element.

11. Install new ATF filter element.
12. Pour about 5 liters of new ATF. Then, add more
ATF carefully as necessary using the levei
gage. Refer to “ATF LEVEL” previously in this
section. Figure 4. TCM

CAUTION: Keep the engine idle (do not stop it)

during the oil level adjustment.

13. Remove the safety stands and wheel blocks.

e inspect

. Check the drain plug tip for adhesion of foreign

substances.
2. Check the drained ATF for color, smell and
inclusion of foreign substances.
3. Check the oil pan bottom and magnet for
adhesion of foreign substances.
If a problem is discovered during those checks,
the Automatic transmission must be overhauled.
7A3-4 ON-VEHICLE SERVICE

THROTTLE POSITION SENSOR AND 4. Depress the accelerator pedal until injection
KICK-DOWN SWITCH pump side full open.
5. Adjust the stopper bolt that has no clearance.
6. Remove the throttle position sensor connectors.
7. Throttle position sensor terminals (5), (6), and
(7).
a. Apply 5 volts to the terminal (5).
b. Measure the output voltage between the
terminal(6) and (7) (Terminal (7) is ground).
c. If the output voltage is 3.8 ~ 4.5 V, under the
above condition, throttle position sensor
setting is “OK”.
d. If the reading is beyond 3.8 — 4.5 V, loosen
the throttle position sensor fixing bolts, and
turn it right or left, so that the specified
output voltage be obtained.
After adjusting, tighten the throttle position
sensor fixing bolts.

IC O

3. Connector

1. Throttle Position Sensor

2. Kick-Down Switch

Figure 5. Throttle Position Sensor, Kick-Down Figure 6. Throttle Position Sensor

Switch and Related Part

Throttle Position Sensor

The throttle position sensor is fitted to ihe

accelerate linkage (figure 5).
The throttle position sensor should be adjusted
under the following condition.
1. When shift shock is harsh.
2. When shift up is fate.
[5] eae’ ®
3. When the following parts replaced.
» Engine assembly or injection pump [¢]
« Accelerator pedal
* Throttle position sensor
oe
» Kick-down switch

Adjust (Figures 6 and 7)

Figure 7. Throttle Position Sensor Connector
Under the idling condition, set the throttle position
sensor according to the following procedure:
1. Block the wheels.
2. Disconnect the battery negative cable.
3. Eliminate play of accelerator pedal cabie.
 ON-VEHICLE SERVICE 7A3-5

Re-learning of the Throttle Position 15. Connect the QWS connector and remove the
Sensor Voltage jumper wire from DLC connector.
The flashing of check trans light will quits.
NOTICE: In case of miss-operation, clear the
It need re-learning of the throttle position sensor
memory and try again from step 6.
voltage when following parts are replaced or
adjusted.
Confirmation of learning
» Engine assembly or injection pump
16. Stop the engine. Turn the starter switch to "ON"
» Accelerator pedal, cable or linkage
position, the check trans light becomes flashing
» Throttle position sensor
again. Depress the accelerator pedal fully
» Kick-down switch
(=kick-down switch is ON) and release the pedal
slowly.
Clearing Memory of current Value of Throttle If the full open position voltage is out of
Position Sensor Voltage specification or the TCM learns no value, the
To clear the memory, perform the following check trans light flash continuously. Clear the
operation at once.
memory and try again from step 6. If the
1. Turn the starter switch to ON position.
flashing is stopped, learning operation is
2. Turn the Overdrive OFF Switch to "ON" position.
completed.
(O/D OFF lamp illuminated.)
3. Place the select lever in the "1" range.
Kick-Down Switch
4. Depress and hold the accelerator pedal fully (=
Kick-down switch is ON).
The kick-down switch is fitted to the accelerator
5. Depress and hold the brake pedal fully (=Brake
switch is ON). linkage (figure 5).
The memory is cleared normally in this procedure,
the CHECK TRANS light flashes.
[A] Adjust (Figure 8)
If the TCM function is normal, the CHECK TRANS 1. Depress the accelerator pedal by hand until
light will flash 5 times. injection pump side opens fully.
if the TCM function is abnormal, the CHECK 2. At the above condition, adjust the projection
TRANS light will flash 5 times slow and then 6-times level of the kick-down switch, so that it may
fast. become “ON”.
3. “Tick, Tick” sound indicates that the kick-down
Preparation switch turns to “ON” condition.
6. Disconnect QWS connector in order to inhibit it's 4. Connect the battery negative cable.
operation. 5. Remove the wheei blocks.
7. Turn the starter switch to ON position.
8. Connect terminal 1 and 3 of the data link
connector (DLC). The check trans light becomes
flashing (0.4 seconds interval).
9. Place the select lever in the "P" range.

Learning voltage at full open position

10. Depress accelerator pedal by hand until
injection pump side opens fully.
11. At the condition in step 10., depress brake pedal
more than 3 seconds.
12. After check trans light changes from intermittent ON
8. Plunger
flashing ~ illuminate (3 seconds)-> slow flashing
6 times> flashing again, then release the brake 9g. Nut
pedal. If check trans light does not change to
Figure 8. Kick-Down Switch
iNuminate (3 seconds), clear memory and try
again from step 7.

Learning voltage at idle position

13. Start the engine.
14. Depress the accelerator pedal slowly 3 times.
(The TCM try to search the point of idle
position.)
7A3-6 ON-VEHICLE SERVICE

INHIBITOR SWITCH

The inhibitor switch is attached to the left side of

the transmission.

Inspect (Figures 9, 10and 11)

1, Block the wheels.

2. Disconnect the negative battery cable.
3. Disconnect the control cable from the lever.
4. Remove the harness connector cover and
disconnect the harness connectors (figure 11).
5. Use a ohmmeter to check the inhibitor switch
continuity between the following terminals
(figure 10).
6. Place the select lever in the “N” range (figure 9).

Figure 10. Inhibitor Switch Connector

Figure 9. Selector Lever

7. Move the select lever to either side.

Check the inhibitor switch continuity between
the terminals shown in Step 5.
The continuity readings should remain fairly
steady as the select lever is moved.
If there is no continuity or the continuity is
intermittent, the inhibitor switch must be
reinstalled correctly.
After reinstallation, if there is still a problem with
the inhibitor switch continuity, the switch must
be replaced.
8. Connect the contro! cable to the lever.
9. Connect the harness connector and install the
cover (figure 11).
Figure 11. Harness Connector Location
 ON-VEHICLE SERVICE 7A3-7

Tighten

« Inhibitor switch nut 7 N-m (61 Ib-in)

5. Loosen the two temporarily tightened bolts and

move the inhibitor switch as necessary to align the
reference line (D) with the groove (E).

Figure 12. Moving Select Lever

[-] Remove or Disconnect (Figure 13) Figure 14. Adjusting Inhibitor Switch
1. Nut retainer.
2. Loosen the nut. 6. Steadying the inhibitor switch with one hand,
3. Remove the inhibitor switch bolts.
tighten the two bolts.
4. Inhibitor switch from the transmission.

| Install or Connect (Figures 13 and 14)

Tighten
« Inhibitor switch bolts 12.5 N-m (109 Ib-in)
1. Place the select fever in the “N” range.
2. Assemble the inhibitor switch to the end of the 7. Bend the nut retainer of the inhibitor switch at two
shaft (A). places.

Figure 13. Inhibitor Switch

3. Temporarily tighten the inhibitor switch bolts (B).

4. Tighten the nut (C).
7A3-8 ON-VEHICLE SERVICE

VEHICLE SPEED SENSOR-2

Vehicle speed sensor-2 is attached on the
speedometer driven gear assembly.

Inspect (Figure 15)

1. Block the wheels.
2. Disconnect the negative battery cable.
3. Disconnect the harness connector from vehicle
speed sensor 2.
. Connect the vehicle speed sensor connector
terminal (1) to the battery (+) terminal and
terminal (2) to the battery (-) terminal.
. Connect a resistance of 1.3 kQ to 1.5 kQ (1.4 W
or more) between terminals (1) and (3).

CAUTION: Be extremely careful not to connect

the battery (+) terminal to the vehicle speed
sensor terminal(3).
This may damage the vehicle speed sensor.

. Rotate the shaft of the vehicle speed sensor O Battery

slowly and measure the voltage at both ends
with a digital voltmeter.

Measure Figure 15. Vehicle Speed Sensor-2

» The voltage, with one rotation of vehicle speed
sensor shaft, fluctuates four times in the fe] Remove or Disconnect
following range: 10 to 14 V ~«-» 2V or less.
1. Remove cover and clip.
. Replace the sensor when the result of 2. Harness connector.
inspection is found abnormal. 3. Vehicle speed sensor with key rod.

[oe] Install or Connect

1. Vehicle speed sensor with key rod.

Tighten
* Vehicle speed sensor 27 N-m (20 lb-ft)

2. Harness connector.
3. Cover and clip.
4. Negative battery cable.
5. Remove wheel blocks.
 ON-VEHICLE SERVICE 7A3-9

VEHICLE SPEED SENSOR-1 Tighten

The vehicle speed sensor-1 is attached on the * Vehicle speed sensor screw 8 N-m (69 Ib-in)
transmission rear cover (figure 17).
; 4. Harness connector.
[78] Inspect (Figure 16) 5. Raise the transmission jack and install mount
bolt.
1 . Block ck the wheels.
the wheels 6. Negative battery cable.
2 . Disconnect
isconnect the the n negative
i battery cable . 7 Remove the wheel blocks.
3. Disconnect the harness connector.
4. Use a onmmeter to measure the resistance
between terminals (1) and (2).

Measure

» Resistance 560 — 680 Q at approx. 20°C (68°F)

€
\

{©
5. if the measured value is outside the specified ES —“
. Cf
range, the vehicle speed sensor-1 must be
replaced. ay

)/' \ Sil
= WyoIL a —
2 Data cm <
i
2 & Figure 17. Vehicle Speed Sensor-1

Figure 16. Vehicle Speed Sensor-1

[| Remove or Disconnect (Figure 17)

1. Support transmission with a transmission jack.

2. Remove the mount bolt (8 pcs) from the
crossmember. Then lower the transmission
assembly slightly.
. Harness connector.
@

. Fixing screw.
nb

. Vehicle speed sensor 2 from transmission rear

cover.

| Install or Connect (Figure 17)

1. Apply grease to the new O-ring then attach to

the vehicle speed sensor.
2. Vehicle speed sensor to the rear cover.
3. Fixing screw.
7A3-10 ON-VEHICLE SERVICE

AUTOMATIC TRANSMISSION FLUID (ATF)

TEMPERATURE SWITCH
The ATF temperature switch fitted to the right side
of the transmission (figure 18).

Figure 19. Testing the ATF Temperature Switch

Figure 18. ATF Temperature Switch Approx. 147°C

(Approx. 297°F)

| Remove or Disconnect (Figure 18) Continuity

1. Harness connector and harness clip.
No continuity
2. ATF temperature switch.

125°C
Inspect (Figure 19 and 20) (257°F)
1. Heat ATF in a container and piace the ATF
temperature switch.
2. Check the electrical continuity between the
switch terminal and the switch body. Figure 20. Continuity of the ATF Temperature
Switch

| Install or Connect (Figure 18)

1. ATF temperature switch.

Tighten
- ATF temperature switch 25 N-m (18 Ib-ft)

2. Harness connector and harness clip.

 ON-VEHICLE SERVICE 7A3-11

ENGINE SPEED SENSOR [| Remove or Disconnect

The engine speed sensor attached to left side of 1. Harness connector.

the flywheel housing (figure 21). 2. Engine speed sensor.

Inspect (Figure 22) bd Install or Connect

1. Block the wheels. 1. Engine speed sensor.

2. Disconnect the negative battery cable.
3. Use a ohmmeter to measure the resistance Tighten
between terminal (1) and (2).
« Engine speed sensor 8 N-m (69 Ib-in)
Measure
2. Harness connector.
* Resistance 670 - 1000 Q 3. Negative battery cable.
4. Remove wheel blocks.
4. Replace the sensor when the result of
inspection is found abnormal. OVERDRIVE OFF SWITCH
Inspect (Figure 23)
= .
Block the wheels.
.
Disconnect the negative battery cable.
WH

.
Remove the select lever cover
.
Disconnect the harness connector
Oomnb

.
Check continuity between terminals (3) and (4).
.
Replace the control lever assembly when the
result of inspection is found abnormal.
Refer to "CONTROL LEVER ASSEMBLY" later
in this section.
7. Gonnect the harness connector.
8. Connect negative battery cable.
9. Remove wheel blocks.

Figure 21. Engine Speed Sensor Location

ri) Ty
i Qo. 32 v }5

6 2 4)
Ny

Terminal] 3 | 4
é [1 OFF
5 io. ON | OO
5
— O-O
Figure 22. Engine Speed Sensor _ Continuity

Figure 23. Overdrive OFF switch

7A3-12 ON-VEHICLE SERVICE

OIL PAN
| Remove or Disconnect

Tool Required:
J-37228 Oil Pan Seai Cutter
. Block the wheels.
. Negative battery cable.
wr

. Raise vehicle and support with suitable safety

stands.
. Drain the Automatic Transmission Fluid (ATF).
Refer to “ATF CHANGE” previously in this
section.
. Remove the oil pan bolts (20 pcs).
Leave several bolts attached (2-3 pitch).
. Insert an oil pan seal cutter from a corner of the Figure 25. Magnet
oil pan and separate the oil pan (figure 24).
. Remove the sealant in the contact surface
between the transmission case and the oil pan.

CAUTION: Work carefully to keep the contact

surface between the transmission case and
the oil pan free of ATF.

. Apply sealant (ThreeBond 1281B or equivalent)

and attach the oil pan to the transmission case.

CAUTION: The sealant must be 2-3 mm (0.03-

0.12 in.) diameter without interruption.
Assembie the oil pan within 10 minutes after
the sealant is applied (figure 26).

Figure 24. Oii Pan Seal Cutter

CAUTION:
Drive the oil pan cutter carefully. Do not
deform the oil pan.
The oil pan cannot be emptied completely. Do
not tilt.

fp install or Connect

1. Clean the oil cleaner magnet and set it to the oil

pan (figure 25).

Figure 26. Sealant

. Oil pan to the transmission case and tighten the

oil pan bolts.

QQ} Tighten
* Oil pan bolts 7 N-m (61 {b-in)
* Drain plug 27 N-m (20 Ib-ft)
 ON-VEHICLE SERVICE 7A3-13

CAUTION: Tighten the boits evenly in several OIL FILLER TUBE

times.
feo] Remove or Disconnect (Figure 27)
5. Refill the transmission with new ATF.
Refer to “ATF CHANGE”. 1. Block the wheels.
6. Negative battery cable. 2. Negative battery cable.
7. Remove safety stands. 3. Remove the oil level gauge.
4, Remove the nut from bracket, then remove the
8. Remove wheel blocks.
oil filler tube with O-ring.

Saat
Pa
‘e
M7
0

Figure 27. Oil Filler Tube

[><] install or Connect (Figure 27)

1. Oil filler tube with O-ring.

Tighten
« Oil filler tube nut 47 N-m (35 Ib-ft}

2. Install level gauge.

3. Negative battery cable.
4. Remove wheel blocks.
7A3-14 ON-VEHICLE SERVICE

OIL STRAINER SOLENOIDS

| Remove or Disconnect (Figure 28) Inspect
1. Block the wheels. 1. Block the wheels.
2. Negative battery cable. 2. Disconnect the negative battery cable.
3. Raise vehicle and support with suitable safety 3. Oil pan.
stands. Refer to “OIL PAN” previously in this section.
4. Oil pan. 4. Disconnect the connectors from the solenoids.
Refer to “OIL PAN” previously in this section. Use the ohmmeter to measure the resistance of
5. Oil strainer bolts (4 pcs), and then oil strainer. each solenoid.

Measure

Resistance (Q)
Solenoid (at approx. 20°C/68°F)

Timing solenoid

No. 1 Shift solenoid

re ne 11-15
No. 2 Shift solenoid

Lock-up solenoid

Line pressure solenoid 3.7—4.1

| Remove or Disconnect (Figure 29)

1. Loosen the bolts and remove the solenoids.

Figure 28. Oil Strainer

Inspect

Check oil pan bottom and oil strainer mesh for

foreign substances (facing of clutches and metal
flakes, etc.}.

| Install or Connect (Figure 28)

1. Oil strainer.

Tighten
+ Oil strainer bolts 10 N-m (87 Ib-in)

2. Oil pan.
Refer to "OIL PAN" previously in this section.
3. Negative battery cable. Figure 29. Solenoids
4. Remove safety stands.
5. Remove wheel blocks. [oe] Install or Connect (Figure 29)

1. Install solenoids and tighten the bolts

[RQ] Tighten
* Solenoid bolts 10 N-m (87 Ib-in)
 ON-VEHICLE SERVICE 7A3-15

REAR COVER OIL SEAL

| Remove or Disconnect (Figure 30)

Tool Required:
J-26941 Rear Oil Seal Remover
J-23907 Sliding Hammer
. Block the wheels.
—

. Negative battery cable.

Wh

. Raise vehicie and support with suitable safety

stands.
. Reference mark the flange yoke to the parking
brake drum.
. Propeller shaft.
NO

. Lock nut.
Make sure to raise the caulking of the lock nut.
Apply the parking brake or move the select lever
to the "P" range to prevent the output shaft from
turning. Figure 31. Rear Cover Oil Seal Installation
. Remove the O-ring using a screwdriver.
oo

. Release the parking brake and remove the CAUTION: Drive the oil seal evenly.
parking brake drum. Take care not to damage or deform the oil seal.
10. Drive coupling from output shaft.
11. Remove parking brake assembly. . Parking brake assembly.
11. Remove the oil seal using oil seal remover.
Tighten

* Parking brake bolts 83 N-m (61 Ib-ft)

. Drive coupling to the output shaft.

CAUTION: Take care not to damage the oil seal

lip .

. Apply the parking brake or move the select lever

to the "P" range to prevent the output shaft from
turning.
. New O-ring and new lock nut.

Tighten
* Driver coupling nut 170 N-m (125 Ib-ft)

CAUTION: Always install a new lock nut. Nevel

reuse the original coupling nut.

« Stake nut by chisel (figure 32).

Figure 30. Rear Cover Oil Seal Removal

[oe] Install or Connect

Tool Required:
J-41736 Rear Oil Seal Installer
1. Apply grease to the new oil seal lip.
2. Drive the oil seal to the rear cover end surface
using oil seal installer (figure 31).
7A3-16 ON-VEHICLE SERVICE

VEHICLE SPEED (SPEEDOMETER)

SENSOR DRIVEN GEAR

¥ | Remove or Disconnect (Figures 33 and 34)

1. Block the wheels.

2. Negative battery cable.
3. Raise vehicle and support with suitable safety
stands.

+
4, Harness clip (1) and protector (2).

Figure 32. Lock Nut

7. Parking brake drum.

8. Line up reference mark and install propeller
shaft to the driver coupling.

Tighten
* Propeller shaft nuts 102 N-m (75 Ib-ft)

9. Negative battery cable.

10. Remove safety stands.
11. Remove wheel blocks.

Figure 33. Vehicle Speed Sensor Connector

5. Wiring connector.
6. Vehicle speed sensor (3) with key rod.
7. Fixing bolt (4) and plate (5).
8. Driven gear assembly (6).
9. Remove clip (7) and disassemble driven gear
assembly.
 ON-VEHICLE SERVICE 7A3-17

foe] Install or Connect (Figures 33 and 34)

CONTROL LEVER ASSEMBLY

1. Driven gear assembly (6). [es] Remove or Disconnect (Figure 35)

2. Install clip (7). 1. Block the wheels.
3. Plate (5) and fixing bolt (4). 2. Negative battery cable.
3. Raise vehicle and support with suitable safety
Tighten
stands.
* Driven gear fixing bolt 12.5 N-m (109 Ib-in) 4, Control fever cover (1).
5. Harness connector (2).
6. Control cable (3) fram contro! lever assembly
7. Bolts (4) and nuts (5)
8. Control lever assembly (6).

Figure 34. Vehicle Speed Sensor and

Driven Gear Assembly

4. Vehicle speed sensor (3) with key rod.

Tighten

* Vehicle speed sensor 27 N-m (20 lb-ft)

5. Wiring connector.
6. Protector (2) and harness clip (1). 1. Control Lever Cover
7. Negative battery cable. 2. Harness Connector
&. Remove safety stands.
3. Control Cable
9. Remove wheel blocks.
4, Bolt
5. Nut
6. Control Lever Assembly

Figure 35. Control Lever Assembly

7A3-18 ON-VEHICLE SERVICE

x Install or Connect (Figure 35) [+] pa or Disconnect (Figures 36, 37 and

1. Control lever assembly (6).

2. Bolts (4) and nut (5).
3. Control cable (3) to the control lever assembly. Disconnect the negative battery cable.
Apply parking brake.

*
Adjust . Remove the retaining pin.

=
. Remove the cable rod and washer.

ON
* When connecting the control cabie to the . Remove the cable from rear bracket.
select lever, adjust the cable. . Remove the control lever cover.

DAP
Refer to "CONTROL CABLE" later in this . Remove the clip.
section. . Remove the snap pin and washer.
. Remove the cable rod.

=~OGOnN
. Harness connector (2). . Remove the grommet assembly.
. Control lever cover (1). . Remove the cable from the bracket.
Oa

. Negative battery cable. . Remove the clip bands.

ak
. Remove safety stands. . Cable assembly.

a
ON

. Remove wheel blocks.

CONTROL CABLE
Check that the each control lever position
matches the corresponding shift indicators ("P", "R",
"N", "D", nou and "ary,

If the control lever positions and shift indicators do

not match, the control cable must be adjusted.

[A] Adjust (Figure 37)

Disconnect the negative battery cable.
*

Apply parking brake.

ONkOoONM-~*

. Remove the retaining pin.

. Remove the cable rod and washer.
. Put the control lever in the "N" position.
. Put the transmission in the "N" range.
. Move the control lever towards the "R"
position until a slight resistance is feit. Figure 36. Control Cable (Transmission Side)
Do not move the lever fully into the "R"
position.
. Loosen the cable lock nuts. | Install or Connect (Figures 36, 37 and 38)
NO

. Adjust the cable rod length by rotating the

1. Install temporarily the control cable.
turn buckle.
8. Tighten the lock nuts. [] Important
9. Install the cable rod and washer to the
control lever. « Never bend the cable to radius less than 450
10. Install the new retaining pin mm (18 in) unless it is necessary to do so for
* Install the negative battery cable. wiring purposes. And never bend the cable to
radius less than 180 mm (7 in) even during
wiring.
« Install the cable carefully without unnecessary
twisting of the cable boots.

2. Cable rod and washer to control lever.

3. New snap pin.
4, Cable to front bracket.
5. Clip.
6. Control lever cover.
 ON-VEHICLE SERVICE 7A3-19

7. Grommet assembly.
8. Put the control lever in the "N" position.
9. Put the transmission in "N" range.
10. Cable to rear bracket.
11. Clip.
12. Cable rod and washer to shift lever.
13. Clip bands.
Adjust the control cable.
Negative battery cabie.

Figure 38. Shift Positions

1. Control Lever Cover 5. Grommet Assembly

2. Retaining Pin 6. Lock Nuts
3. Control Cable 7. Turn Buckle
4, Clip

Figure 37. Control Cable (Cab Side)

7A3-20 ON-VEHICLE SERVICE

TRANSMISSION ASSEMBLY

Remove or Disconnect
(Figures 37, 38, 39, and 40)

1. Block the wheels.

2. Negative battery cabie.
3. Raise vehicle and support with suitable safety \ N ace et

i
stands. Sw 4
4. Tilt the cab.
5. Oil filler tube with bracket.
6. Propeller shaft guard.
7. Center bearing bracket (if equipped).
8. Reference mark (2) the flange yoke (3) to the
parking brake drum (4).

Figure 38. Parking Brake Cable

12. Harness connectors (figure 39).

Remove the harness connector bracket (1) on
the transmission. Then disconnect four
connectors (inhibitor switch, solenoid, vehicle
speed sensor 2 and ATF temperature switch).

Figure 37. Propeller Shaft

9. Propeller shaft (5).

10. Starter assembly. Wire the starter assembly to
frame.
11. Parking brake cable with bracket (figure 38).

Figure 39. Harness Connector

13. Vehicle speed sensor 1.

14. Disconnect transmission fluid cooler lines above
the transmission.
15, Control cable with bracket from transmission.
16. Exhaust pipe bracket.
17. Under cover from converter housing (figure 40).
18. Torque converter bolts (6pcs).
 ON-VEHICLE SERVICE 7A3-21

foe] install or Connect

(Figures 37, 38, 39, and 40)

. Set the transmission assembly on a

transmission jack.
* Hold the front end of the transmission higher
than the rear end of the transmission.
* This will prevent the torque converter from
falling from the transmission.
. Transmission to the flywheel housing.

[QJ Tighten
* Torque converter housing to flywheel housing
fixing bolts 40 N-m (30 lb-ft).

. Operate the hoist to slowly raise the engine and

Figure 40. Under Cover transmission assembly.
. Torque converter to the flywheel.
* By turning the flywheel.
19. Support the transmission with a transmission
jack. Tighten
20. Attach a lifting cable/chain to the engine.
21. Operate the hoist to slightly raise the engine « Torque converter bolts 40 N-m (30 lb-ft)
and support it. NOTICE: Discard used bolts and install new
22. Torque converter housing to flywheel housing ones.
bolts.
23. Operate the hoist to slowly lower the engine. . Under cover (figure 40).
Hold the front end of the transmission higher
than the rear end of the transmission. Tighten
This will prevent the torque converter from
falling from the transmission. « Under cover bolt 9 N-m (78 lIb-in)
24. Lower the transmission jack.
. Exhaust pipe bracket.
. Control cable and bracket to the transmission.
. Adjust control cable.
* Refer to "CONTROL CABLE" previously in this
section.
10. Transmission fluid cooler line.

Tighten

* Cooler line joint connector 34 N-m (25lb-ft)

11. Vehicle speed sensor 1.

12 . Harness connectors and bracket (figure 39).
13. Parking brake cable (figure 38).
Adjust parking brake cable.
14. Siarter assembly.
15. Propeller shaft to the driver coupling.
« Line up reference mark (figure 37).

Tighten
¢ Propeller shaft bolts 102 N-m (765 Ib-ft)
7A3-22 ON-VEHICLE SERVICE

16. Center Bearing Bracket (If equipped).

fA] Tighten

* Center bearing bracket bolts 40 N-m (30 lb-ft)

17. Propeller shaft guard.

18. Oil filler tube with bracket.
19. Negative battery cable.
20. Remove safety stands.
21. Remove wheel blocks.

TORQUE CONVERTER
[>] Remove or Disconnect

1. Remove the transmission assembly from the

vehicle.
2. Remove the torque converter from the torque Figure 41. One-way Clutch Test
converter housing.

Inspect bd Install or Connect

Whenever the transmission is replaced, inspect the 1. Pour new ATF (approximately 2 liters) if a new
torque converter and replace it if any of the torque converter is being installed.
following conditions exists: 2. Install the torque converter to the oil pump.
* Line pressure is normal but a stalling test fails 3. Measure the dimention A from the torque
(idle in "D" or "R" range). converter housing to the torque converter set
* Metallic sound is heard from the torque converter block and confirm that the torque converter is
during a stall test or when in "N" range. inserted to the correct position (figure 42).
- The torque converter center piece is deformed.
* The extension sleeve is rusty, has a large vertical Measure
scratch, or is worn excessively.
« Debris of paper, bearing or foreign materials is * Dimension A: 23.0 mm (0.91 in) or less
found from the ATF in the torque converter.
« Check the one-way clutch of the torque converter
by using the special tools (figure 41).
Tool Required:
J-35467 One-way Clutch Test Tool
1. Set the pilot nut in the test tool to the wrench.
Insert the wrench to stator shaft fitting face of
the torque converter.
2. Insert stator stopper through the sleeve in
converter and set it to cutaway portion of the
sleeve.
3. If both direction of the one-way clutch are free,
or turns counterclockwise and locks clockwise,
torque converter should be replaced.
The normal one-way clutch turns clockwise and
locks counterclockwise.

Figure 42. Torque Converter Installation Position

 ON-VEHICLE SERVICE 7A3-23

SPECIFICATIONS
AUTOMATIC TRANSMISSION

Torque Converter Set Dimention ...............-.. eoeseeanenecaususunsuscacenseoaseessesesteeneatenseerseeeseeteseeesnees 23.0 mm (0.91 in) or less

FASTENER TORQUES

Drain PIUG ........ccceccseeceseeeesseesresseesscecssceneussnsenpsssunessaneessvanessaeesseeesussstansessesnsseseessueteenaeseeensucestacaesasanussaes 7 N-m (61 Ib-ft)

Oil Pan Bolt... cee ceeseeseseneeeeseeenessnevseeseeucsnsesateaeeseasonsautensennesseuseneasaneessedsseasecesecsnsesanerseecseerseauees 27 N-m (20 lb-ft)
Inhibitor Switch Nut ............cceessccescecsensenessecseessseeenesssesuseesnssetseeanes beeeusdseusvanseenseessecseaeeraeseeasenseeeneneaees 7 N-m (61 Ib-ft)
Inhibitor Switch Bolt 0. ee cc eseeeseeesnesenseensnenaevsiessnessearsnedenuseaeesegenseneses sesesecaeseneetasensenesereaes 12.5 N-m (109 lb-ft)
Vehicle Speed Sener 2 oo... ceeccsssssssscccsssesesersecsscnstessenscetesesenseveesaesassnessenseesssneeeesasenenseaessursetseeesees 27 N-m (20 lb-ft)
Vehicle Speed Senser 1 Screw oo... eccsssssseresseteesseenseseesseetvensecuesesseanausaatsentsonssesnsesueessgutsetecsanesseenss 8 N-m (69 Ib-ft)
ATF Temperature Switch oo... cee csesecesserscesaneeeseeseaesaesscsessuacesaestuereasnoauacenscescessnetsedenssneeaasecoussaesaees 25 N-m (28 lb-ft)
Oll Filler Tube@ Nut... cee cescseesesscseetsevsseneseusnenasenessssceneseeenensesnassuesesaccaesonseseseesssateseatseaeatenesseas 47 N-m (365 lb-ft)
Oil Strainer Bolts ............:ccccsccsscseessecseesecnseesecenessuessnsnsesssnecuatensesssensesenastesseusuceasesnesecencenseasneessensersuceas 10 N-m (87 Ib-ft)
SOlENOI DONS ........ecccesccecscaneecceesscesenseeseneanesaunsnsussseassasceameeseesnecsesusnsdensesuagesaeseaneesatensorseateesseeseeeseuns 10 N-m (87 Ib-ft)
Driver Coupling NUt. . . .0. . cc essessesesssensoecseraserseensseenensusastenseaeaenseneesanseueserennenaeseutteeessteneersnerseneneeas 170 N-m (1285 lb-ft)
Speed Meter Driven Gear Fixing Bolt 20... seeessserossssssessetectecetaenesensancessaeceateesseensensusersesceerentes 12.5 N-m (109 Ib-in)
Torque Converter Bolts... ccs secceessecsesecortsseseessenscuananceseasoeseossanaecsensessseasesseasenoeuaseneeaeeesenesacearseesaees 40 N-m (30 Ib-ft)
Under Cover Bolts..........cccccccssenscsscsesrscuecssuttenscsaeessnseneucauessnessaneaueesacescuussnssesdesuatsnscdesesensapesseessusesasseses 9 N-m (78 lb-ft)
Cooler Line Joint COMNM@CtOIS.........cccasessececcecerseessesauevssoennesneesonsusnencssesseaesseuseusseeucsouseseeseunsonsanseesenaees 34 N-m (25 lb-ft)

SPECIAL TOOLS

TOOL NO.
ILLUSTRATION TOOL NAME

J-37228
Oil Pan Seaj Cutter

J-26941
Rear Oil Seal Remover

J-23907
oe Sliding Hammer

J-41736
GG _»?d Rear Oil Seal installer

) J-35467
One-way Clutch
al Test Tool
MEMO
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-1

SECTION 7A4

AUTOMATIC TRANSMISSION OVERHAUL

CONTENTS
SUBJECT PAGE
General Repair Instruction ......0.. 00. s cece cette newer e eee e enema eet e stew eenenonees TA4-2
Component Parts Removal ........ ccc e ence c ence crete eee tere ee eee teneneeneeneeeunenee TA4-3
OM PUMP 20... cee cee cece mee ete eee e eee nent eee Eee ena eee een enone enn ees 7A4-18
Overdrive Planetary Gear and Direct Clutch ......... 0. cece ccna seen ener e rem ee senceereteuae TA4-22
Overdrive Brake 2.0.0... ccc e eee eee meena eee ee eee een eaten ee tate anes 7A4-32
Front Clutch ....... 00: ccs cence eet n eee new eu ree enaoeene cen eneee eevee eee ewe st eeees TA4-38
Rear Clutch ........ cece cece cece semen ements eee ennee beeen teeta n earn eet aeeene TA4-45
Second Brake ........ 0c ccc ene ee meee e ee renee eee eee eee e tees tenner anon neeeae TA4-51
Planetary Gears, One-Way Ciutch and Output Shaft ......... 0... 0 cee cence n etn eneenneoes TA4-58
First and Reverse Brake ..... ben renee teen eee eee eaten eee eee ee eee ere eee e meee TA4-87
Valve Body ..... 00. c cece cece nce e eee e nena etna nee un eue seen ne ceeteenenastenene TA4-73
Extension Housing ........00 ccc ence renee eter see er nso r nate es sn ene neuer tan eeeseenene 7A4-81
Component Parts Installation .....0... ccc cue e een ence erence ane en sues eee ce rest eeteeeees 7A4-85
Specifications ..........cc cece eee cece ee nee eee eee ee snes seen en eee entaeseaeeusaueneee TA4-107
Special Tools ......... 00. ec e eects cence sen eeeeseenes ben eee er en eeenesennueneas TA4-111
7A4-2 AUTOMATIC TRANSMISSION OVERHAUL

GENERAL REPAIR INSTRUCTIONS

. Before assembling, remove sand or mud etc. 18. Non - reusable parts:
adhered to the outside of the transmission to Always replace cotter pin, gaskets, O-rings and
prevent them from coming into the inside when oil seals etc. with new ones.
disassembling or assembling. 19. Precoated parts are bolts and nuts, etc. that are
. Do not face the oil pan upward to avoid foreign coated with a sealant at the factory.
particle coming in until oil pan is removed. a) If a precoated parts is retightened, loosened
. When disassembling the attaching the part or caused to move in any way, it must be
made of light alloy such as a case, co not pry recoated with the specified adhesive.
out with a screwdriver but tap with a plastic. b) When reusing precoated parts, clean off the
. When disassembling or assembling, do it with old adhesive and dry with compressed air.
bare hands or using vinyl grabs. To avoid lint Then apply the specified adhesive to the
coming in, do not use grabs or shop rug. bolt, nut or threads.
. Ensure those disassembled parts are well 20. When necessary, use a sealer on gaskets to
organized and free from dust. prevent leaks.
. Before assembling, wash each disassembled 21. Carefully observe all specifications for bolt
part and all the water has evaporated, apply tightening torques. Always use a torque wrench.
DEXRON®-III.Do not clean the aluminum or 22. Use of special tools and sealants may be
rubber part with alkaline agent. Never clean the required, depending on the nature of the repair.
rubber part of O-ring, gasket and oil seal, and Be sure to use special tools and sealant where
clutch disc and brake disc with white gasoline. specified and follow the proper work procedure.
. Submerge the clutch disc and brake disc into A list of special tools and sealant can be found
DEXRON*®-III before assembling. Especially a at the preparation of automatic transmission
new disc should be submerged in for more than section.
15 minutes to pervade the oil into the lining.
. Apply DEXRON®-III to the sliding and rotating
surfaces and O-ring or oil seal ring, assemble
them being carefully not to damage them.
. Replace the damaged or deformed snap ring
with a new one.
10. When placing a part in a vise,do not place it in a
vise directly but use an aluminum mounting
plate.
11. Take a caution not to damage the contact
surface of case, otherwise it causes fluid
leakage. If damaged, replace the case with a
new one.
12. Before applying sealant, clean off the adhered
sealant on the sealing part, clean the sealing
part with white gasoline.
13. Right after applying sealant, do not pour the
fluid or drive the vehicle. Leave it for more than
2 hours.
14. Pay due attention when assembling those
similar parts such as O-ring, snap ring, bearing
and bearing race and not to lose a part.
15. When assembling oil seal ring, do not spread
the ring ends as thick as more than necessary.
16. When assembling the thrust bearing, race and
thrust washer, to prevent dropping off, a little
amount of petroleum jelly in over haul gasket kit
should be applied. Unless there is petroleum
jelly, a little amount of Vaseline can be used.
17. Use fluid is DEXRON®-III.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-3

COMPONENT PARTS REMOVAL

. Gasket
. Vehicle Speed Sensor 4
1. O-ring 37 32. Bolt
2. Oil Cooler Union = 11. Bolt 19. Control Shaft 33. Oil Seal
3. Clip 12. O-ring Lever 34. Companion Flange
4. Hose 13. Parking Lock 20. Bolt 35. O-ring
5. Clip Gear 21. Gasket 36. Lock Nut
6. ATF Temperature 14. Speedometer 22. PTO Cover 37. Extension Housing
Switch Drive Gear 23, Bolt 38. Bolt
7. O-ring 15. Spacer 24. Bolt 39. Inhibitor Switch
8. Oil Cooler Union 16. Torque Converter 25. Lock Plate 40. Bolt
9. O-ring Housing 26. O-ring 41. Grommet
0. Transmission 17. Nut 27. Speedometer Driven Gear 42. Lock Washer
Solenoid Wire 18. Nut 28. Speedometer Sleeve 43. Nut

Figure 1. Component Parts (1)

7A4-4 AUTOMATIC TRANSMISSION OVERHAUL

. Spring 13. BO Accumulator Piston 25. Oil Strainer

O-ring 14, O-ring 26.
OHONAARWN—

Bolt
. Ci Accumulator 15. O-ring 27. Manual Valve Lever Shaft
O-ring 16. Spring 28. Spacer
Gasket 17. C2 Accumulator Piston 29. parking Lock Rod
Plate 18. B1 Accumulator Piston 30. Oil Pan
. Front Clutch Accumulator Cover 19. O-ring 31 . Drain Plug
Bolt 20. Spring 32. Gasket
. Transmission Case 21. Valve Body Assembly 33. Bolt
. Center Support Apply Gasket 22. Bolt 34. Pin
el
po-oO

. Spring 23. Oil Seal 35. Manual Valve Lever

cel

. O-ring 24. Magnet 36. Oil Seal

ee

Figure 2. Component Parts (2)

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-5

|
|
|
|
|
|
|

1. Bolt 11. Thrust Bearing 21. Thrust Bearing

2. Oil Pump 12, Race 22. Race
3. O-ring 13. O/D Case Assembly 23. Rear Clutch Assembly
4. Gasket 14. O-ring 24. Center Support assembly
5, Race 15. Race 25. Boit
6. Thrust Bearing 16. Thrust Bearing 26. Thrust Washer
7. O/D Planetary Gear, 17. Race 27. Snap Ring
O/D Direct Clutch and 18. Spacer 28. Planetary Gear,
One-way Clutch Assembly 19. Oil Seal ring One-way Clutch and
8. Thrust Bearing 20. Front Clutch Assembly Output Shaft Assembly
9, O/D Ring Gear assembly 29. O-ring
10. Race

Figure 3. Component Parts (3)

 7A4-6 AUTOMATIC TRANSMISSION OVERHAUL

[es] Remove or Disconnect

Transmission Wiring
Disconnect the connectors, and remove the
transmission wiring.

Breather Plug and Hose

1. Using 2 screwdrivers, pry out the breather plug
and hose.

Figure 6. Lock Washer

2. Remove the nut, lock washer and grommet.

3. Remove the 2 bolts and inhibitor switch.

Figure 4. Breather Plug

2. Remove the O-ring from the breather plug.

Control Shaft Lever

Remove the 2 nuts and the lever.

Figure 7. Inhibitor Switch Removal

ATF Temperature Switch

1. Remove the switch.
2. Remove the O-ring from the switch.

Figure 5. Control Shaft Lever

Inhibitor Switch
1. Unstake the lock washer.

Figure 8. ATF Temperature Switch

Oil Cooler Unions

1. Remove the 2 unions.
2. Remove the O-ring from the both the unions.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-7

Speedometer Driven Gear ASSY

1. Remove the lock bolt and plate.
2. Remove speedometer driven gear ASSY.
3. Remove the O-ring from the driven gear ASSY.

Figure 9. Oil Cooler Union

Torque Converter Housing

Remove the 8 bolts and torque converter
housing. Figure 12. Speedometer Driven Gear ASSY

Extension Housing
1. Remove the 10 bolts.

Figure 10. Torque Converter Housing

Vehicle Speed Sensor 1

1. Remove the bolt and the sensor. Figure 13. Extension Housing Bolt
2. Remove the O-ring from sensor. 2. Using a plastic hammer, remove the extension
housing and gasket.

Figure 11. Vehicle Speed Sensor 1

Figure 14. Extension Housing Removal
7A4-8 AUTOMATIC TRANSMISSION OVERHAUL

Speedometer Drive Gear and Spacer 2. Insert the blade of oil pan seal cutter between
Remove the spacer and speedometer drive the transmission and oil pan, cut off applied
gear from the output shaft. sealer.
Tool Required:
J-37228 Oil Pan Seal Cutter
NOTICE:
« Be careful not to damage the oil pan
flange.
* Install several mounting bolts by
tightening 2 to 3 pitches.
* Do not tilt the oil pan as all the oil in the
pan has not been drained.

Figure 15. Speedometer Drive Gear

Parking Lock Gear

Remove the parking lock gear from the output
shaft.

Figure 18. Oil Pan Removal

3. Examine particles in pan.
Remove the magnets and use them to collect
any steel particles.
Carefully look at the foreign matter and particles
in the pan and on the magnets to anticipate the
type of wear you will find in the transmission:
* Steel (magnetic): Bearing, gear, and clutch
* Brass (non-magnetic): Bushing wear

Figure 16. Parking Lock Gear

Oil Pan
NOTICE: Do not turn the transmission over as
this will contaminate the vaive body with any
foreign matter at the bottom of the pan.
1. Remove the 20 bolts.

Figure 19. Particles

Oil Strainer
Remove the 4 bolts and oil strainer.

Figure 17. Oi! Pan Bolt

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-9

Center Support Apply Gaskets

Remove the 4 apply gaskets.
NOTICE: Check the installation direction of
apply gaskets.

Figure 20. Oil Strainer

Solenoid Connectors
1. Disconnect the 4 connectors from the solenoids.
2. Disconnect the connector from the ATF
temperature sensor. Figure 23. Center Support Apply Gasket
3. Disconnect the connector from the line pressure
solenoid. Solenoid Wiring
1. Remove the bolt and the solenoid wiring.
2. Remove the O-ring from it.

Figure 21. Solenoid Connectors

Figure 24. Solenoid Wiring Removal

Valve Body
Remove the 21 bolts.
C: Accumulator Piston and Spring
1. Remove the 4 bolts, front clutch accumulator
cover, 2 gaskets and plate.

\ SERIF

Figure 22. Valve Body Removal

Figure 25. Front Clutch Accumulator Cover

7A4-10 AUTOMATIC TRANSMISSION OVERHAUL

2. Remove the accumulator piston and spring by

applying compressed air 392-785 kPa (4-8
kg/cm’, 57-114 psi) to the oil hole.
NOTICE: Cover the area around the piston with
a shop rag as the piston and oil gush out.

Figure 28. Bo/B1 Accumulator Piston Removal

3. Remove the Bo and B: accumulator pistons.

4. Remove the O-ring from the accumulator
pistons.
Figure 26. C1 Accumulator Piston Removal

C2 Bo B: Accumulator Pistons And Springs

1. Remove the Cz accumulator piston and spring
by applying compressed air 392~—785 kPa (4—8
kg/cm?, 57-114 psi) to the oil hole.
NOTICE: Cover the area around the piston with
a shop rag as the piston and oil gush out.

Figure 29. Accumulator Piston and O-ring

Manual Valve Lever, Shaft and Oil Seals

1. Using a screwdriver or chisel, cut off the spacer
and remove it from the shaft.

Figure 27. C2 Accumulator Piston Removal

2. Remove the Bo accumulator piston together with

the B: accumulator piston by applying
compressed air to the oil hole.

Figure 30. Spacer Removal

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-11

2. Using a pin punch, tap out the pin. Thrust Clearance of Overdrive Input Shaft
NOTICE: Do not drop the pin into the (Overdrive Planetary Gear)
transmission case. 1. Push the O/D input shaft toward the rear of the
transmission by applying a force of 49-98 N
{5-10 kg, 11.0-22.0 Ib).

Figure 31. Spring Pin Removal

3. Pull the manual valve lever shaft out through Figure 34. O/D Input Shaft
the case, remove the manual valve lever,
parking lock rod assembly, the 2 plate washers 2. Using dial indicator, measure the thrust
and wave washer. clearance of the input shaft.
4. Disconnect the parking lock rod from the Standard thrust clearance: 0.40—-0.90 mm
manual vaive lever. (0.0157—0.0354 in.)
Maximum thrust clearance: 0.90 mm
(0.0354 in.)

Figure 32. Manual Valve Lever Shaft Removai

5. Using a screwdriver, pry out the 2 oil seals. Figure 35. Thrust Clearance of Input Shaft

Oil Pump
1. Place matchmarks on the oil pump and
transmission case.
2. Remove the 11 bolts holding the oil pump to the
transmission case.

Figure 33. Oil Seal Removal

7A4-12 AUTOMATIC TRANSMISSION OVERHAUL

Overdrive Planetary Gear, Overdrive Direct Clutch

and One-Way Clutch Assembly
1. Place plate on the installation surface of the oil
pump.
Tool Required:
J-44166 Plate
2. Using calipers, measure the distance between
the tops of plate and the clutch drum for
assembly.
NOTICE: Record the measured distance to
keep it as a reference when assembling.

Figure 36. Matchmarks

3. Using oil pump remover, remove the oil pump

and gasket.
Tool Required:
J-44170 Oil Pump Remover
4. Remove the O-ring from the oil pump.

Figure 39. Measuring Distance

ny
PE

3. Remove the O/D planetary gear, direct clutch

5
‘

and one-way clutch assembly.

i:
.
»

on
A

Figure 37. Oil Pump Remover

5. Remove the race and thrust bearing from the

O/D direct clutch drum or oil pump.
6. Remove the O-ring from the transmission case.

Figure 40. Clutch Assembly Removal

4. Remove the thrust bearing from the O/D

planetary gear.

Figure 38. Race, Thrust Bearing and O-ring

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-13

Thrust Clearance of Input Shaft (Front Clutch

Drum)
1. Temporarily install the 3 bolts.

©
Figure 41. Thrust Bearing

Overdrive Planetary Ring Gear Assembly

1. Remove the ring gear assembly from the O/D Figure 44. Bolt Installation
case. 2. Push the transmission output shaft toward the
front of the transmission by applying a force of
49-98 N (5-10 kg, 11.0-22.0 Ib).
3. Push the O/D case toward the rear of the
transmission by applying a force of 49-98 N
(5-10 kg, 11.0-22.0 Ib).

<x

Figure 42. Ring Gear Removal

2. Remove the thrust bearing and the 2 races from

the O/D case.

Figure 45. Trust Clearance

4. Using the extension bar and dial indicator,

measure the thrust clearance of the input shaft.
Tool Required:
J-44169 Extension Bar
Standard thrust clearance: 0.30—0.70 mm
(0.01 18—-0.0276 in.)
Maximum thrust clearance: 0.70 mm
(0.0276 in.)

Figure 43. Thrust Bearing and Race

7A4-14 AUTOMATIC TRANSMISSION OVERHAUL

3. Remove the 3 O-rings from the oil holes of the

O/D case.

Figure 46. Measuring Clearance

Overdrive Case Assembly Figure 49. O-ring Location

1. Remove 3 bolts.
Front Clutch Assembly
1. Place the plate, on the installation surface of
the oil pump.
Tooi Required:
J-44166 Plate
2. Using calipers, measure the distance between
the tops of the plate and the clutch drum for
assembly.
NOTICE: Record the measured distance to
keep it as a reference when assembling.

Figure 47.Bolt Removal

2. Using the oil pump remover, remove the O/D

case assembly.
Tool Required:
J-44170 Oil Pump Remover

Figure 50. Measuring Distance

3. Remove the front clutch assembly.

Figure 48. O/D Case Assy Removal

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-15

Figure 51. Front Clutch Assembly Removal Figure 54. Thrust Bearing and Race

4. Using a screwdriver, remove the oil seal ring

from the input shaft. Rear Clutch Assembly
install 2 wires into flukes of the clutch discs,
and remove the rear clutch assembly.

Figure 52. Oil Seal Removal

5. Remove the 2 races, thrust bearing and spacer Figure 55. Rear Clutch Assembly Removal
from the front clutch drum.
Center Support Assembly
1. Push the transmission output shaft toward the
front of the transmission by applying a force of
49-98 N (5-10 kg, 11.0-22.0 Ib).
2. Push the center support toward the rear of the
transmission by applying a force of 49-98 N
(5-10 kg, 11.0-22.0 Ib), then pull with the same
amount of force.

Figure 53. Race, Thrust Bearing and Spacer

6. Remove the thrust bearing and race from the

rear clutch drum.

Figure 56. Thrust Clearance

7A4-16 AUTOMATIC TRANSMISSION OVERHAUL

3. Place the plate on the center support. 8. Turn over the center support together with the
Tool Required: thrust washer, and place it on a flat surface.
J-44166 Piate 9. inserting the calipers into the thrust washer
4. Using calipers, measure distance (A) between hole, measure the distance (C) between it and
the tops of the plate and the thrust washer on the flat surface.
the front planetary gear. Center support thrust clearance: A - (B + C)
5. Using calipers, measure the thickness (B) of the Standard thrust clearance: 0.30-0.70 mm
plate. (0.0118-0.0276 in.)
Maximum thrust clearance: 0.90 mm
(0.0354 in.)

Figure 57. Measuring Distance

6. Remove the 3 center support set bolts. Figure 60. Measuring Distance

10. Remove the 3 O-rings from the center support.

Figure 58. Center Support Bolt

7. Using the oil pump remover, remove the center Figure 61. O-ring of Center Support
support assembly.
Tool Required: 11. Remove the thrust washer from the center
J-44170 Oil Pump Remover support.

Figure 59. Center Support Assembly Removal Figure 62. Thrust Washer
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-17

Planetary Gears, One-Way Clutch and Output General Notes

Shaft Assembly The instructions here are organized so that you
1. Remove the thrust washer from the planetary work on only one component group at a time.
gear. This will help avoid confusion from similar-looking
parts of different subassemblies being on your
workbench at the same time.
The component groups are inspected and repaired
from the converter housing side.
As much as possible, complete the inspection,
repair and assembly before proceeding to the next
component group. if a component group can not be
assembled because parts are being ordered, be
sure to keep ail parts of that group in a separate
container while proceeding with disassembly,
inspection, repair and assembly of other component
groups.
Recommended fluid of the automatic transmission
is DEXRON®-IIL.
Figure 63. Thrust Washer
GENERAL CLEANING NOTES:
2. Using a screwdriver, remove the snap ring. 1. All disassembled parts should be washed clean
and any fluid passages and holes blown
through with compressed air.
2. When using compressed air to dry parts, always
aim away from yourself to prevent accidentally
spraying automatic transmission fluid or
kerosene cn your face.
3. The recommended automatic transmission fluid
or kerasene should be used for cleaning.

PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection,
repairs, and reassembly with efficiency.
2. When disassembling a valve body, be sure to
Figure 64. Snap Ring Removal keep each vaive together with the
corresponding spring.
3. Remove the planetary gears, one-way clutch 3. New disc for the brakes and clutches that are to
and output shaft assembly. be used for replacement must be soaked in
transmission fluid for at least 15 minutes before
assembly.

GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates,
rotating parts, and sliding surfaces should be
coated with transmission fluid prior to
reassembly.
2. All gaskets and rubber O-rings should be
replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed
in the groove correctly.
4. lf a worn bushing is to be replaced, the
subassembly containing that bushing must also
Figure 65. Output Shaft Assembly Removal
be replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
 7A4-18 AUTOMATIC TRANSMISSION OVERHAUL

Oil. PUMP

1. Oil Seal 5. Oil Pump Cover 9. Spring

2. Oil Pump Body 6. Bolt 10. Spring Seat
3. Oil Pump Driven Gear 7. Oil Seal Ring
4. Oil Pump Drive Gear 8. Check Ball

Figure 66. Oil Pump Assembly

[S] Disassemble CAUTION:

« Do not damage the oil seal rings and do
1. Use torque converter as work stand. not deform them unless necessary.
Make sure the drive gear rotates smoothly when * Do not damage the claws on the oil seal
installed to the torque converter. rings.

Figure 67. Drive Gear Rotation Check Figure 68. Oi! Seal Removal
2. Remove the 2 oil seal rings. 3. Using a screwdriver, compress the spring and
remove the spring seat.
Remove the spring and check ball.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-19

inspect

1. Inspect bushing of oil pump body.

Using a dial indicator, measure the inside
diameter.
Standard inside diameter: 42.050-—42.075 mm
(1.6555-~1.6565 in.)
Maximum inside diameter: 42.13 mm
(1.6587 in.)
NOTICE: Measure at several points and take
the average value.
lf the inside diameter is greater than maximum,
replace the oil pump assembly.

Figure 69. Check Ball Removal

4. Remove 7 bolts and pump cover.

Figure 72. Bushing Inside Diameter Measurement

2. inspect bushings of oil pump cover.

Using a dial indicator, measure the inside
Figure 70. Pump Cover Removal diameter.
Front bushing standard inside diameter:
5. Using a screwdriver, pry off the oil seal.
24.000—24.021 mm (0.9449--0.9457 in.)
Rear bushing standard inside diameter:
26.500~—26.521 mm (1.0433~1.0441 in.)
Front bushing maximum inside diameter:
24.07 mm (0.9476 in.)
Rear bushing maximum inside diameter:
26.57 mm (1.0461 in.)
NOTICE: Measure at several points and take
the average value.
lf the inside diameter is greater than the
maximum, replace the oil pump assembly.

Figure 71. Oil Seal Removal

Figure 73. Bushing Inside Diameter Measurement

7A4-20 AUTOMATIC TRANSMISSION OVERHAUL

Assemble

1. Install oil seal.

Coat the new oil seal with DEXRON®-I.
Using installer, tap in a new oil seal.
Tool Required:
J-44163 Oi! Seal Installer
The oil seal end should be flushed with the
outer edge of the pump body.
Apply grease to the oil seal lip.

Figure 76. Check Ball Installation

. Coat the 2 oil seal rings with ATF.

Contract the oil seal rings, and install them onto
the stator shaft.
CAUTION:
* Do not spread the ring ends too much.
* Do not damage the claws on the oil seal
rings.
NOTICE:
If the rings are damaged or deformed,
Figure 74. Oil Seai Instaliation replace them with new ones.
« After installing the oil seal rings, check
2. Install oil pump cover to oil pump body.
that they rotate smoothly.
Align the bolt holes of the oii pump body and
cover.
Install the pump cover with the 7 bolts.

Tighten

Torque: 21 N-m (2.1 kg-m, 15lb-ft)

Figure 77. Oil Seal Instaliation

6. Check oil pump drive rotation.

Make sure the drive gear rotates smoothly when
installed to the torque converter.

Figure 75. Oil Pump Cover Instaliation

3. Install the check ball and spring.

Using a screwdriver, compress the spring and
install the spring seat.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-21

Figure 78. Drive Gear Rotation Check

 7A4-22 AUTOMATIC TRANSMISSION OVERHAUL

OVERDRIVE PLANETARY GEAR AND DIRECT CLUTCH

1. O/D Direct Clutch Drum 11. Thrust washer 21. Oil Seal Ring
2. O-ring 12. One-way Clutch Outer Race
3. O/D Direct Clutch Piston 13. Retainer
4. Piston Return Spring 14, One-way Clutch
5. Snap Ring 15. Thrust Washer
6. Plate 16. O/D Planetary Gear
7. Disc 17. Thrust Washer
8. Flange 18. Planetary Ring Gear
9. Snap Ring 19. Ring Gear Flange
10. Snap Ring 20. Snap Ring

Figure 79. O/D Planetary Gear and Direct Clutch Assembly

[S] Disassembie

1. Check operation of one-way clutch.

Hold the O/D direct clutch drum and turn the
input shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.

Figure 80. One-way Clutch Operation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-23

2. Remove overdrive direct clutch assembly from

overdrive planetary gear.

Figure 83. Piston Stroke Check (2)

4. Remove flange, plates and discs

Figure 81. O/D Direct Clutch Removal Using a screwdriver, remove the snap ring.
. Check piston stroke of overdrive direct clutch.
Place the oi! pump onto the torque converter,
and then piace the O/D direct clutch assembly
onto the oil pump.
jj

oT
Figure 84. Snap Ring Removal

Remove the flange, 3 discs and 3 plates.

Figure 82. Piston Stroke Check (1)

Using No.1 measure terminal and a dial

indicator, measure the piston stroke by applying
and releasing compressed air 392-785 kPa
(4-8 kg/cm’, 57~114 psi).
Tool Required:
J-44167 No.1 measure terminal
NOTICE:
+ Stand the measure terminal on the piston
vertically.
- Ensure that the measure terminal does not
touches other parts than the piston.
Figure 85. Disc and Plate Removal
» Measure the stroke at more than 3 points.
Piston stroke: 1.80-2.07 mm . Remove piston return spring.
(G.0709--0.08165 in.) Place No.2 piston spring compressor on the
lf the piston stroke is not as specified, inspect
spring seat, and compress the return spring with
the discs and the plates.
a shop press.
Tool Required:
J-44160 No.2 Piston Spring
Compressor
7A4-24 AUTOMATIC TRANSMISSION OVERHAUL

NOTICE: Stop compressing the return spring

at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
deformed.
Using snap ring pliers, remove the snap ring.

Figure 88. O/D Direct Clutch Piston Removal

8. Remove oil seal ring from ring gear flange.

Figure 86. Piston Return Spring Removal (1)

6. Remove the piston return spring.

Figure 89. Oil Seal Ring Removal

9. Remove ring gear flange.

Using a smail screwdriver, remove the snap
ring.
Figure 87. Piston Return Spring Removal (2)

7. Remove overdrive direct clutch piston.

Place the oil pump onto the torque converter,
and then place the O/D direct clutch onto the oil
pump.
Hold the clutch piston with hand, apply
compressed air into the oil hole of the oil pump
to remove the clutch piston.
Remove the 2 O-rings from the clutch piston.

Figure 90. Snap Ring Removal

10. Remove the ring gear flange.

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-25

Figure 91. Ring Gear Flange Removal Figure 94. One-way Clutch and Outer Race Removal

11. Remove one-way cluich from overdrive 14. Remove the thrust washer.
planetary gear. NOTIGE: Check the installation direction of the
Using small screwdriver, remove the snap ring. thrust washer.

Figure 92. Snap Ring Removal Figure 95. Thrust Washer Removal

12. Remove the thrust washer. 15. Remove the one-way clutch from the outer race.
NOTICE: Do not remove the upper and lower
plates of the one-way clutch.

Figure 93. Thrust Washer Removal

13. Remove the one-way clutch together with the Figure 96. One-way Clutch Removal
outer race.
NOTICE: Check the installation direction of the
one-way clutch.
7A4-26 AUTOMATIC TRANSMISSION OVERHAUL

NOTICE: Measure at several points and take

Inspect
the average value.
1. Inspect discs, plates and flange. If the inside diameter is greater than maximum,
Check to see if the sliding surface of the disc, replace the clutch drum.
plate and flange are worn or burnt. If necessary, inspect the bushing contacting surface of the
replace them. planetary gear input shaft, when discoloration or
NOTICE: damage on the surface is found, replace the
« If the lining of the disc is peeling off or planetary gear.
discolored, or even if a part of the printed
numbers are defaced, replace all discs.
* Before assembling new discs, soak them
in ATF for at least 15 minutes.

Figure 99. O/D Direct Ciutch Drum Inspection

4. Inspect bushings of overdrive planetary gear.

Using a dial indicator, measure the inside
diameter.
Figure 97. Disc Inspection
Standard inside diameter: 12.000-12.018 mm
2. Inspect overdrive direct clutch piston. (0.4724-0.4731 in.)
Check that check ball is free by shaking the Maximum inside diameter: 12.070 mm
piston. (0.4752 in.)
Check that the valve does not leak by applying NOTICE: Measure at several points and take
low pressure compressed air. the average value.
If the inside diameter is greater than maximum,
replace the planetary gear.
inspect the bushing contacting surface of the
front clutch drum input shaft, when discoloration
or damage on the surface is found, replace the
front clutch drum.

Figure 98. Valve Leakage Check

3. Inspect bushings of overdrive direct clutch

drum.
Using a dial indicator, measure the inside
diameter.
Standard inside diameter: 26.500—26.521 mm Figure 100. O/D Planetary Gear inspection
(1.0433-—1.0441 in.)
Maximum inside diameter: 26.57 mm
(1.0461 in.)
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-27

. Inspect planetary pinion gear thrust clearance.

[a] Assemble
Using a feeler gauge, measure the clearance
between the pinions and carrier. 1. Install one-way clutch to overdrive planetary
Standard clearance: 0.20-0.59 mm gear.
(0.0079-0.0232 in.) a) install the one-way clutch into the outer
Maximum clearance: 0.80 mm (0.0315 in.) race.
if the thrust clearance is greater than maximum,
replace the planetary gear.

Figure 102. One-way Clutch Installation

Figure 101. Thrust Clearance Check b) Install the thrust washer, facing the grooved
side upward.
NOTICE: Insert the pin of thrust washer into
holes in the O/D planetary gear.

Figure 103. Thrust Washer Installation

c) Install the one-way clutch and outer race

assembly, facing the flanged side of the
one-way clutch upward.
7A4-28 AUTOMATIC TRANSMISSION OVERHAUL

Figure 104. One-way Clutch Direction Figure 107. Ring Gear Flange Installation

d) Install the thrust washer. b) Using a screwdriver, install the snap ring.

Figure 105. Thrust Washer Installation Figure 108. Snap Ring Installation

e) Using a screwdriver, install the snap ring. 3. Install oil seal ring.
Coat the oil seal ring with ATF, and install it to
the ring gear flange, then sank it down by
squeezing their ends together.
CAUTION: Do not spread the ring ends more
than necessary.
NOTICE: After installing the oil seal ring, check
that it moves smoothly.

©)

Figure 106. Snap Ring Installation

2. Install ring gear flange to overdrive planetary

ring gear.
a) Install the ring gear flange as shown.

Figure 109. Oil Seal Ring Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-29

4. Install overdrive direct clutch piston.

a) Coat new O-rings with ATF, and install them
on the clutch piston.
O-ring diameters mm (in.)
Inside Wire diameter
Inner side 64.1 (2.524) 2.6 (0.102)
Outer side 117.4 (4.6227) | 3.1 (0.122)

Figure 112. Return Spring Installation (1)

b) Place No.2 piston spring compressor on the

spring seat, and compress the return spring
with a shop press.
Tool Required:
J-44160 No.2 Piston Spring
Compressor
NOTICE: Stop compressing the return spring
Figure 110. O-ring Location at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
b) Push in the clutch piston into the clutch
drum with both hands. deformed.
CAUTION: Be careful not to damage the O- c) Using snap ring pliers, install the snap ring.
NOTICE: Be sure the end gap of the snap ring
rings.
is not aligned with the spring retainer claw.
NOTICE: Push in the piston uniformly.

Figure 113. Return Spring Installation (2)

Figure 111. Clutch Piston Installation
6. Install pilates, discs and flange.
5. Install piston return spring.
a) Install the 3 plates and 3 discs in order:
a) Place the piston return spring on the clutch
P = Plate D = Disc
piston.
P-~-D-P-~D-P-D
7A4-30 AUTOMATIC TRANSMISSION OVERHAUL

Figure 114. Plate and Disc Installation Figure 117. Piston Stroke Check (1)

b) Install the flange, facing the rounded edge b) Using No.1 measure terminal and a dial
upward. indicator, measure the piston stroke by
appiying and releasing compressed air
392-785 kPa (4-8 kg/cm’, 57-114 psi).
Too! Required:
J-44167 No.i Measure Terminal
NOTICE:
¢ Stand the measure terminal on the piston
vertically.
¢ Ensure that the measure terminal does not
touches other parts than the piston.
* Measure the stroke at more than 3 points.
Piston stroke: 1.80-2.07 mm
(0.0709-0.0815 in.)
if the piston stroke is less than specified, parts
may have been assembled incorrectly, check
Figure 115. Flange Direction and reassemble again.
If the piston stroke is not as specified, select
c) Using a screwdriver, install the snap ring. another flange.
NOTICE: Be sure the end gap of the snap ring NOTICE: There are 4 different thicknesses for
is not aligned with the cutout portion of the flange.
clutch drum. Fiange thicknesses mm (in.)
No. Thickness No. Thickness
A 4.6 (0.181) Cc 4.94 (0.194)
jj B 4.77 (0.188) D 5.11 (0.201)

I
Figure 116. Snap Ring Installation

7. Check piston stroke of overdrive direct clutch.

a) Place the oil pump onto the torque
converter, and then place the O/D direct Figure 118. Piston Stroke Check (2)
clutch assmebly onto the oil pump.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-31

. Install overdrive direct clutch assembly.

Install the direct clutch assembly onto the O/D
planetary gear.
NOTICE: Mesh the spline of the O/D pianetary
gear with the flukes of the discs by rotating
and pushing the O/D direct clutch
counterclockwise.

Figure 119. O/D Clutch Installation

. Check operation of one-way clutch

Hold the O/D direct clutch drum and turn the
input shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.

Figure 120. One-way Clutch Operation

7A4-32 AUTOMATIC TRANSMISSION OVERHAUL

OVERDRIVE BRAKE

1. Snap Ring 7. O/D Brake Piston

2. Flange 8. O-ring
3. Disc 9. O/D Case
4. Plate 10. Ring Retainer
5. Snap Ring 11, Oil Seal Ring
6. Piston Return Spring

Figure 121. O/D Brake Assembly

| Disassemble
1. Check piston stroke of overdrive brake.
a) Place the O/D case assembly onto the front
clutch assembly.

Figure 122. Piston Stroke Check (1)

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-33

b) Using No.2 measure terminal and a diai b) Using screwdriver, remove the snap ring.
indicator, measure the piston stroke by
applying and releasing compressed air
392-785 kPa (4-8 kg/cm’, 57-114 psi).
Tool Required:
J-44168 No.2 Measure Terminal
Piston stroke: 1.25-1.85 mm
(0.0492-0.0728 in.)
NOTICE:
* Stand the measure terminal on the piston
vertically.
« Ensure that the measure terminal does not
touches other parts than the piston.
* Measure the stroke at more than 3 points.
if the piston stroke is not as specified, inspect
the discs and plates. Figure 125. Return Spring Removal (1)

c) Remove the return spring.

Figure 123. Piston Stroke Check (2)

2. Remove fiange, discs and plates. Figure 126. Return Spring Removal (2)
a) Using a screwdriver, remove the snap ring.
b) Remove the flange, 3 discs and 3 plates. . Remove overdrive brake piston
Place the No.3 piston spring compressor on the
brake piston.
Hold piston spring compressor so it does not
slant, and apply compressed air 392~785 kPa

i:
(4-8 kg/cm’, 57-114 psi) into the oil hole of the
Q/D case to remove the brake piston.
iyVf Esa,
(TH Sy) Remove the 2 O-rings from the brake piston.

Youle)
VT — 4
NOTICE: Be careful not to slant the brake
piston while appiying compressed air. If the
brake piston siants, it is difficult to remove.
UP

Figure 124. Snap Ring Removal

3. Remove piston return spring.

a) Place No.3 piston spring compressor on the
spring seat, and compress the return spring
with a shop press.
Tool Required:
J-44161 No.3 Piston Spring
Compressor
7A4-34 AUTOMATIC TRANSMISSION OVERHAUL

Inspect

1. Inspect discs, plates and flange.

Check to see if the sliding surface of the disc,
plate and flange are worn or burnt. If necessary,
replace them.
NOTICE:
+ If the lining of the disc is peeling off or
discolored, or even if a part of the printed
numbers are defaced, replace all discs.
« Before assembling new discs, soak them
in ATF for at least 15 minutes.

Figure 127. Brake Piston Removal

5. Remove the 2 oil seal rings from the O/D case.

Figure 130. Disc Inspection

. Inspect bushing of overdrive case.

Using a dial indicator, measure the inside
diameter.
Figure 128. Oil Seal Ring Removal Standard inside diameter: 33.10-33.15 mm
6. Remove ring retainers. (1.3031-1.3051 in.)
Maximum inside diameter: 33.20 mm
Using needle nose pliers, remove the 3 ring
retainers from the oil holes of O/D case. (1.3071 in.)
NOTICE: Measure at several points and take
the average value.
lf the inside diameter is greater than maximum,
replace the O/D case.
Inspect the bushing contacting surface of the
front clutch drum input shaft and the planetary
ring gear flange, when discoloration or damage
on the surface is found, replace the front clutch
drum and pianetary ring gear flange.

Figure 129. Ring Retainer Removal

Figure 131. O/D Case Inspection

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-35

Assemble

1. Install ring retainers.

Coat the new 3 ring retainers with ATF.
Using needle nose pliers, install the 3 ring
retainers into the oil holes of the O/D case.

Figure 134. O-ring Location

b) Align the protrusions of the brake piston with

the grooves of the O/D case.
c) Push in the brake piston into the O/D case
with both hands.
CAUTION: Be careful not to damage the O-
Figure 132. Ring Retainer Installation rings.
NOTICE: Push in the piston uniformly.
2. Install oil seal rings.
Coat the new 2 oil seal rings with ATF.
Contract the oil seals, and install them onto the
O/D case.
CAUTION:
+ Do not damage the claws on the oil seal
rings.
* Do not spread the ring ends more than
necessary.
NOTICE: After installing the oil seal rings,
check that they rotate smoothly.

Figure 135. Brake Piston installation

4. Install piston return spring.

a) Place the return spring on the brake piston.

Figure 133. Oil Seal Ring Installation

3. Install overdrive brake piston.

a) Coat new 2 O-rings with ATF, and install
them on the brake piston.
O-ring diameters mm (in.}
Inside Wire diameter
Inner side 145.3 (6.7) 3.1 (0.1) Figure 136. Return Spring Installation (1)
Outer side 163.7 (6.4) 3.1 (0.1)
7A4-36 AUTOMATIC TRANSMISSION OVERHAUL

b) Place No.3 piston spring compressor on the

spring on the spring seat, and compress the
return spring with a shop press.
Tool Required:
J-44161 No.3 Piston Spring
Compressor
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
deformed.
c) Using a screwdriver, install the snap ring.
NOTICE: Be sure the end gap of the snap ring
is not aligned with the cutout portion of the
O/D case.
Figure 139. Flange Direction

c) Using a screwdriver, install the snap ring.

NOTICE: Be sure the end gap of the snap ring
is not aligned with the cutout portion of the
O/D case.

Figure 137. Return Spring Installation (2)

5. Install plates, discs and flange.

a) Install the 3 plates and 3 discs in order:
P = Plate D = Disc
P—-D-~P—~D-P-—D
Figure 140. Snap Ring Installation

6. Check piston stroke of overdrive brake.

a) Place the O/D case assembly onto the front
clutch assembly.

Figure 138. Plate, Disc and Flange Installation

b) install the flange, facing the rounded edge

upward.

Figure 141. Piston Stroke Check (1)

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-37

b) Using No.2 measure terminal and a dial

indicator, measure the piston stroke by
applying and releasing compressed air
392-785 kPa (4-8 kg/cm’, 57-114 psi).
Tool Required:
J-44168 No.2 Measure Terminal
Piston stroke: 1.25-1.85 mm
(0.0492-0.0728 in.)
NOTICE:
* Stand the measure terminal on the piston
vertically.
« Ensure that the measure terminal does not
touches other parts than the piston.
» Measure the stroke at more than 3 points.
{f the piston stroke is less than specified, parts
may have been assembled incorrectly, check
and reassemble again.

Figure 142. Piston Stroke Check (2)

 7A4-38 AUTOMATIC TRANSMISSION OVERHAUL

FRONT CLUTCH

1. Front Clutch Drum 8. Disc

2. O-ring 9. Race
3. Front Clutch Piston 10. Thrust Bearing
4. Piston return Spring 11. Front Clutch Hub
5. Snap Ring 12. Rear Clutch Hub
6. Cushion Plate 13. Snap Ring
7. Plate

Figure 143. Front Clutch Assembly

[S] Disassemble

1. Remove rear and front clutch hubs.

a) Place the front clutch assembly onto the
O/D case assembly.
b) Using a screwdriver, remove the snap ring.
c) Remove the rear clutch hub.

Figure 144. Snap Ring Removal

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-39

d) Remove the front clutch hub.

Figure 147. Piston Stroke Check (1)

Figure 145. Front Clutch Hub Removal d) Using No.1 measure terminal and a dial
indicator,
, measure the piston stroke by
e) Remove the race and thrust bearing.
applying and releasing compressed air
392-785 kPa (4-8 kgf/cm’, 57—114 psi).
Piston stroke: 3.93—4.23 mm
(0.1547—0.1665 in.)
NOTICE: Measure the stroke at more than 3
points. If the piston stroke is greater than
specified, inspect the discs.

Figure 146, Race and Thrust Bearing Removal

2. Check piston stroke of front clutch.

a) Install No.1 measure terminal to a dial
indicator.
Tool Required:
J-44167 No.1 Measure Terminal
b) Place the assembled measure terminal and Figure 148. Piston Stroke Check (2)
a dial indicator on the clutch piston. ; ;
NOTICE: 3 Remove discs, plates and cushion plate.
+ Stand the measure terminal on the piston a) Remove the snap ring and rear clutch hub.
vertically.
- Ensure that the measure terminal does not
touches other parts than the piston.
c) Install the rear clutch hub with the snap ring.
NOTICE: Do not install the front clutch hub.

Figure 149. Rear Clutch Hub Removal

7A4-40 AUTOMATIC TRANSMISSION OVERHAUL

b) Remove the 7 discs, 7 plates and cushion

plate.

Figure 152. Front Clutch Piston Removal

Figure 150. Disc and Plate Removal

4. Remove piston return springs.

a) Place No.2 piston spring compressor on the
spring seat, and compress the return
springs with a shop press.
Tool Required:
J-44160 No.2 Piston Spring Compressor
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
deformed.
b) Using snap ring pliers, remove the snap
ring.
NOTICE: Do not damage the snap ring and do
not deform them unless necessary.

Figure 151. Piston Return Spring Removal

c) Remove the piston return spring.

5. Remove front clutch piston.
a) Hoiding the clutch piston by hand, apply
compressed air 392-785 kPa (4~—8 kgi/cm?,
57-114 psi) into the oil hole of the O/D case
to remove the clutch piston.
b) Remove the 2 O-rings from the clutch
piston.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-41

Inspect fa] Assemble

1. Inspect discs, plates and cushion plate. 1. Install front clutch piston.
Check to see if the contacting surface of the a. Place front clutch drum onto overdrive case
disc, plate and cushion plate are worn or burnt. assembly.
If necessary, replace them.
NOTICE:
: If the lining of the disc is peeling off or
discolored, or even if a parts of the printed
numbers are defaced, replace all discs.
- Before assembling new discs, soak them
in ATF for at least 15 minutes.

Figure 155. Front Clutch Piston Installation

b) Coat new 2 O-rings with ATF, and install

them on the clutch piston.
O-ring diameters mm (in.)
Inside Wire diameter
Inner side 62.9 (2.476) 2.6 (0.102)
Figure 153. Disc Inspection Outer side 117.4 (4.622) 3.1 (0.122)

2. Inspect front clutch piston.

a) Check that the check ball is free by shaking
the piston. tae " ae
LJ &
b) Check that the valve does not leak by \
applying compressed air 392-785 kPa (4-8
kgf/cm’, 57-114 psi). ie Gee a
a SSeS pr
ASX Uy)
SSB / _

Figure 156. O-ring Location

c) Push in the clutch piston into the clutch

drum by both hands.
CAUTION: Be careful not to damage the O-
rings.
Figure 154. Front Clutch Piston Inspection
7A4-42 AUTOMATIC TRANSMISSION OVERHAUL

Figure 157. Clutch Piston Installation Figure 159. Piston Return Spring Installation (2)
2. Install piston return springs. 3. Install cushion plate, plates and discs.
a) Install the piston return spring on the clutch a) Install the cushion plate, facing the rounded
piston. edge downward.

Figure 158. Piston Return Spring Installation (1) Figure 160. Cushion Plate Installation
b) Place No.2 piston spring compressor on the b) Install the 7 plates and 7 discs in order:
spring seat, and compress the return P = Plate D = Disc
springs with a shop press. P—~D-P-~D-~P-D-P~D—-P-—-D-—P-
Tool Required: D-®-D
J-44160 No.2 Piston Spring NOTICE: ©®) = This plate is used to adjust
Compressor piston stroke.
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
deformed.
c) Using snap ring pliers, install the snap ring.
NOTICE: Be sure the end gap of the ring is not
aligned with the spring seat claw.
\(

‘.

Figure 161. Plate and Disc Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-43

4. Check piston stroke of front clutch.

a) Install No.1 measure terminal to a dial
indicator.
Tool Required:
J-44167 No.1 Measure Terminal
b) Place the assembled measure terminal and
a dial indicator on the clutch piston.
NOTICE:
« Stand the measure terminal on the piston
vertically.
- Ensure that the measure terminal does not
touches other parts than the piston.
c) Install the rear clutch hub with the snap ring.
NOTICE: Do not install the front clutch hub.
Figure 163. Piston Stroke Check (2)

5. Install front and rear clutch hubs.

a) Coat the race and thrust bearing with
petroleum jelly, and install them onto the
front clutch drum.
Race and bearing diameter
Diameter mm (in.} Inside Outside
Bearing 32.8 (1.291) 52.0 (2.047)
Race 37.0 (1.457) 52.0 (2.047)

Figure 162. Piston Stroke Check (1)

d) Using No.1 measure terminal and a dial

indicator, measure the piston stroke by
applying and releasing compressed air
392—785 kPa (4—8 kgf/cm’, 57-114 psi).
Piston stroke: 3.93-4.23 mm
(0.1547-0.1665 in.)
NOTICE: Measure the stroke at more than 3
points.
If the piston stroke is less than specified, parts
may have been assembled incorrectly, check Figure 164. Bearing Installation
and reassemble again.
b) Install the front clutch hub into the clutch
if the piston stroke is not as specified, select
drum.
another plate. NOTICE: Mesh the spline of the front clutch
Plate thicknesses
hub with the flukes of the discs by rotating the
Thickness mm (in.) Thickness mm (in.) front clutch hub clockwise or
1.8 (0.071) 2.2 (0.087) counterclockwise.
2.0 (0.079) 2.4 (0.094)
e) Remove the snap ring and rear clutch hub.
7A4-44 AUTOMATIC TRANSMISSION OVERHAUL

Figure 165. Front Clutch Hub Installation

c) install the rear clutch hub onto the clutch

drum.
d) Using a screwdriver, install the snap ring.
NOTICE: Be sure the end gap of the snap ring
is not aligned with the cutout portion of the
front clutch drum.
e) Remove the front clutch assembly from the
O/D case.

Figure 166. Rear Clutch Hub Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-45

REAR CLUTCH

1. Snap Ring 6. Piston Return Spring

2. Flange 7. Rear Clutch Piston
3. Disc 8. O-ring
4, Plate 9. Rear Clutch Drum
5. Snap Ring

Figure 167. Rear Clutch Assembly

rN
<>} Disassemble
1. Check piston stroke of rear clutch.
a) Place the center support assembly on
wooden blocks.
NOTICE: Provide clearance so that the sun
gear does not touch the rear clutch drum.
b) Place the rear clutch assembly into the
center support assembly.

Figure 168. Piston Stroke Check (1)

7A4-46 AUTOMATIC TRANSMISSION OVERHAUL

Using No.1 measure terminal and a dial

indicator, measure the piston stroke by applying
and releasing the compressed air 392-785 kPa
(4-8 kgf/cm’, 57-114 psi).
Tool Required:
J-44167 No.1 Measure Terminal
Piston stroke: 2.00-2.20 mm
(0.0787—0.0866 in.)
NOTICE:
* Stand the measure terminal on the piston
vertically.
« Ensure that the measure terminal does not
touches other parts than the piston.
* Measure the stroke at more than 3 points. " j
If the piston stroke is greater than specified, Figure 171. Flange, Disc and Plate Removal
inspect the discs. . .
P © 3. Remove piston return spring.
a) Place No.2 piston spring compressor on the
spring seat, and compress the return spring
with a shop press.
Tool Required:
J-44160 No.2 Piston Spring
Compressor
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
deformed.
b} Using snap ring pliers, remove the snap
ring.
NOTICE: Do not damage the snap ring and do
not defrom them unless necessary.
Figure 169. Piston Stroke Check (2)

2. Remove flange, discs and plates.

a) Using a screwdriver, remove the snap ring.

Figure 172. Piston Return Spring Removal

c) Remove the piston return spring.

Figure 170. Snap Ring Removal

b) Remove the flange, 5 discs and 5 plates.

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-47

Inspect

1. Inspect discs, plates and flange.

Check to see if the contacting surface of the
disc, plate and flange are worn or burnt. If
necessary, replace them.
NOTICE:
« if the lining of the disc is peeling off or
discolored, or even if a parts of the printed
numbers are defaced, replace all discs.
« Before assembling new discs, soak them
in ATF for at least 15 minutes.

Figure 173. Piston Return Spring Removal (2)

4, Remove rear clutch piston.

a) Place the center support assembly on
wooden blocks.
b) Place the rear clutch drum onto the center
support assembly.
c) Hold the piston with hand, apply
compressed air 392—785 kPa (4-8 kgf/cm’,
57—114 psi) into the oil hole of the center
support to remove the clutch piston.
d) Remove the 2 O-rings from the clutch
piston.
Figure 175. Disc Inspection

2. Inspect rear clutch piston.

a) Check that check ball is free by shaking the
piston.
b) Check that the valve does not leak by
applying low-pressure compressed air.

Figure 174. Rear Clutch Piston Removal

Figure 176. Rear Clutch Piston Check

7A4-48 AUTOMATIC TRANSMISSION OVERHAUL

Assemble

1. Instali rear clutch piston.

a) Coat new O-rings with ATF, and install them
in the clutch drum.
O-ring diameters mm (in.)
Inside Wire diameter
Inner side 62.9 (2.4767) 2.6 (0.1024)
Outer side 109.7 (4.3189) | 3.1 (0.1220)

Figure 179. Piston Return Spring Instailation (1)

b) Place No.2 piston spring compressor on the

spring seat, and compress the return spring
with a shop press.
Tool Required:
J-44160 No.2 Piston Spring
Compressor
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
Figure 177. O-ring Location deformed.
c) Using snap ring pliers, install the snap ring.
b) Push in the clutch piston into the clutch
NOTICE: Be sure the end gap of the snap ring
drum with both hands.
is not aligned with the spring retainer claw.
CAUTION: Be careful not to damage the O-
rings.
NOTICE: Push in the piston uniformly.

Figure 180. Piston Return Spring Installation (2)

3. Install plates, discs and flange.

Figure 178. Clutch Piston Installation a) Install the 5 plates and 5 discs in order:
P = Plate D = Disc
2. Install piston return springs. P-~-D-P-D-P-D-P-D-P-D
a) Place the piston return spring on the clutch
piston.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-49

4, Check piston stroke of rear clutch.

a) Place the center support assembly on
wooden blocks.
NOTICE: Provide clearance so that the sun
gear does not touch the rear clutch drum.
b) Place the rear clutch assembly onto the
center support assembly.

(
Figure 181. Plate and Disc Installation

b) Instail the flange, facing the rounded edge

upward.
NOTICE: !f the flange is step-edged, install the
flange with the step-edge, facing downward.

Figure 184. Piston Stroke Check (1)

c) Using No.1 measure terminal and a dial

indicator, measure the piston stroke while
applying and releasing compressed air
392-785 kPa (4-8 kgf/cm’, 57~114 posi).
Tool Required:
J-44167 No.1 Measure Terminal
Piston stroke: 2.00~2.20 mm
(0.0787-0.0866 in.)
NOTICE:
« Stand the measure terminal on the piston
vertically.
Figure 182. Flange Installation « Ensure that the measure terminal does not
touches other parts than the piston.
c) Using a screwdriver, install the snap ring. * Measure the stroke at more than 3 points.
NOTICE: Be sure the end gap of the snap ring If the piston stroke is less than specified, parts
is not aligned with the cutout portion of the may have been assembied incorrectly, check
rear clutch drum. and reassemble again.
If the piston stroke is not as specified, select
another flange.
Flange thicknesses
No. | Thickness mm (in.) | No. | Thickness mm (in.)
A 5.0 (0.197) E 4.6 (0.181)
B 5.2 (0.205) F 4.8 (0.189)

Figure 183. Snap Ring Installation

7A4-50 AUTOMATIC TRANSMISSION OVERHAUL

Figure 185. Piston Stroke Check (2)

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-51

SECOND BRAKE

1. Flange 8. O-ring
2. Plate 9. Snap Ring
3. Snap Ring 10. Oil Seal Ring
4, Disc 11. Center Support
5. Snap Ring 12. Front Planetary Sun Gear
6. Piston return Spring 13. Retainer
7. Second Brake Piston

Figure 186. Second Brake Assembly

[S] Disassemble

1. Remove front planetary sun gear.

a) Using snap ring pliers, remove the snap
ring.

Figure 187. Sun Gear Removal

7A4-52 AUTOMATIC TRANSMISSION OVERHAUL

b) Remove the sun gear.

2. Check piston stroke of second brake.
Using No.2 measure terminal and a dial
indicator, measure the piston stroke by applying
and releasing compressed air 392-785 kPa
(4—8 kgf/cm’, 57~114 psi).
Tool Required:
J-44168 No.2 Measure Terminal
Piston stroke: 1.86-2.06 mm
(0.0732-0.0811 in.)
NOTICE:
* Stand the measure terminal on the piston
vertically.
¢ Ensure that the measure terminal does not
touches other parts than the piston. Figure 190. Flange, Disc and Plate Removal
¢ Measure the stroke at more than 3 points.
lf the piston stroke is greater than specified, 4. Remove piston return spring.
inspect the discs. a) Place No.3 piston spring compressor on the
spring seat, and compress the return spring
with a shop press.
Tool Required:
J-44161 No.3 Piston Spring
Compressor
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
deformed.
b) Using a screwdriver, remove the snap ring.

Figure 188. Piston Stroke Check

3. Remove flange, discs and plates.

a) Using a screwdriver, remove the snap ring.

Figure 191. Return Spring Removal (1)

c) Remove the piston return spring.

Figure 189. Snap Ring Removal

b) Remove the flange, 5 discs and 5 plates.

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-53

Figure 192. Return Spring Removal (2) Figure 194. Oil Seal Removai

5. Remove second brake piston. . Remove ring retainers.

a) Place the No.3 piston spring compressor on Using needle nose pliers, remove the 3 ring
the brake piston. retainers from the oil holes of the center
Tool Required: support.
J-44161 No.3 Piston Spring
Compressor
b) Hold the spring compressor so it does not
slant, and apply compressed air 392-785
kPa (4-8 kg/cm’, 57-114 psi) into the oil
hole of the center support to remove the
brake piston.
NOTICE: Be careful not to slant the brake
piston while applying compressed air. If the
brake piston slants, it is difficult to remove.
c) Remove the 2 O-rings from the brake piston.

Figure 195. Ring Retainer Removal

Figure 193. Piston Removal

. Remove oil seal rings.

Remove the 2 oil seal rings from the center
support.
CAUTION:
¢ Do not damage the oil seal rings and do
not deform them unless necessary.
¢ Do not damage the claws on the oil seal
rings.
7A4-54 AUTOMATIC TRANSMISSION OVERHAUL

Inspect

1. Inspect discs, plates and flange.

Check to see if the contacting surface of the
disc, plate and flange are worn or burnt. If
necessary, replace them.
NOTICE:
« If the lining of the disc is peeling off or
discolored, or even if parts of the printed
numbers are defaced, replace all discs.
* Before assembling new discs, soak them
in ATF for at least 15 minutes.

Figure 197. Bushing Inspection

3. Inspect bushings of front planetary sun gear.

Using a dial indicator, measure the inside
diameter.
Standrad inside diameter: 25.500-25.521 mm
(1.0039—1.0048 in.)
Maximum inside diameter: 25.570 mm
(1.0067 in.)
NOTICE: Measure at several points and take
the average value.
If the inside diameter is greater than the
maximum, replace the front planetary sun gear.
Figure 196. Disc Inspection Inspect the bushing contacting surface of the
2. Inspect bushing of center support. intermediate shaft, when discoloration or
Using a dial indicator, measure the inside damage on the surface is found, replace the
diameter , intermediate shaft with a new one.
Standrad inside diameter: 35.000—35.025 mm
(1.3780-1.3789 in.)
Maximum inside diameter: 35.08 mm
(1.3811 in.)
NOTICE: Measure at several points and take
the average value.
If the inside diameter is greater than the
maximum, replace the center support.
Inspect the bushing contacting surface of the
front planetary sun gear, when discoloration or
damage on the surface is found, replace the
front planetary sun gear with a new one.

Figure 198. Sun Gear Bushing Inspection

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-55

O-ring diameters mm (in.)

Assemble
Inside Wire diameter
1. Install ring retainers. Inner side | 145.3 (5.72047)} 3.1 (0.12208)
Using needle nose pliers, install the 3 ring Outer side | 163.7 (6.44489) | 3.1 (0.12208)
retainers into the oil holes of the center support.

Figure 199. Ring Retainer Installation Figure 201. O-ring Installation

2. Install oii seal rings. b) Align the protrusions of the brake piston with
a) Coat the new 2 oil seal rings with ATF. the grooves of the center support.
b) Contract the oil seal rings, and install them c) Push in the brake piston into the center
onto the center support. support with both hands.
CAUTION: CAUTION:
« Do not spread the ring ends more than * Be careful not to damage the O-rings.
necessary. ¢ Push in the piston uniformly.
¢ Do not damage the claws on the oil seal
rings.
NOTICE:
- If the oil seal rings are damaged or
deformed, replace them with new ones.
¢ After installing the oil seal rings, check
that they rotate smoothly.

Figure 202. Piston Installation

4. Install piston return spring.

a) Place the return spring on the brake piston.

Figure 200. Seal Ring Installation

3. Install second brake piston.

a) Coat the new 2 O-rings with ATF, and install
them on the brake piston.
7A4-56 AUTOMATIC TRANSMISSION OVERHAUL

Figure 203. Return Spring Installation (1) Figure 205. Plate and Disc Installation

b) Place the No.3 piston spring compressor on b) Install the flange, facing the rounded edge
the return spring, and compress the return upward.
spring with a shop press. NOTICE: If the flange is step-edged, install the
Tool Required: flange with the step-edge, facing downward.
J-44161 No.3 Piston Spring
Compressor
NOTICE: Stop compressing the return spring
at the pesition 1 to 2 mm away from the snap
ring to prevent the spring sheet from being
deformed.
c) Using a screwdriver, install the new snap
ring.
NOTICE: Be sure the end gap of the snap ring
is not aligned with the cutout portion of the
center support.

Figure 206. Flange Installation

c} Using a screwdriver, install the snap ring.

NOTICE: Be sure the end gap of the snap ring
is not aligned the cutout portion of the center
support.

Figure 204. Return Spring Instaliation (2) cre

exsssrssss
SeSlescsssS
5. Install piates, discs and flange.
a) Install the 5 plates and 5 discs in order:
P = Plate D = Disc
P~D-—-P-D-P-D-P-D-P-D
t

Figure 207. Snap Ring Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-57

6. Check piston stroke of second brake.

Using the No.2 measure terminal and a dial
indicator, measure the piston stroke by applying
and releasing compressed air 392~785 kPa
(4-8 kg/cm’, 57-114 psi).
Piston stroke: 1.86-—2.06 mm
(0.0732-0.0811 in.)
NOTICE:
¢ Stand the measure terminal on the piston
vertically.
« Ensure that the measure terminal does not
touches other parts than the piston.
* Measure the stroke at more than 3 points.
If the piston stroke is less than specified, parts
may have been assembled incorrectly, check
and reassemble again.
If the piston stroke is not as specified, select
another flange.
Flange thicknesses
No. | Thickness mm (in.) | No. | Thickness mm (in.)
5.0 (0.197) Cc 5.4 (0.213)
Om) >

5.2 (0.205) D 5.6 (0.220)

rh 7
Figure 208. Piston Stroke Check

6. Install front planetary sun gear.

a) Instali the sun gear.
b) Using snap ring pliers, install the snap ring.

Figure 209. Sun Gear Installation

7A4-58 AUTOMATIC TRANSMISSION OVERHAUL

PLANETARY GEARS, ONE-WAY CLUTCH AND OUTPUT SHAFT

1. One-way Clutch 8. Rear Planetary Gear 15. Ring Gear Flange

2. Front Planetary Gear 9. Rear Planetary Sun Gear 16. Snap Ring
3. No.1 Thrust Washer 10. Thrust Bearing 17. Thrust Bearing
4. Front Planetary Ring Gear 11. Oil Seal Ring 18. Output Shaft
5. Snap Ring 12. Intermediate Shait 19. Snap Ring
6. No.2 Thrust Washer 13. Snap Ring
7. O-ring 14, Rear Planetary Ring Gear

Figure 210. Planetary Gear, One-way Clutch and Output Shaft Assembly

[S] Disassemble

1. Remove the rear planetary gear and output

shaft assembly from the front planetary gear.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-59

4, Remove the one-way clutch from the front

pianetary gear.

Figure 211. Rear Planetary Gear Removal

2. Remove No.1 rear thrust washer.

Figure 214. One-way Clutch Removal
Remove the thrust washer from the rear side of
the front planetary gear. 5. Remove output shaft.
a) Using a screwdriver, remove the snap ring.

Figure 212. No.1 Thrust Washer Removal

Figure 215. Output Shaft Removal (1)
3. Check operation of one-way clutch.
Hold the one-way clutch outer race and turn the b) Remove the output shaft from the rear
front planetary gear. The front planetary gear planetary gear.
should turn freely counterclockwise and should
lock clockwise.
If operation is not as specified, replace the one-
way Clutch.

Figure 216. Output Shaft Removal (2)

c) Remove the thrust bearing and race from

the rear side of the ring gear flange.
Figure 213. One-way Ciutch Check
7A4-60 AUTOMATIC TRANSMISSION OVERHAUL

qu
nl

Figure 217. Thrust Bearing Removal Figure 220. Sun Gear Removal

6. Remove rear planetary ring gear and 8. Remove oil seal ring.
intermediate shaft assembly. Using a small screwdriver, pry out the oil seal
a) Remove the ring gear and intermediate ring.
shaft assembiy from the rear planetary gear.
NOTICE: Do not drop the planetary sun gear.

Figure 221. Oil Seal Ring Removal

Figure 218. Ring Gear and Shaft Removal 9. Remove rear planetary ring gear and flange
assembly.
b) Remove the thrust bearing from the front a) Using snap ring pliers, remove the snap ring
side of the ring gear flange. from the rear side of the intermediate shaft.

Figure 219. Thrust Bearing Removal Figure 222. Snap Ring Removal

7. Remove the sun gear from the rear planetary b) Remove the ring gear and flange assembly
gear. from the intermediate shaft.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-61

Figure 223. Ring Gear and Flange Removal Figure 226. Ring Gear Flange Removal (2)

c) Using snap ring pliers, remove the snap ring 11. Remove front planetary ring gear.
from the front side of the intermediate shaft. Using needle nose pliers, pry out the ring gear
while compressing the snap ring.

Figure 224. Snap Ring Removal

Figure 227. Ring Gear Removal
10. Remove rear planetary ring gear flange.
a) Using a small screwdriver or awis, remove 12. Using a screwdriver, remove the No.2 thrust
the snap ring. washer from the rear planetary gear.
CAUTION: Do not damage the No.2 thrust
washer.

Figure 225. Ring Gear Fiange Removal (1)

b) Remove the ring gear flange from the rear Figure 228. Thrust Washer Removal
planetary ring gear.
13. Using a small screwdriver, remove the O-ring
from the rear planetary gear.
7A4-62 AUTOMATIC TRANSMISSION OVERHAUL

inspect

1. inspect bushing of output shaft.

Using a dial indicator, measure the inside
diameter.
Standard inside diameter: 17.000-17.021 mm
(0.6693-0.6701 in.)
Maximum inside diameter: 17.07 mm
(0.6720 in.)
lf the inside diameter is greater than maximum,
replace the output shaft.
Inspect the bushing contact surface of the
intermediate shaft, when discoloration or
damage on the surface is found, replace the
Figure 229. O-ring Removal intermediate shaft with a new one.

Figure 230. Bushing Inspection

. Inspect planetary pinion gear thrust clearance.

Using a feeler gauge, measure the thrust
clearance between the pinions and carrier.
Siandrad clearance: 0.20-0.59 mm
(0.0079—~0.0232 in.)
Maximum clearance: 0.75 mm (0.0295 in.)
If the thrust clearance is greater than maximum,
replace the planetary gear.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-63

fa] Assemble

1 . Install O-ring.
Coat a new O-ring with ATF, and install it onto
the rear planetary gear.
CAUTION: Be careful not to damage the O-
ring.

Figure 232. O-ring Installation

. Install No.2 thrust washer.

Figure 231. Thrust Ciearance Inspection Coat the thrust washer with petroleum jelly, and
install it onto the rear planetary gear.
NOTICE: Securely fit the lips of the thrust
washer into the holes of the rear planetary
gear.

Figure 233. No.2 Thrust Washer Installation

. Install front planetary ring gear.

a) Align the snap ring end with the wide cutout
portion of the rear planetary gear.
b) Using needle nose pliers, compress the
snap ring and then install the ring gear.
c) Gheck that the snap ring is installed into the
groove of the rear planetary gear.
7A4-64 AUTOMATIC TRANSMISSION OVERHAUL

Figure 234. Ring Gear Installation Figure 237. Snap Ring Installation

4. Install rear planetary ring gear flange. b) Install the ring gear and flange assembly.
a) Instail the ring gear flange to the rear c) Using snap ring pliers, install the snap ring
planetary ring gear. on the rear side of the intermediate shaft.

OH iL
i)

Figure 235. Ring Gear Flange installation Figure 238. Snap Ring Instaliation

b) Using a small screwdriver, install the snap 6. Install oil seal ring.
ring. Coat the new oil seal ring with ATF, and install it
on the intermediate shaft.

Figure 236. Snap Ring installation

Figure 239. Oil Seal Ring Installation
5. Install rear planetary ring gear and flange
assembly. 7. install rear planetary sun gear.
a) Using snap ring pliers, install the snap ring install the sun gear to the rear planetary gear.
on the front side of the intermediate shaft.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-65

9. Install output shaft.

a) Coat the thrust bearing with petroleum jelly.
b) Install the thrust bearing onto the rear side
QD of the ring gear flange.
Un Thrust bearing diameter
Diameter mm {in.) Inside Outside
Bearing 32.8 (1.291) 53.2 (2.094)

Figure 240. Sun Gear Installation

8. Install rear planetary ring gear and intermediate

shaft assembly.
a) Coat the thrust bearing with petroleum jelly.
b) Install the thrust bearing onto the front side
of the ring gear flange.
Thrust bearing diameter
Diameter mm (in.) inside Outside Figure 243. Thrust Bearing Installation
Bearing 32.8 (1.291) §3.2 (2.094)
c) Install the output shaft to the rear planetary
gear.

Figure 241. Thrust Bearing Installation

Figure 244. Output Shaft Installation
c) Install the ring gear and intermediate shaft
assembly to the rear planetary gear. d) Using a screwdriver, install the snap ring.
NOTICE: Do not drop the planetary sun gear. NOTICE: Be sure the end gap of the snap ring
is not aligned with the cutout portion of the
rear planetary gear.

Figure 242. Ring Gear and Shaft installation

7A4-66 AUTOMATIC TRANSMISSION OVERHAUL

Figure 245. Snap Ring Installation Figure 247. One-way Clutch Check

10. Install one-way clutch. 12. Install No.1 thrust washer.

a) Position the one-way clutch on the front Coat the thrust washer with petroleum jelly, and
planetary gear, facing the flanged sice of install it onto the rear side of the front planetary
the one-way clutch downward. gear.
b) Install the one-way clutch to the front NOTICE: Securely fit the claws of the thrust
planetary gear by rotating the one-way washer into the grooves of the front planetary
clutch counterclockwise. gear.

Figure 246. One-way Clutch Installation Figure 248. No.1 Thrust Washer Installation
11. Check operation of one-way clutch. 13. Install the rear planetary gear and output shaft
Hold the one-way clutch outer race and turn the assembly to the front planetary gear.
front planetary gear. The front planetary gear
should turn freely counterclockwise and should
lock clockwise.
If operation is not as specified, replace the one-
way clutch.

Figure 249. Planetary Gear and Shaft Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-67

FIRST AND REVERSE BRAKE

1. Snap Ring 6. Snap Ring

2. Flange 7. Piston Return Spring
3. Disc 8. First and Reverse Brake Piston
4, Plate 9. O-ring
5. Cushion Plate 10. Output Shaft Front Bearing

Figure 250. First and Reverse Brake Assembly

[S] Disassemble NOTICE:

» Stand the measure terminal on the piston
1. Check piston stroke of first and reverse brake vertically.
piston. » Ensure that the measure terminal does not
a) Using the No.2 measure terminal and a dial touches other parts than the piston.
indicator, measure the piston stroke by . Measure the stroke at more than 3 points.
applying and releasing the compressed air if the piston stroke is not as specified, inspect
392-785 kPa (4-8 kg/cm’, 57-114 psi). the discs.
Tool Required:
J-44168 No.2 Measure Terminal
Piston stroke: 3.30—3.80 mm
(0.1299--0.1496 in.)
7A4-68 AUTOMATIC TRANSMISSION OVERHAUL

Figure 253. Flange, Disc, Plate and Cushion Plate

3. Remove piston return spring.

a) Set the No.1 piston spring compressor on
the spring retainer, and compress the return
spring.
Tool Required:
J-44162 No.1 Piston Spring
Compressor
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap
Figure 251. Piston Stroke Check ring to prevent the spring sheet from being
deformed.
2. Remove flange, discs, plates and cushion plate.
a) Using screwdriver, remove the snap ring.

cm

> ZL
ire uf ? = 4
: Ls = [

Figure 254. Return Spring Removal (1)

Figure 252. Snap Ring Removal b) Using a snap ring pilers, remove the snap
ring.
b) Remove flange, 6 discs, 6 plates and
CAUTION: Do not damage the snap ring and
cushion plate.
do not defrom them unless necessary.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-69

cS y))

Figure 255. Return Spring Removal (2) Figure 257. Brake Piston Removal

c) Remove the piston return spring. Inspect

Inspect discs, plates and cushion plate.

Check to see of the contacting surface of the
disc, plate and flange are worn or burnt. If
necessary, replace them.
NOTICE:
+ If the lining of the disc is peeling off or
discolored, or even if a part of the printed
numbers are defaced, replace all discs.
+ Before assembling new discs, soak them
in ATF for at least 15 minutes.

Figure 256. Return Spring Removal (3)

4. Remove first and reverse brake piston.

a) Hold first and reverse brake piston with
hand or piston spring compressor with
return spring, remove first and reverse
brake piston by applying compressed air
392-785 kPa (4-8 kg/cm’, 57-114 psi) into
the oil hole of the transmission case.
NOTICE: Be careful not to slant the brake
piston while applying compressed air. If the
Figure 258. Disc inspection
brake piston slants, it is difficult to remove.
b) Remove the 2 O-rings from brake piston.
Output shaft front bearing replacement
1. Remove output shaft front bearing.
Using oil seal installer (for oil pump), steel plate
and a shop press, press out the bearing.
Tool Required:
J-44163 Oil Seal Installer
7A4-70 AUTOMATIC TRANSMISSION OVERHAUL

Reassemble

1. Instail first and reverse brake piston.

a) Coat the new 2 O-rings with ATF, and install
them in the first and reverse brake piston.
O-ring diameter mm (in.)
Inside Wire diameter
Inner side 94.4 (3.7165) | 3.1 (0.1221)
Outer side 163.7 (6.4449) | 3.1 (0.1221)

Figure 259. Bearing Replacement (1)

2. Install output shaft front bearing.

a) Using the bearing installer, handie and a
shop press, press in the new bearing.
Tool Required:
J-44164 Handle
J-44165 Bearing installer
b) Check that the bearing rotates smoothly.

Figure 261. O-ring Location

b) Using the No.1 piston spring compressor

and the handle, push in the brake piston.
Tool Required:
5

J-44162 No.1 Piston Spring

Compressor
J-44164 Handle
. r CAUTION: Be careful not to damage the O-

Figure 260. Bearing Replacement (2)

(CEES
PO OL BUG
Lok

PS
Figure 262. Brake Piston Instaliation

2. Install piston return spring.

a) Place the return spring on the brake piston.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-71

3. Install cushion plate, plates, discs and flange.

a) Install the cushion plate, facing the rounded
edge inward.

Figure 263. Return Spring Installation (1)

b) Using No.1 piston spring compressor,

compress the return spring.
Figure 266. Cushion Plate Installation
NOTICE: Stop compressing the return spring
at the position 1 to 2 mm away from the snap b) Install the 6 plates and 6 discs in order:
ring to prevent the spring sheet from being P = Plate D = Disc
deformed. P-D-P-D-P-D-P-D-P-D

Figure 264. Return Spring Installation (2) Figure 267. Plate and Disc installation
c) Using snap ring pliers, install the snap ring. c) Install the flange, facing the rounded edge
NOTICE: If the snap ring are damaged or outward.
deformed, replace it with a new one. NOTICE: If the flange is step-edged, install the
flange with the step-edge, facing inward.

Figure 265. Return Spring Installation (3)

Figure 268. Flange Direction
7A4-72 AUTOMATIC TRANSMISSION OVERHAUL

d) Using screwdriver, install the snap ring.

NOTICE: Be sure the end of the snap ring is
not aligned with the cutout portion of the
transmission case.

Figure 269. Snap Ring Installation

4. Check piston stroke of first and reverse brake.

a) Using No.2 measure terminal and a
dialindicator, measure the piston stroke by
applying and releasing the compressed air
392-785 kPa (4-8 kg/cm’, 57-114 psi).
Figure 270. Piston Stroke Check
Tool Required:
J-44168 No.2 Measure Terminal
Piston stroke: 3.3-3.8 mm (0.130—0.150 in.)
NOTICE:
* Stand the measure terminal on the piston
vertically.
* Ensure that the measure terminal does not
touches other parts than the piston.
¢ Measure the stroke at more than 3 points.
If the piston stroke is less than specified, parts
may have been assembled incorrectly, check
and reassemble again.
If the piston stroke is not as specified, select
another flange.
Flange thickness mm (in.)
No. Thickness
E 6.65 (0.2618)
F 7.05 (0.2776)
G 7.45 (0.2933)
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-73

VALVE BODY

. Drain Tube 9. Timing Solenoid

10. No.2 Shift Solenoid
ON=

Plate
. Upper Valve Body 11. No.1 Shift Solenoid
. No.1 Gasket 12. O-ring
Plate 13. Spring Cover
ONAN

. No.2 Gasket 14. Manual Detent Spring

. Lower Valve Body 15. Manual Valve
. Lock Up Solenoid

Figure 271. Valve Body Assembly

7A4-74 AUTOMATIC TRANSMISSION OVERHAUL

Disassemble 4, Remove 4 solenoid valves.

a) Remove the 2 bolts, the No.1 and No.2
1. Remove the bolt and the drain tube. solenoids.
b) Remove the 2 O-rings from them.

Figure 272. Drain Tube Removal

Figure 275. Solenoid Removal (1)
2. Remove the manual valve.
c) Remove the boit, the timing and lockup
solenoids.
d) Remove the 2 O-rings from them.

Figure 273. Manual Valve Removal

3. Remove manual detent spring.

a) Turn over the valve body assembly. Figure 276. Solenoid Removal (2)
b) Remove the bolt, spring cover and detent
spring. 5. Separate upper and lower valve bodys.
a) Remove the 12 bolts, and washers from the
lower valve body.

GR
6 0 a ca CO ~*) |

o DSS ber C0

Figure 274. Detent Spring Removal

Figure 277. Lower Valve Body Bolts

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-75

b) Remove 2 bolts and plates.

1. Install valve body plate and gaskets.

NOTICE: If there is dirt on the valve body,
wash the valve body clean and install it.

Figure 278. Plate Removal

c) Remove the 16 bolts from the upper valve

body.

Ny a ae
0 o 9

Figure 279. Upper Valve Body Bolts

d) Remove the upper valve body together with 1. No.1 Gasket

the 2 gaskets and plate. 2. No.2 Gasket
e) Remove the 2 gaskets and plate from the
upper valve body.
NOTICE: Be careful that the check balls, Figure 281. Gasket
springs and check valves do not fall out from
the lower valve body. a) Place a new No.1 gasket, plate and a new
No.2 gasket on the lower valve body.
NOTICE: Since No.1 and No.2 gaskets look
similar, use the illustrations above to
differentiate between them.

Figure 280. Upper Valve Body Removal

7A4-76 AUTOMATIC TRANSMISSION OVERHAUL

1. No.2 Gasket
2. Plate
3. No.1 Gasket

Figure 282. Gasket and Piate Installation Figure 284. Lower Valve Body Bolts
2. Install lower valve body. 3. Install upper valve body.
a) Turn over the valve body assembly together a) Turn over the valve body assembly.
with the plate and 2 gaskets. b) Install the 2 bolts and 2 washers indicated
NOTICE: Be careful that the check balls, check as “C” in the illustration and tighten them
valve and spring do not fall out. temporarily.
b) Place the lower valve body on the upper c}) Install and tighten the rest of 14 bolts
valve body. temporarily.
NOTICE: Each bolt length (mm) is indicated in
the illustration.
Bolt length:
28 mm (1.10 in.)
© >

32 mm (1.26 in.)
OO

36 mm (1.42 in.) with washer

40 mm (1.57 in.)

Figure 283. Lower Valve Body installation

c) Install the 2 bolts and 2 washers indicated

as “C” in the illustration and tighten them
temporarily.
d) Install and tighten the rest of 10 bolts
temporarily.
NOTICE: Each bolt length (mim) is indicated in Figure 285. Upper Valve Body Bolts
the illustration.
Bolt length: . Install the plate and tighten the 2 bolts
50 mm (1.97 in.) temporarily.
moO >

42 mm (1.68 in.) NOTICE: Each bolt length (mm) is indicated in

50 mm (1.97 in.) with washer the illustration.
50 mm (1.97 in.) Bolt length:
53 mm (2.09 in.) A 42 mm (1.65 in.)
B 50 mm (1.97 in.)
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-77

6. Install 4 solenoid vaives.

a) Coat the 2 O-rings with ATF, install them to
the No.1 and No.2 solenoids.
b) Install the No.1 and No.2 solenoids with the
2 bolts.

[QI Tighten
Torque: 10 N-m (1.0 kg-m, 87 Ib-in)

Figure 286. Plate Installation

5. Tighten bolts of upper and lower valve bodies.

Upper side: Tighten the 16 bolts.

[A] Tighten

Torque: 5.5 N-m (55 kg-cm, 48 lb-in)

Figure 289. Solenoid installation (1)

c) Coat the 2 O-rings with ATF, install them to

the timing and lockup solenoids.
d) Install the timing and lockup solenoids.

Tighten
Torque: 10 N-m (1.0 kg-m, 87 lb-in)

Figure 287. Upper Side Bolts

Lower side: Tighten the 12 bolts.

[QJ Tighten

Torque: 5.5 N-m (55 kg-cm, 48 Ib-in)

Figure 290. Solenoid installation (2)

. Install manual detent spring.

Install the detent spring and cover with the boli

Tighten
Torque: 5.5 N-m (55 kg-cm, 48 \b-in)
NOTICE: Use the bolt which is 43 mm (1.69 in.)
in length.

Figure 288. Lower Side Bolts

7A4-78 AUTOMATIC TRANSMISSION OVERHAUL

a
6&y a

qq .
NOa

Figure 291. Detent Spring Installation

8. Install manual valve into the valve body.

Figure 292. Manual Valve Installation

9. Install the drain tube.

NOTICE: Use the bolt which is 10.5 mm (0.41
in.) in length.

[Ql] Tighten

Torque: 5.5 N-m (55 kg-cm, 48 Ib-in)

Figure 293. Drain Tube Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-79

Upper Valve Body Parts Location

1. Strainer

Figure 294. Check Bali Location

Mark Name Diameter mm (in.)

@ Check Ball 6.4 (0.252)
7A4-80 AUTOMATIC TRANSMISSION OVERHAUL

Lower Vaive Body Parts Location

\,
a
() aS

\
ccCCO *
(OO
CRS
MN SQ C3

ss Swe

1. Pressure Relief Valve NS .

2. Case Dy o

Figure 295. Parts Location

Mark Name Diameter mm (in.)

@ Check Ball 8.7 (0.343)

Mark Name (Color) Free length / Outer canines Total No. of Coils

Check Bail (Pink) 14,0 /9.8 (0.551 / 0.386) 8.0

© Pressure Relief Valve (White) 24.0 / 8.2 (0.945 / 0.323) 12.0
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-81

EXTENSION HOUSING

1. Oil Seal Ring 5. Torsion Spring

7 2. Bearing 6. Washer
3. Snap Ring 7. Parking Lock Pawl Shaft
4, Bracket 8. Parking Lock Pawl

Figure 296. Extension Housing Assembly

[$] Disassemble

1. Remove the parking lock pawl shaft from the

extension housing.

Figure 297. Shaft Removal

7A4-82 AUTOMATIC TRANSMISSION OVERHAUL

2. Remove parking lock pawi, torsion spring and 5. Remove bearing.

plate washer. a) Using a screwdriver, remove the snap ring.
a) Remove the parking lock pawl.
b) Remove the spring and plate washer.
CAUTION: Do not damage the spring and do
not deform it unless necessary.

Figure 301. Bearing Removal (1)

b) Using the rear bearing replacer and a shop

press, press out the bearing.
Figure 298. Parking Lock Paw! Removal Tool Required:
J-44165 Rear Bearing Replacer
3. Remove the 2 bolts and parking lock pawl
bracket.

Figure 302. Bearing Removal (2)

Figure 299. Bracket Removai

4. Using a screwdriver, remove the oil seal.

Figure 300. Oil Seal Removai

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-83

Assemble

1. Install bearing.
a) Using the rear bearing replacer, Oil seal (for
lever shaft) installer and a shop press, press
in the bearing.
Tool Required:
J-44165 Rear Bearing Replacer
J-44171 Oil Seal (for lever shaft)
Installer

Figure 305. Oil Seal Installation

. Install parking lock pawl bracket.

a) Apply sealant (Three Bond 1344 or
equivalent) to the threads of the 2 bolts.
b) Temporarily install the bracket with the 2
bolts.
NOTICE: These bolts are precoated bolt.

Figure 303. Bearing Installation

b) Install the snap ring.

Figure 306. Bracket installation (1)

b) Using the plate and a calipers, set the

bracket so that the distance between the
extension housing surface and the top of the
bracket tab is the standard distance.
Figure 304. Snap Ring Installation Standard distance
= Total distance — Plate thickness
2. Using the oil seal installer and a hammer, install Standard distance:
the oil seal. 49.76-—49.86 mm (1.959-—1.963 in.)
Tool Required: c) Tighten the 2 bolts.
J-44163 Oil Seal installer
Tighten
Torque: 19 N-m (1.9 kg-m, 14 lb-ft)
7A4-84 AUTOMATIC TRANSMISSION OVERHAUL

Figure 307. Bracket Installation (2)

4. Install parking lock pawi.

a) Insert the torsion spring end to the hole of
the extension housing.
b) Install the parking lock pawl, shaft and plate
washer.

Figure 308. Parking Lock Pawl Installation

c) Hook another spring end to the parking lock

pawl.
d) Make sure the parking lock pawl moves
smoothly.

Figure 309. Spring Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-85

COMPONENT PARTS INSTALLATION

Disassembly, inspection and assembly of each
component group have been indicated in the
preceding chapter. Before assembly, make sure
again that all component groups are assembled
correctly.
If something wrong is found in a certain component
group during assembly, inspect and repair this
group immediately.
Recommended ATF:
DEXRON®*H

General Installation Notes:

1. The automatic transmission is composed of
highly precision-finished parts, necessitating
careful inspection before assembly because
even a small nick could cause fluid leakage and
affect performance.
2. Before assembling new clutch discs, soak them
in automatic transmission fluid for at least 15
minutes.
Apply automatic transmission fluid on sliding or
rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep smail parts in their
places.
5. Do not use adhesive cements on gaskets and
similar parts.
6. When assembling the transmission, be sure to
use new gaskets and O-rings.
7. Dry all parts with compressed air, never use
shop rags.
7A4-86 AUTOMATIC TRANSMISSION OVERHAUL

Bearings and Races Location

i
® ®
Figure 310. Bearing and Race Location

Mark Thrust Bearing Diameter Front Race Diameter Rear Race Diameter
Inside/Outside mm (in.) Inside/Outside mm (in.) Inside/Outside mm (in.)
@® 32.8 / 52.0 (1.291 / 2.047) _ 37.0 / 52.0 (1.457/ 2.047)
34.7 / 52.0 (1.366/ 2.047) 37.0 / 52.0 (1.457/ 2.047) 32.8/ 50.4 (1.291 / 1.984)
© 34.7 / 58.4 (1.366 / 2.299) 34.6 / 58.2 (1.362 / 2.291) 37.0 / 60.5 (1.457 / 2.382)
© 23.2 / 42.0 (0.913 / 1.654) _ -
27.1 / 43.0 (1.067/ 1.693)
© 28.5 / 48.0 (1.122 / 1.819) 27.9 / 43.0 (1.098/ 1.693) -
28.3 / 43.0 (1.114/ 1.693)
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-87

5. Install the manual valve lever shaft to the

fe] install or Connect
transmission case through the manual valve
Manual Valve Lever, Shaft and Oil Seals lever.
1. Using the oil seal installer, tap in new 2 oil CAUTION: Be careful not to damage the oil
seals. seais.
Tool Required:
J-44171 Lever Shaft Oil Seal Installer
2. Apply multi purpose grease to the oil seal lip.

Figure 314. Lever Shaft installation

6. Using a punch and hammer, tap in the pin with

Figure 311. Oil Seal Installation the slot at right angie to the shaft.

3. Install the new spacer to the manual vaive

lever.

Figure 315. Pin installation

7. Match the spacer hole to the lever calking

Figure 312. Spacer Installation hollow and caik the spacer to the lever.
8. Make sure the manual valve lever shaft turns
4. Connect the parking lock rod to the manual smoothly.
valve lever.

Figure 316. Spacer Caiking

Figure 313. Manual Valve Lever Installation
7A4-88 AUTOMATIC TRANSMISSION OVERHAUL

Planetary Gears, One-Way Clutch and Output 6. Remove the 2 bolts from the front planetary
Shaft Assembly gear.
1. Place the transmission case on a cylinder. 7. Using a screwdriver, install the snap ring.
2. Install the rear planetary gear and output shaft NOTICE: Be sure the end of the snap ring is
assembly to the transmission case. not aligned with the cutout portion of the
transmission case.

Figure 317. Output Shaft Assembly installation

3. Temporarily install 2 bolts to the front planetary Figure 319. Snap Ring Installation
gear. . Coat the thrust washer with petroleum jelly, and
NOTICE: Use two 6 mm (1 mm pitch) bolts. Do install it onto the front planetary gear.
not screw more than 5 revolutions. NOTICE: Securely fit the claws of the thrust
. Align the spline of the one-way clutch assembly washer into the grooves of the front planetary
into the transmission case. gear.
5. Install the front planetary gear and one-way
clutch assembly into the transmission case.
NOTICE:
* Mesh the spline of the front planetary gear
with the flukes of the discs by rotating and
pushing the front planetary gear
clockwise.
« If the front planetary gear will not rotate
clockwise, check the installation of the
one-way clutch.

Figure 320. Thrust Washer installation

Temporarily Install Center Support Assembly

1. Coat the thrust washer with petroleum jelly, and
install it onto the rear side of the center support.
NOTICE: Securely fit the claws of the thrust
washer into the grooves of the center support.

Figure 318. Front Planetary Gear Assembly

Installation
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-89

Parking Lock Gear

install the parking lock gear onto the output
shaft.

Figure 321. Thrust Washer Installation

2. Install oil pump remover (2 bolts) to the center

support.
Tool Required:
Figure 324. Parking Lock Gear Installation
J-44170 Oil Pump Remover
3. Align the oil holes and bolt holes of the center
support and transmission case. Output Shaft Spacer and Speedometer Drive Gear
4. Install the center support assembly into the Install the spacer and speedometer drive gear
transmission case. onto the output shaft.

—
=> Rear Side

Figure 322. Center Support Installation Figure 325. Speedometer Drive Gear Installation

5. Install the 3 center support bolts.

Extension Housing
Tighten 1. Place the new gasket on the transmission case.
2. Install the parking lock rod between the parking
Torque: 25 N-m (2.5 kg-m, 18 Ib-ft) lock paw! and bracket, and attach the extension
housing on the transmission case.

Figure 323. Center Support Bolt

7A4-90 AUTOMATIC TRANSMISSION OVERHAUL

Figure 326. Extension Housing Installation Figure 328. Thrust Clearance Adjustment (1)

3. Apply sealant (Three Bond 1344, Loctite 572 or 3. Place the plate on the center support.
equivalent) to the thread of the 2 bolts. Tool Required:
4, Install the 2 bolts indicated by + marks in the J-44166 Plate
iHustration and tighten them. 4, Using calipers, measure distance (A) between
5. Install and tighten the 7 bolts. the tops of the plate and the thrust washer on
Bolt length: the front planetary gear.
45 mm (1.77 in.) 5. Using calipers, measure thickness (B) of the
moowu,

50 mm (1.97 in.) plate.

85 mm (3.35 in.)
117 mm (4.61 in.)
120 mm (4.72 in.)

Tighten

Torque: 37 N-m (3.8 kg-m, 27 lb-ft)

Figure 329. Thrust Clearance Adjustment (2)

6. Remove the 3 center support set bolts.

Figure 327. Extension Housing Boits

Thrust Clearance of Center Support

1. Push the transmission output shaft toward the
front of the transmission by applying a force of
49-89 N (5—10 kg, 11.0-22.0 Ib).
2. Push the center support toward the rear of the
transmission by applying a force of 49-89 N
(5-10 kg, 11.0-22.0 Ib), then pull with the same
amount of force.
Figure 330. Thrust Clearance Adjustment (3)
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-91

7. Using the oil pump remover, remove the center

support assembly from transmission case.
Tool Required:
J-44170 Oil Pump Remover

Figure 333. Thrust Clearance Adjustment (6)

Center Support Assembly Installation

1. Coat new 3 O-rings with ATF and install them to
Figure 331. Thrust Clearance Adjustment (4) the oil holes of the center support.
8. Turn over the center support together with the
thrust washer, and place it on a flat surface.
9. Inserting calipers into the thrust washer hole,
measure the distance (C) between it and the flat
surface.
Center support thrust clearance: A ~ (B + C)
Standard thrust clearance: 0.30-0.70 mm
(0.01 18~—0.0276 in.)
Maximum thrust clearance: 0.90 mm
(0.0354 in.)

Figure 334. O-ring installation

2. Install the oil pump remover (2 balts) to the

center support.
Tool Required:
J-44170 Oil Pump Remover
3. Align the oil holes and bolt hole of the center
support and transmission case.
4. Install the center support assembly into the
transmission case.

Figure 332. Thrust Clearance Adjustment (5)

If the thrust clearance is greater than the

maximum, select and install a thrust washer.
Thrust washer thicknesses
Thickness mm (in.)
1.5 (0.069) 1.8 (0.071)
2.1 (0.083) 2.4 (0.094)
2.7 (0.108)

Figure 335. Center Support Installation

7A4-92 AUTOMATIC TRANSMISSION OVERHAUL

5. Apply sealant (Three Bond 1344, Loctite 572 or

equivalent) to the threads of the center support
set bolts.

Figure 338. Rear Clutch Assembly installation

Front Clutch Assembly

Figure 336. Sealant 1. Coat the race with petroleum jelly, and install it
onto the rear clutch drum.
6. Install the 3 center support set bolts. Race diameter
Tighten Diameter mm (in.} Inside Outside
Race 37.0 (1.457) 52.0 (2.047)
Torque: 25 N-m (2.6 kg-m, 19 ib-ft)

Figure 337. Center Support Bolt Figure 339. Race Installation

2. Coat the bearing with petroleum jelly, and install

Rear Clutch Assembly it onto the front clutch hub.
Install the rear clutch assembly into the Bearing diameter
transmission case. Diameter mm (in.) Inside Outside
NOTICE: Mesh the spline of the rear clutch
Bearing 32.8 (1.291) 52.0 (2.047)
drum with the flukes of the discs by rotating
and pushing the rear clutch drum clockwise or
counterclockwise.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-93

6. Install the front clutch assembly into the rear

cluich assembly.
NOTICE: Mesh the spline of the front clutch
hub with the flukes of the discs by rotating and
pushing the front clutch drum clockwise or
counterclockwise.

Figure 340. Bearing Installation

3. Coat the spacer, race and bearing with

petroleum jelly, and install these parts onto the
front clutch drum.
Bearing and race diameter
Diameter mm (in.) Inside Outside Figure 343. Front Clutch Assembly Installation
Bearing 34.7 (1.366) 52.0 (2.047)
Race (Rear) 32.8 (1.291) 50.4 (1.984) 7. Place the plate on the installation surface of the
oil pump.
Tool Required:
J-44166 Plate
aren oo 8. Using calipers, measure the distance between
the tops of the plate and the clutch drum.
lf the distance corresponds to that during
disassembly, the front clutch assembly is
1-
installed correctly.

1. Spacer

Figure 341. Bearing and Race Installation

4. Coat the new oil seal ring with ATF.

5. Install the oil seal ring to the clutch drum, then
sank it down by squeezing their ends together.
CAUTION: Do not spread the ring seals more
than necessary.
Figure 344. Correct Installation Check

Temporarily Install Overdrive Case Assembly

1. Coat the race with petroleurn jelly, and install it
into the O/D case.
Race diameter
Diameter mm (in.} Inside Outside
Race (Rear) 32.8 (1.291) 50.4 (1.984)
2. Install the oil pump remover (2 bolts) to the O/D
case.
3. Align the oil hales and boit holes of the O/D
case and transmission case.
Figure 342. Oil Seal Ring Installation
7A4-94 AUTOMATIC TRANSMISSION OVERHAUL

Figure 345. O/D Case Assembly Installation Figure 347. Thrust Clearance Adjustment (1)

3. Temporarily install the 3 bolts. 3. Using the extension bar and a dial indicator,
measure the thrust clearance of the input shaft.
By Tighten Tool Required:
J-44169 Extension Bar
Torque: 25 N-m (2.5 kg-m, 18 Ib-ft) Standard thrust clearance: 0.30-0.70 mm
(0.0118-0.0276 in.)
Maximum thrust clearance: 0.70 mm
(0.0276 in.)
lf the thrust clearance is greater than the
maximum, adjust with a spacer.

Figure 346. O/D Case Bolt

Thrust Clearance of Input Shaft (Front Clutch

Drum)
1. Push the transmission output shaft toward the
front of the transmission by applying a force of Figure 348. Thrust Clearance Adjustment (2)
49-98 N (5—10 kg, 11.0-22.0 Ib).
2. Push the O/D case toward the rear of the 4. Remove the 3 O/D case set bolts.
transmission by applying a force of 49-98 N
(5-10 kg, 11.0-22.0 Ib).

Figure 349. O/D Case Bolt

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-95

5. Using the oil pump remover, remove the O/D

case assembly.
Tool Required:
J-44170 Oil Pump Remover

Figure 352. O-ring Installation

2. Install the oil pump remover (2 bolts) to the O/D

case.
Tool Required:
Figure 350. O/D Case Removal J-44170 Oil Pump Remover
6. Remove the thrust bearing, two races, and 3. Align the oil holes and bolt holes of the O/D
case and transmission case.
spacer from the front clutch drum or O/D case.
7. Select a spacer.

Spacer thicknesses
Thickness mm (in.)
0.9 (0.035) 1.8 (0.071)
1.2 (0.047) 2.1 (0.083)
1.5 (0.059)

8. install the spacer, 2 races and bearing onto the

front clutch drum.

Figure 353. O/D Case Installation

Overdrive Ring Gear Assembly

1. Coat the race and bearing with petroleum jelly,
and install them onto the O/D case.
Race and bearing diameter
Diameter mm (in.) Inside Outside
Race 37.0 (1.457) 60.5 (2.382)
Bearing 34.7 (1.366) 58.4 (2.299)

Figure 351. Race, Bearing and Spacer Installation

Overdrive Case Assembly installation

1. Coat the new 3 O-rings with ATF, and instail
them to the oil holies of the O/D case.
7A4-96 AUTOMATIC TRANSMISSION OVERHAUL

Overdrive Planetary Gear, Overdrive Direct Clutch

and One-Way Clutch Assembly
1. Coat the 2 bearings with petroleum jelly, and
install them onto the planetary gear.
Bearing diameters
Diameter mm (in.) Inside Outside
Bearing (A) 28.5 (1.122) 48.0 (1.889)
Bearing (B) 23.2 (0.913) 42.0 (1.654)

Figure 354. Race and Bearing Installation

2. Coat the race with petroleum jelly, and install it

onto the ring gear flange.
Race diameter
Diameter mm (in. inside Outside
Race 34.6 (1.362) 58.2 (2.291)

Figure 357. Bearing Installation

2. Instail the planetery gear, direct clutch and one-

way clutch assembly into transmission case.
NOTICE: Mesh the spline of the O/D direct
clutch drum with the flukes of the discs by
rotating and pushing the O/D direct clutch
drum clockwise or counterclockwise.

Figure 355. Race Instailation

3. Install the ring gear assembly into the O/D case.

Figure 358. O/D Direct Clutch Assembly Installation

3. Place the plate on the installtion surface of the

oil pump.
Tool Required:
J-44166 Plate
4. Using calipers, measure the distance between
the tops of the plate and the clutch drum.
Figure 356. Ring Gear Assembly Installation lf the distance corresponds to that during
disassembly, the O/D planetary gear, O/D direct
clutch and one-way clutch assembly are
installed correctly.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-97

3. Align the bolt holes of the pump body and

transmission case, and install it.

/ er a,
AS me

Cats \

ie
WS

Figure 359. Correct Installation Check

Temporarily Install Oil Pump Figure 362. Oil Pump Instaliation (1)
1. Coat the race with petroleum jelly, and install it 4, install a bolt to the matchmarked position,
onto the oii pump. tighten all the 11 bolts temporarily, then tighten
Race diameter (Reference) them completely a little at a time.
Diameter mm (in.} Inside Outside
27.1 (1.067) 43.0 (1.693) Tighten
Race 27.9 (1.098) 43.0 (1.693) Torque: 21 N-m (2.1 kg-m, 15 lb-ft)
28.3 (1.114) 43.0 (1.693)

Figure 363. Oil Pump installation (2)

Figure 360. Race Installation

2. Place the gasket on the transmission case. Thrust Clearance of Overdrive Input Shaft
(Overdrive Planetary Gear)
1. Push the O/D input shaft toward the rear of the
transmission by applying a force of 49-98 N
(6-10 kg, 11.0-22.0 Ib).

Figure 361. Gasket Installation

7A4-98 AUTOMATIC TRANSMISSION OVERHAUL

4. Using the oil pump remover, remove the oil

pump and gasket.
Tool Required:
J-44170 Oil Pump Remover

Figure 364. Thrust Clearance Adjustment (1)

2. Using a dial indicator, measure the thrust

clearance of the input shaft.
Standard thrust clearance: 0.40—0.90 mm
Figure 367. Oii Pump Removal
(0.0157-0.0354 in.)
Maximum thrust clearance: 0.90 mm 5. Remove the race from the oil pump cover.
(0.0354 in.) 6. Select a race.
lf the thrust clearance is greater than the
maximum, adjust with a race. Race thicknesses
Thickness mm (in.)
0.8 (0.031) 1.4 (0.055)
1.0 (0.039)
7. Coat the race with petroleum jelly, and install it
onto the oil pump cover. :

Figure 365. Thrust Clearance Adjustment (2)

3. Remove the 11 oil pump set bolts.

Figure 368. Race Installation

Figure 366. Oil Pump Bolt

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-99

Oil Pump Installation

1. Place a new gasket on the transmission case.

Figure 371. Sealant

. . 4. install a bolt to the matchmarked position,

Figure 369. Gasket Installation tighten all the 11 bolts temporarily, then tighten
2. Align the bolt holes of the pump body and them completely a little at a time.
transmission case. Tighten

Torque: 21 N-m (2.1 kg-m, 15 !b-ft)

Figure 372. Oil Pump Installation (2)

5. Coat the new 2 O-rings with ATF, and install

them to the oil pump body.
NOTICE: Be careful not to damage the O-rings.
O-ring diameters mm (in.)
Inside Thickness
O-ring (A) 241.6 (9.512) 3.1 (0.122)
O-ring (B) 250.0 (9.843) 2.7 (0.106)
Figure 370. Oil Pump Installation (1)

3. Apply sealant (Three Bond 1344, Loctite 572 or

equivalent) to the threads of the oil pump set
bolts.
7A4-100 AUTOMATIC TRANSMISSION OVERHAUL

Figure 373. O-ring Installation Figure 375. Accumulator Installation (1)

3. Place the new 2 gaskets, plate and accumulator

Accumulator Springs and Pistons on the transmission case.
1. Coat the new 8 O-rings with ATF, and install
them to the pistons.
CAUTION: Be careful not to damage the O-
rings.
O-ring diameter mm (in.)
Inside Outside
B-0 A 29.9 (1.177) 2.6 (0.102)
B 26.1 (1.028) 2.6 (0.102)
B-1 A 37.5 (1.476) 2.6 (0.102)
B 29.9 (1.177) 2.6 (0.102)
C-1 A 28.5 (1.122) 2.6 (0.102)
B 22.3 (0.878) 2.6 (0.102)
C-2 A 33.7 (1.327) 2.6 (0.102)
B 28.5 (1.122) 2.6 (0.102) Figure 376. Plate Installation

4, Install the 4 bolts.

[&] Tighten
Torque: 8 N-m (80 kg-cm, 69 Ib-in)
2

ene

Figure 374. O-ring and Piston

2. Install the spring and accumulator pistons into

the bore of the transmission case.
Spring diameter mm (in.)
C-1 Figure 377. Bolt Installation
Free length 93.3 (3.673) 5. Install the 4 springs and accumulator pistons
Diameter 17.7 (0.697) into the bore of the transmission case as
Color Red shown.
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-101

2. Install the solenoid wiring to the transmission

case.

[2] Tighten

Torque: 8 N-m (80 kg-cm, 69 ib-in)

Figure 378. Accumulator Installation (2)

Spring diameter and free length mm (in.)

Free length} Diameter Color
B-0 67.9 21.1 White
(2.673) (0.831) Figure 380. Solenoid Wiring
B-1 (Upper) 30.4 11.0 Yellow
(1.197) (0.433)
Valve Body
B-1 (Low) 66.0 25.1 Yellow 1. Align the groove of the manual valve with the
(2.598) (0.988) pin of the manual valve lever.
C-2 81.8 22.4 Beige
(3.220) (0.882)

Center Support Apply Gasket

Coat the new gaskets with ATF, and install
them, facing the pitted side toward the
transmission case.

Figure 381. Valve Body Installation

2. Connect the line pressure solenoid connector.

Figure 379. Gasket Installation

Solenoid Wiring
1. Coat a new O-ring with ATF, and install it to the
wiring.
O-ring diameter mm {ind
inside dimeter Thickness
O-ring 17.8 (0.701) 2.4 (0.094)

CAUTION: Be careful not to damage the O- Figure 382. Solenoid Connector

ring.
7A4-102 AUTOMATIC TRANSMISSION OVERHAUL

3. Install the 2 bolts indicated by + marks in the Oil Strainer

illustration and tighten them temporarily. install the oil strainer with the 4 bolts.
4. Install and tighten the rest of 19 bolts
temporarily, then tighten all of them completely [Q] Tighten
a little at a time.
Torque: 10 N-m (1.0 kg-m, 87 ib-in)
fa] Tighten Bolt tength:
A 16mm (0.63 in.)
Torque: 10 N-m (1.0 kg-m, 77 Ib-in) B 32.4 mm (1.28 in.)
NOTICE: Each bolt length is indicated in the
illustration.
Bolt length:
A 22 mm (0.87 in.
28 mm (1.70 in.)
NmMmMoow

32 mm (7.26 in.)
37.5 mm (7.48 in.)
40 mm (1.57 in.)
4i mm (1.61 in.)
45 mm (1.77 in.)
~TO

52mm (2.05 in.)

57 mm (2.24 in.)

Figure 385. Oil Strainer Installation

Magnet in Pan
Install the 4 magnets in the oil pan as shown in
the illustration.

Figure 383. Valve Body Bolt

Solenoid and ATF Thermosensor Connectors

1. Connect the 4 connectors to the solenoids.
2. Connect the connector to the ATF
thermosensor.

Figure 386. Magnet Installation

Oil Pan
1. Remove any sealants and be careful not to drop
oil on the contacting surface of the transmission
case and oil pan.
2. Apply sealants (Three Bond 1281 or equivalent)
to the oil pan.

Figure 384. Solenoid Connector

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-103

HI Ne
EN St —
A=¢2to3mm
Qa
OL
A a RR EK
NIE Ga I OY
SN

Figure 387. Sealant Application Figure 389. Torque Converter Housing Installation

3. Install and tighten the 20 bolts.

Transmission PTO Cover
[RQ] Tighten 1. Apply sealant (Three Bond 1344, Loctite 572 or
equivalent) to the thread of the PTO cover fixing
Torque: 7 N-m (70 kg-cm, 61 Ib-in) bolt.
2. Install the transmission PTO cover and new
gasket with 6 bolts.

Tighten
Torque: 15 N-m (1.5 kg-m, 11 Ib-ft)

Figure 388. Oil Pan Installation

Torque Converter Housing

1. Install the torque converter housing with the 8
bolts.
CAUTION: Be careful do not damage the 2 O- Figure 390. PTO Cover Installation
rings around the oil pump body when
installing the torque converter housing.
Vehicle Speed Sensor 1
[J Tighten 4. Coat the new O-ring with ATF, and install it to
the sensor.
Torque: 64 N-m (6.5 kg-m, 47 Ib-ft) CAUTION: Be careful not to damage the O-
Bolt length: ring.
A 35 mm (1.38 in.) O-ring diameter mm (in.)
B 45 mm (1.77 in.) inside Thickness
O-ring 11.8 (0.465) 1.9 (0.075)

2. Install the speed sensor to the extension

housing with the bolt.

I Tighten
Torque: 8 N-m (80 kg-cm, 69 Ib-in)
 7A4-104 AUTOMATIC TRANSMISSION OVERHAUL

2. Instail the sensor to the transmission case.

Tighten
Torque: 25 N-m (2.5 kg-m, 18 Ib-ft)

Figure 391. Vehicle Speed Sensor 1 Installation

Transmission Oi! Cooler Unions

1. Coat the new 2 O-rings with ATF, and install
them to each union.
Figure 393. ATF Temerature Switch Installation
CAUTION: Be careful not to damage to the O-
rings.
O-ring diameters mm (in.) Inhibitor Switch
Inside Wire diameter 1. Temporarily install the inhibitor switch with the 2
bolts.
O-rings 11.6 (0.457) 2.0 (0.079)
2. Install the gasket, a new lock washer and the
2. Install the 2 unions. nut.

Tighten [)] Tighten

Torque: 32 N-m (3.3 kg-m, 24 lb-ft) Torque: 7 N-m (70 kg-cm, 61 Ib-in)

Be
LU AT

Figure 392. Cooler Union Installation Figure 394. Inhibitor Switch Installation

3. Using a screwdriver, bend the tabs of the lock

ATF Temperature Switch washer.
1. Coat the new O-ring with ATF, and install it to NOTICE: Bend at least 2 of the lock washer
the switch. tabs.
CAUTION: Be careful not to damage to the 0-
ring.
O-ring diameters mm (in.)
Inside Wire diameter
O-ring 13.8 (0.543) 1.9 (0.075)
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-105

Contro! Shaft Lever

[a] Tighten

Torque: 13 N-m (1.3 kg-m, 113 Ib-in)

Figure 395. Lock Washer

4. Using the control shaft lever, fully turn the

control shaft lever back and return 2 notches, it
is now in neutral position.
5. Remove the control shaft lever.
Figure 398. Control Shaft Lever
Breather Plug and Hose
1. Coat a new O-ring with ATF, and install it to
breather plug.
2. install the breather plug and hose.

Figure 396. Control Shaft Lever

6. Align the neutral basic line with the switch

groove and tighten the 2 bolts.

fQ] Tighten
Figure 399. Breather Plug
Torque: 13 N-m (1.3 kg-m, 113 Ib-in)

Speedometer Driven Gear Assy

1. Coat the new O-ring with ATF, and install it to
the speedometer sleeve.
CAUTION: Be careful not to damage the O-
ring.
O-ring diameter mm (in.)
Inside Wire diameter
1. Neutral O-ring 18.7 (0.736) 2.6 (0.102)
Basic Line
2. Switch
Groove

Figure 397. Neutral Basic Line

7A4-106 AUTOMATIC TRANSMISSION OVERHAUL

2. Install the speedometer driven gear to the

speedometer sleeve with the clip.
3. Install the speedometer driven gear assembly to
the extension housing with the bolt.

RQ] Tighten

Torque: 12 N-m (1.2 kg-m, 104 Ib-in)

°C

Figure 400. Speedometer Driven Gear Installation

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-107

SPECIFICATIONS
SERVICE DATA

Pump body bushing inside STD | 42.050 to 42.075 mm | 1.6555 to 1.6566 in.
diameter Limit 42.13 mm 1.6587 in.
; STD | 24.000 to 24.021 mm | 0.9449 to 0.9467 in.
Oil Pump Front —— ; :
Pump cover bushing Limit 24.070 mm 1.9476 in.
inside diameter Rear | STD | 26.500 to 26.521 mm | 1.0433 to 1.0441 in.
Limit 26.57 mm 1.0467 in.
O/D input shaft thrust clearance STD 0.40 to 0.90 mm 0.0157 to 0.0354 in.
(O/D planetary gear) Limit 0.90 mm 0.0345 in.
0.8 mm 0.031 in.
Pico shaft thrust bearing race 1Omm 0.039 in.

1.4mm 0.0565 in.

4.6 mm 0.181 in.
; 4.77 mm 0.188 in.
O/D Planetary O/D direct ciutch flange thickness 194 mm 0.4104 in
Gear and
Direct Clutch 5.11 mm 0.201 in.
Piston stroke 1.80 to 2.00 mm 0.0709 to 0.0787 in.
O/D direct clutch drum bushing STD | 26.500 to 26.521 mm | 1.0433 to 1.0441 in.
inside diameter Limit 26.57 mm 1.0461 in.
O/D planetary gear bushing inside | STD | 12.000to 12.018mm | 0.4724 to 0.4731 in.
| diameter Limit 12.07 mm 0.4752 in.
Planetary piston gear thrust STD 0.20 to 0.59 mm 0.0079 to 0.0232 in.
clearance Limit 0.80 mm 0.3165 in.
Piston stroke 1.25 to 1.85 mm 0.0492 to 0.0728 in.
O/D Brake oo, ; STD | 33.100 to 33.150 mm 1.3031 to 1.305 in.
O/D case bushing inside diameter —
Limit 32.20 mm 1.3071 in.
Input shaft thrust clearance STD 0.30 to 0.70 mm 0.0118 to 0.0276 in.
(forward clutch hub) Limit 0.70 mm 0.0276 in.
0.9 mm 0.0365 in.
1.2mm 0.047 in.

input shaft spacer thickness 1.5mm 0.059 in.

1.8mm 0.071 in.
Front Clutch ;
2.1mm 0.083 in.

Piston stroke 3.93 to 4.23 mm 0.1547 to 0.1665 in.

1.8mm 0.071 in.
2.0 mm 0.079 in.
Front clutch plate thickness 3D mm 0.084 in.

2.4mm 0.094 in.

7A4-108 AUTOMATIC TRANSMISSION OVERHAUL

Piston stroke 2.00 to 2.20 mm 0.0790 to 0.0866 in.

4.6mm 0.181 in.
Rear Clutch . 4.8mm 0.189 in.
Rear clutch flange thickness - :
5.0 mm 0.197 in.
5.2mm 0.2065 in.
STD 0.30 to 0.70 mm 0.0118 to 0.0276 in.
Center support thrust clearance — :
Limit 0.90 mm 0.0345 in.
1.6mm 0.059 in.
1.8 mm 0.071 in.
Center support thrust washer thickness 2.imm 0.083 in.
24mm 0.094 in.
2./mm 0.106 in.
Piston stroke 1.86 to 2.06 mm 0.0732 to 0.0811 in.
Second Brake

diameter Limit 35.08 mm 1.3811 in.

Front planetary sun gear bushing STD | 25.500 to 25.521 mm | 1.0039 to 1.0048 in.
inside diameter Limit 25.57 mm 1.0067 in.
5.0 mm 0.197 in.
; 5.2 mm 0.205 in.
Second brake flange thickness : -
5.4 mm 0.213 in.
5.6 mm 0.220 in.

Planetary | Output shaft bushing inside STD | 17.000 to 17.021 mm | 0.6693 to 0.6701 in.
Gears, One- | diameter Limit 17.07 mm 0.6720 in.
way Clutch

Shaft clearance Limit 0.75 mm 0.0295 in.

Piston stroke 3.3 to 3.8 mm 0.130 to 0.150 in.
First and 6.65 mm 0.2618 in.
Reverse Brake] First and reverse brake flange thickness 7.05 mm 0.2776 in.
7.45 mm 0.2933 in.

Parking Lock
Parking lock pawl bracket distance 49.76 to 49.86 mm 1.959 to 1.963 in.
Pawl

Upper Valve Check ball diameter 6.4 mm 0.252 in.

Body

Check ball diameter 8.7 mm 0.343 in.

“4 Free length 14.0 mm 0.551 in.

Lower Valv@ | Check ball spring 8
Body Outer diameter 9.8mm 0.386 in.
Pressure relief valve Free length 24.0 mm 0.945 in.

spring Outer diameter 8.2 mm 0.323 in.

 AUTOMATIC TRANSMISSION OVERHAUL 7A4-109

Pistons and Springs Specifications

Mark Piston diameter Spring Free length / Outer Diameter Spring Color
mm (in.) mm (in.) mm (in.)
Bo 35.9 (1.413) 67.9/21.1 (2.673
/ 0.831) White
66.0
/ 25.1 (2.598
/ 0.988) Yellow
Bi 43.9 (1.728)
30.4 / 11.0 (1.197 / 0.433) Yellow
Cr 34.4 (1.354) 93.3 / 17.7 (3.673 / 0.697) Red
Ce 39.9 (1.571) 81.8 / 22.4 (3.220 / 0.882) Beige
7A4-110 AUTOMATIC TRANSMISSION OVERHAUL

FASTENER TORQUES
Part tightened Nem lb-ft (Ib-in) kg-m (kg-cm)
Oil Pump cover x Oil purnp body 21 15 2.4
Upper valve body x Lower valve body 5.5 4 56
Manual detent spring x Lower valve body 5.5 (47) (55)
Parking lock pawi bracket x Extension housing 19 14 1.9
Ci accumulator cover x Transmission case 8 (69) (80)
Transmission case x Extension housing 37 a7 3.8
Center support set bolt 25 18 2.5
Oil pan x Transmission case / (61) (70)
Transmission case x Transmission housing 64 AT 6.5
ATF temperature sensor x Transmission case 25 18 2.5
Oil cooler union x Transmission case 29 22 3.0
inhibitor switch x Transmission case 12.5 (78) (130)
inhibitor switch x Manual vaive shaft 7 (61) (70)
Control shaft x Transmission case 12.5 (78) (130)
Oil pump x Transmission case 25 18 20
Valve body x Transmission case 10 (87) 1.0
Solenoid valve x Valve body 10 (87) 1.0
Oil strainer x Valve body 10 (87) 1.0
Drain plug x Oil pan a? 20 2.8
Speedometer sleeve lock plate x Transmission case 12.5 (78) (130)
Speed sensor x Transmission case 8 {69) (80)
Solenoid wire x Transmission case 8 {69) (80)
PTO cover x Transmission case 15 1 1.5
 AUTOMATIC TRANSMISSION OVERHAUL 7A4-111

SPECIAL TOOLS
TOOL NO. ier TOOL NO.
ILLUSTRATION TOOL NAME ILLUSTRATION TOOL NAME

SS J-37228 _ a J-44166
Oil Pan Seal Cutter eel Plate

J-44160
Jedd 167
on No.2 Piston Spring No.1 Measure Termial
“oe Compressor

J-44161
J-44168
——_ No.3 Piston Spring No.2 Measure Termial
&9 Compressor

J-44162
hohe 169
AL No.1 Piston Spring Extension Bar
Compressor

J-44163 J-44170
Oil Pump Oil Seal Installer Oil Purnp Remover

seh PA
3 J-44164 Lever Shaft Oil Seal
a Handle installer

J-44165
Rear Bearing Installer
MEMO
 MANUAL TRANSMISSION 7B1-1

SECTION 7B1

MANUAL TRANSMISSION (MXA)

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE
DeSCription .........cssscceessssessssusnesssnessenesseensersnseusesoeaeesenteneserseoneereneseueunscneeesansesansensceaeatrsensesssaeenesesessnesnssnieassents 7B1i- 2
Diagnosis Of Manual TransSmiSSion..........cssccuccsscessnsccesecnsssesnsesesaseeraceneneuanecsacaesantsansersnenenastnansusonenneenenans 7Bi- 2
On-Vehicle ServiCe .........cccsccssesrssesessessserseessvssssresuusenerenevarenness sateeeseaneseatonseeesansaseneuseneasessersesesentasesounesseenieaat 7B1- 6
Transmission Oil Level CHeCK.........cccsscsscseressscsersanserernnscessancnrnserscenseecausvsnsenassneanesineaeseeanenenonaaerarantons® 7Bi- 6
Changing Transmission Oiil ..........::scsesssssssessersirenrensensscosscassssesoenssoensnsescaeanessnenneatannensecusnsgensnnentennnonassoae® 7Bi- 6
Gearshift Lever Replacement .........:cccssesesssessestsensuarsvenvsrsvsnuseesceronsmnsacensesecsneveesensepencossstesnasenseasuseenenas 7Bi-+ 6
Gearshift Cable AdjuStment...........ccccssssescsneseresssessnessentusianscpeeceusuenesseausestensesatnassecnatsossanaesegesseaisenerserenaas 7B1- 7
Gearshift Cable Replacement.........:c0ccssssssusennnenssssconsressenestezes se densaneausnerssenseucnorsausoranreraeetaensecuecennacene 7B1- 8
Vehicle Speed sensor driven Gear Repiacement........ snseensnanenseaanesasssussensaaevesenueneeeastasensntaccateouerseasueseenace 7B1-10
Rear Cover Gasket Replacement ...........:.scssscssecsesecesssnsesseesacssnuseccenserasesensesanenenesennrsecansansorserseepnennen 7Bi-10
Vehicle Speed sensor Drive Gear Replacement .........0.:ceccesssrssssmsansassscnenstessnesnersesenecenseeninoessenceaeas 7TBi-13
Rear Oil Seal Replacement ...........0:ccssssrsanserenesessensennsereens ssenseenusaantanssueausavarsousensesasananaussorarneesetads 7B1-14
Transmission Assembly Replacement ..........ccsesenacevarsensvesuseesssssnemeessesssausnessecsaensoutonsasesscauensnaeasnnaneas 7B1-16
Front Oil Seal Replacement ..........:secccceeneraees sanaeenoeuoqnaassaesssneedsnassbaseadaneusananeeaoussaauonsonstiaqausevanuonasenseanse 7B1-19
Control Box Gasket Replacement.........:ccscmsencrsres saenedesaausaenseesaedeneseusnndaseeaeasunvaneseeavauvoneusaseaetaneessasanmnanens 7B1-20
Unit Repaiir..........csssccssssssesseserssenens sateaessononssanonasunranaususaneassassnsepeanecessunenaesunedousnseuacedennaedsayseassnecsersnensedcatseneegs 7Bi-22
Major Parts ASSOMDIieS ...........:cscsssseesserersserenerennsccsesnencensensnesscntentnuaaeeaneaseuseneseananetsnneueccnanseuarsananennanees 7B1-22
Input Gear Shaft, Mainshaft and Countershaft Assemblies snenaaenesana suas consanenenaaucsuaroesonansateeersnsennayaeancanas 7B1-30
Control BOX ASSEMDIy .........scsesseensseeeessssersuscacesenseiuensesessesersnueeenestesnensersesensasinaracenteonenasansaacsensacenestenacas 7Bi-40
Specifications...........cssecssernecsensrerenssesesnetnesesuseesonsnsesonennasecsueecnunnsaraueneees passeeeessscucsanessataneaaouscansoennventavannnoase 7B1-46
Fastener TOrques...........eccssssosersonssosensarsevsensneesseensesisnssnssnsnasennnenscreonsersnsaacoesaniusatensnemineurestanaeneane eovensueeas 7B1-46
Special TOOINS.........sccceceecsseceseecsensesensaseseenseeensaneecsnenasnerasensnses Lounetusensusensnauceseasnasenonsasosssseneaeeeseensnessennatsessess 7B1-47
7B1-2 MANUAL TRANSMISSION

DESCRIPTION

The transmission is part of the drive line and is line slower than engine speed. in high gear, many
located behind the clutch assembly. Its job is to transmissions will turn the drive line at the same
control the torque, or turning force, from the clutch speed as the engine.
through a series of gears. These gears then A manual transmission is one that is operated
transmit the torque to the vehicle driving wheels. physically by the driver to change gears. The MXA-
The transmission increases engine torque to start 5C transmission has five forward speeds and one
the vehicle moving. reverse. First through fifth gears are synchromesh.
In lower gears, the transmission turns the drive A gearshift lever is used to shift gears (figure 1).

4th 3rd 2nd ist Rev.

Figure 1. MXA-5C Transmission

DIAGNOSIS OF MANUAL TRANSMISSION

The following diagnosis information is to be used transmission model may have a different correction
only as a guide to locating a transmission problem. for the same probiem.
Corrective procedures are not included, as each
 MANUAL TRANSMISSION 7B1-3

DIAGNOSIS OF MANUAL TRANSMISSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Walking or Jumping 1. Improperly adjusted shift linkage. 1. Acjust.

Out of Gear 2. Shift rod detent groove notches 2. Replace shift rod.
worn.
3. Shift arm pads or groove in sliding 3. Replace.
sleeve worn excessively.
4. Shift rod bent or sprung out of 4, Replace.
line.
5. Worn taper on clutch gear teeth. 5. Replace.
6. Shift arm pads not square with 6. Replace.
shift rod bore.
7. Excessive end play in drive gear, 7. Replace worn or loose parts.
mainshaft or countershaft.
8. Thrust washers or faces worn 8. Replace or install.
excessively, or missing.
9. Shift rod detent springs broken. 9. Replace.

Sticking in Gear 1. Clutch linkage improperly 1. Adjust.

adjusted.
2. Improperly adjusted shift linkage. 2. Adjust.
3. Sliding sleeve tight on splines. 3. Free up. Replace worn parts.
4. Misaligned mainshaft or 4, Align.
countershaft.
5. Chips wedged between spline of 5. Remove and lubricate splines.
clutch hub and sleeve.

Noise in Gear 1. Worn or rough mainshaft rear 1. Replace.

bearing.
2. Worn speedometer gears. > @. Replace.
3. Rough, chipped or tapered sliding : 3. Replace.
gear teeth.
4. Excessive end play of mainshaft | 4. Replace worn or loose parts.
gears.

Oil Leaks 1. Oil level too high. 1. Drain to correct level.

2. Welch “seal” plugs loose or 2. Tighten or replace.
missing.
3. Wrong lubricant in unit. 3. Use correct lubricant.
4. Oil drain-back opening in 4, Tighten or replace.
transmission case.
§. Defective or improperly installed 5. Replace or install properly.
gaskets.
6. Seals defective or omitted from 6. Replace or install.
bearing caps.
7. Cracks or holes in castings. 7. Repair or replace.
8. Transmission breather omitted, or 8. Replace or unplug.
plugged internally.
9. Drain or filler plugs loose. | 9. Tighten.
10. Housing bolts ioose or missing. 10. Tighten or replace.
11. Screw-back threads in 11. Replace.
transmission case.
7B1-4 MANUAL TRANSMISSION

DIAGNOSIS OF MANUAL TRANSMISSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Bearing Failures . Dirty bearing, dirt in lubricant or 1. Clean.

poor installation procedure.
2. Acid etch due to water or other 2. Drain and install new lubricant.
contaminants in lubricant.
3 Varnish or sludge coated because | 3. Use proper lubricant and change oil at
the wrong type or grade of scheduled intervals.
lubricant was used. Prolonged oil
change.
4, Fatigue spots, cracks or spalling. 4. Don’t overload vehicle. Be sure proper
Vehicle overloaded or engine engine is installed in vehicle.
torque too high for transmission.
5. Straw- or blue-colored metal. Lack | 5. Fill to proper level. Replace loose or
of lubricant or internal parts worn parts.
interference.
6. Rough rotation or frozen races. 6. Replace.
improper installation-brinelling
bearing, improper fit of shafts or
bore.
7. Rust-colored scoring. Fretting 7. Replace worn parts. Drain and add new
corrosion. fluid.
8. Broken retainer or cage causing 8. Replace.
vibration.
9. Chips in bearing. Look for 9. Repair or replace. Drain oil and add new
clashing clutch gear teeth or other lubricant.
internal damage.

Noisy Operation 1 Fan out of balance or blades are 1. Replace or straighten.

(Noise Arising bent.
Outside 2. Defective vibration damper. 2. Replace.
Transmission) 3. Crankshaft out of balance. 3. Machine to achieve balance.
4, Flywheel out of balance. 4. Machine to achieve balance.
5. Flywheel mounting bolts loose. 5. Tighten.
6. Engine rough at idle producing 6. Check engine and fuel system for
rattle in gear train. problem.
7. Clutch assembly out of balance. 7. Balance.
8. Engine mounts loose or broken. 8. Tighten or replace.
9. Power take-off engaged. 9. Disengage.
10. Universal joints worn out. 10. Replace.
11. Propeller shaft out of balance. 11. Balance.
12. Universal joint angles out of plane | 12. Adjust.
or at excessive angle.
13. Center bearings in drive line dry— | 13. Lubricate or align.
not mounted properly.
14. Wheels out of balance. 14. Balance.
15. Tire treads humming or vibrating 15. Replace tires or balance them
at certain speeds.
16. Air leaks on suction side of 16. Repair leak.
induction system --- especially
with turbochargers.
 MANUAL TRANSMISSION 7B1-5

DIAGNOSIS OF MANUAL TRANSMISSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Noisy Operation 1. Growl, hum or grinding because 1. Replace.

(Noise Arising in of worn, chipped or cracked
Transmission) gears.
2. Detective bearing causing hissing, 2, Repiace.
thumping or bumping.
3. Metallic rattles in transmission. 3. Replace or adjust backlash.
Engine torsional vibrations,
deiective or faulty injector
excessive backlash in Power
Take Off mounting.
4. Metallic rattles caused by 4. Replace with proper lubricant or add to
improper lubricants, or lack of the proper level.
lubrication.
5. Free running gears seizing on 5. Free up thrust face.
thrust face or inside diameter
causing a squeal at high speeds.
6. Gear seizure at high speed 6. Free up gear(s).
accompanied by a loud squealing
noise.
7. Floating gear on mainshaft has 7. Free up gear(s).
seized.
8. Vibration in power train (engine, 8. Balance or repair.
propeller shafts, joint angle, rear
axie, differential)
9. Lack of backlash between mailing 9. Adjust backlash.
gears, or improper shimming of
Power Take Off units producing a
gear whine.

Noise in Neutral 1. Defective anti-lash plate. 1. Replace.

2. Worn fiywheei pilot bearing. 2. Replace bearing.
3. Worn or scored countershaft 3. Replace.
bearings.
4. Excessive end play in 4. Replace worn or loose parts.
countershait or reverse idler gear.
5. Worn or rough reverse idler gear. 5. Replace.
6. Bent or worn countershait. 6. Replace.
7. Excessive backlash in gears. 7. Adjust or replace worn or loose parts.
8. Incorrect clutch linkage 8. Adjust.
adjustment.
9. Worn mainshaft pilot bearing. 3. Replace.
10. Scuffed gear tooth contact 10. Check gear tooth pattern and align.
surface. Replace gear if worn.
11. insufficient lubrication. 11. Add lubricant to proper level.
12. Incorrect grade of lubricant. 12. Use recommended grade.
13. Worn damper spring of cluich 13. Replace.
disc.
7B1-6 MANUAL TRANSMISSION

ON-VEHICLE SERVICE
TRANSMISSION OIL LEVEL CHECK CHANGING TRANSMISSION OIL
Measure (Figure 2) Drain the transmission oil after driving the vehicle.
The oil will drain more completely.
e Block the vehicle so it cannot move.
* Block the vehicle so it cannot move.
« Disconnect the ground cable from the battery
¢ Disconnect the ground cable from the battery
negative (~) pasl.
negative (-) post.
1. Remove the filler plug (2) from the transmission
1. Remove the drain plug.(3) Provide a pan to
case (1).
catch oil.
2. Check oil fevel
2. Install the drain plug and tighten.
e Add lubricant to within 0 to 10 mm (0 to 0.4 in)
of bottom edge of the filler hale if necessary
ry [A] Tighten
(igure.2).
* Drain plug to 49 N-m (89 Ib-ft)
GAUTION: Use ENGINE OIL SAE 5W-30 for the
transmission case.
3. Remove the filler piug (2).
4. Fill the transmission case to level of the filler
3. Install the filler plug.
plug opening.
Tighten CAUTION: Use ENGINE OIL SAE 5W-30 for the
transmission case.
> Filler plug to 49 N-m (39 ib-ft)
5. Install filler plug and tighten.
« Connect the battery ground cable and remove
the wheel blocks. [] Tighten
« Filler plug to 49 N-m (39 Ib-ft)
2
- Connect the battery negative cable and
“S

remove the wheel blocks.

NN
GEARSHIFT LEVER REPLACEMENT

Remove or Disconnect (Figure 3)

« Block the vehicle so it cannot move.

« Disconnect the ground cable from the battery
negative (--) post.
1. Gearshift lever knob (4).
2. Gover assembly (5).
» Remove the fixing screw (6) and 3 clips (7).
8 an 3. Shift cabie (8) and select cable (9).
1. Transmission Case
« Disconnect the cables from the gearshift
2. Filler Plug
lever.
3. Drain Plug « Remove the C-clips (10) and disconnect the
cables from bracket.
Figure 2. Transmission Oil Level 4. Gearshift lever assembly (11).
« Remove 2 screws (12) and 2 nuts (13).
 MANUAL TRANSMISSION 7B1-7

GEARSHIFT CABLE ADJUSTMENT

After cannection of the select cable and the shift

cable, confirm if shift operation Is performed
smoothly. if any dragging or Improper stroke is
present, check and adjust In accordance with the
procedures shown below.

Measure (Figure 4)

Set the transmission in the neutral position, then

confirm if the dimension between the center of the
shift lever play and the instrument center cluster is
within the 283 + 15 mm (11.1 + 0.6 In) . If the
dimension is out of the reference value, adjust as
required.

. Gearshift Lever Knob & m9

nar

. Gover Assembly
. Screw
Cena

. Clip
. Shift Cable
. Select Cable
10. C-Clip
11. Gearshift Lever Assembly
12. Screw Figure 4. Shift Lever Position Check
13. Nut

Figure 3. Gearshift Lever Replacement Adjust (Figures.3 , 4 and 5)

» Biock the vehicle so it cannot move.
| install or Connect (Figure 3) - Disconnect the ground cabie from the battery
negative (~} post.
1. Gearshift lever assembly (11). 1. Remove the gearshift lever knob (4).
2. Shift cable (8) and select cable (9). 2, Remove the cover assembly (5).
+ Connect the cables to the gearshift lever. 3. Disconnect the shift cable (8) and the select
« Install the C-clips (10) to the bracket. cable (9) on the gearshift lever side.
4, Set the transmission in the neutral position,
[A] adjust then adjust the dimension between the center of
the shift lever piay and the instrument center
» When connecting the shift cable and select cluster to the 283 + 15 mm (11.1 + 0.6 in).
cable to the gearshift lever, adjust the cable. (figure 4).
Refer to GEARSHIFT CABLE ADJUSTMENT 5. Loosen the lock nut (14) of the shift cable (8)
in this section. and the select cable (9), then turn the bail joint
3. Gover assembly (5). (14) or turnbuckle (16) as necessary for
4, Gearshift lever knob (4). respective pins.
6. Fasten the lock nut (15) with specific torque.
: Connect the battery negative cable and
remove the wheel blocks. Tighten
* Lock nuts to 6 N-m (2 Ib-in)
7B1-8 MANUAL TRANSMISSION

7. Install the cover assembly (5).

8. Install the gearshift lever knob (4).

* Gonnect the battery ground cable and remove

the wheel blocks.

14 15 8

-_ Sea Aaannnii Se
Shift Lever Side a

8. Shift Cabie 15. Lock Nut

9. Select Cable 16. Turnbuckle
4. Gearshift Lever Knob 10. C-Clip
14. Ball Joint
5. Cover Assembly 11. Gearshift Lever
6.Screw Assembly
Figure 5. Gearshift Cable (1) 7.Clip 17. Grommet Retainer
8. Shift Cable 18. Grommet Seal
9. Select Cable 19. Grommet
GEARSHIFT CABLE REPLACEMENT
Figure 6. Gearshift Cable (2)
[es] Remove or Disconnect (Figures 6, 7 and 8)

¢ Block the vehicle so it cannot move.

« Disconnect the ground cable from the battery r 20
negative (—) post.
ay <? wars
. Gearshift lever knob (4).
-

. Cover assembly (5). oO

Wh

. Shift cable (8) and select cable (9).

¢ Disconnect the shitt cable and select cable n | Lda f
from gearshift lever.
b. 10
* Remove the C-clips (10) and disconnect the
yf 8 7 Lf 5 oO \
cables from gearshift lever bracket.
« Remove the grommet retainer (17), grommet — ff DOG ES 8
seal (18) and grommet (19).
* Tilt the cab. O

+ Disconnect the shift cable and the select

cable on the transmission side. © ©) ° (oOo 1O
+ Remove the C-clips (10) and disconnect the
8.
|
Shift Cable 10.
|
C-clip
xy 9
shift cable and the select cable from the
9. Select cable 20. Bracket
bracket.(20).
» Remove the clips that fix the cables to the Figure 7. Gearshift Cabie (3)
frames or brackets.
« Remove the shift and select cable assemblies.
 MANUAL TRANSMISSION 7B1-9

Se

8. Shift Cable
9. Select Cable
11. Gearshift Lever

Figure 8. Gearshift Cable (4)

o Fasten the cables with C-clips to the brackets
Inspect on the transmission side.
Check the cables for any deformation, damage or : Fasten the cables with C-clips to the gearshift
rust, and also check the sliding portion for any lever bracket.
abnormal condition. « Fasten the cables with clips to the frames and
When there is any abnormal condition found, brackets.
replace it with new one. « Connect the cables to the transmission.
« Install the grommet (19), grommet seal (18)
fe Install or Connect (Figures 6, 7 and 8) and grommet retainer(17).

1. Shift cable (8) and select cable(9). Adjust

« Install temporarily that the shift cable and
select cable. « When connecting the shift cable (8) and the
select cable (9) to the gearshift lever, adjust
[3] Important the cables.
« Never bend the cables to radius less than 450 Refer to GEARSHIFT CABLE ADJUSTMENT
mm (18 in) unless it is necessary to do so for given previously in this section.
2. Cover assembly (5).
wiring purposes. And never bend the cables to
radius less than 180 mm (7 in} even during 3. Gearshift lever knob (4).
wiring.
- Gorinect the battery negative cable and
Install the cables carefully without
unnecessary twisting the cable boots. remove the wheel blocks.
 7B1-10 MANUAL TRANSMISSION

VEHICLE SPEED SENSOR DRIVEN GEAR Install F

.
REPLACEMEN T x nstail or Connect (Figures 9, and 10)

; ; 1. Vehicle speed sensor driven gear assembly (6).

[es] Remove or Disconnect (Figures 9 and 10) 2. Fixing bolt (5).
* Block the vehicle so it cannot move. .
* Disconnect the ground cable from the battery Q] Tighten
negative (-) post. . Fivi
1. Harness clip (1) and protector (2). Fixing bolt to 15 Nem (11 Ib-ft)
2. Wiring connector. : . .
3. Vehicle speed sensor (3) with key rod (4). 3. Vehicle speed sensor (3) with key rod (4).
4. Fixing boit (5). .
5. Vehicle speed sensor driven gear assembly (6). QI Tighten
- Vehicle speed sensor to 25 N-m (18 lb-ft)
1. Clip
2. Protector 4, Wiring connector.
5. Protector (2) and harness clip (1).

« Connect the battery negative cable and

remove the wheel blocks.

REAR COVER GASKET REPLACEMENT

| Remove or Disconnect (Figures 11 - 15)

¢ Block the vehicle so it cannot move.

* Disconnect the ground cable from the battery
negative (-) post.
» Raise vehicle and support with suitable safety
stands.
1. Propeller shaft (figure 11).
» Reference mark the flange yoke (3) to the
parking brake drum (4).
* Disconnect the propeller shaft (2) at flange
yoke (3).
+ Put aside the propeller shaft and tie it to the
frame so it does not interfere with servicing
work.

3 .

; 4
3. Vehicle Speed Sensor
4. Key Rod
5, Fixing Bolt ; Reference Mark
6. Vehicle Speed Sensor Driven Gear Assembly
1. Transmission 3. Flange Yoke
Figure 10. Vehicie Speed Sensor Driven Gear 2. Propeller Shaft 4. Brake Drum

Figure 11. Removing Propeller Shaft

 MANUAL TRANSMISSION 7B1-11

2. parking brake drum (4) (figure 12).

- Remove the screw and the adjust hole cover.
+ It may be necessary to back off the shoe
adjuster.
3. Lock nut (5).
* Make sure to raise the staking of the lock nut,
then remove the lock nut.
4. Drive coupling (6) (figure 13).
* Remove drive coupling using the puller

8. Joint Cover
9. Joint
10. C-clip
11. Parking Brake Cable

Figure 14. Parking Brake Cable Joint

6. Parking brake assembly

7. Vehicle speed sensor wiring connector.
8. Vehicle speed sensor and vehicle speed sensor
driven gear assembly
Refer to VEHICLE SPEED SENSOR DRIVEN
4. Parking Brake Drum GEAR REPLACEMENT given previously in this
5. Lock Nut section.
9. Rear cover (12) (figure 15).
Figure 12. Removing Parking Brake Drum * Remove 7 fixing bolts. Tap the rear cover with
a copper or plastic hammer to remove it. The
rear cover is provided with lugs for hammering
both side.
» Remove the oil seal using the screw driver.

CAUTION: Take care not to damage the sealing

seat of the rear cover with screwdriver.
If the rear cover has been removed, the oii seal
must be replaced with new one.

6. Drive Coupling
7. Parking Brake Assembly

Figure 13. Removing Drive Coupling

5. Parking brake cable joint (figure 14).

« Move the joint cover (8) and disconnect the
cable joint.(9).
- Remove the C-clip (10) then disconnect the 12. Rear Cover
cable (11) from the bracket.
Figure 15. Removing Rear Cover
7B1-12 MANUAL TRANSMISSION

x Instali or Connect (Figures 16, 17 and 18) [3] Important

Tool Required: « Install the rear cover on the transmission case

J-41734 Oil Seal Installer within 30 minutes after liquid gasket
1. Rear cover (figures 16 and 17) application.
* Apply engine oil to the new oil seal outer
circumference and apply multi-purpose grease « Install the rear cover and tighten.
to the oil seal lip.
« Use the oil seal installer install the oil seal to [RJ Tighten
the rear cover.
¢ Rear cover to 40 N-m (30 Ib-ft)

. Vehicle speed sensor and vehicle speed sensor

driven gear assembly
Refer to VEHICLE SPEED SENSOR DRIVEN
GEAR REPLACEMENT given previously in this
section.
. Vehicle speed sensor wiring connector.
. Parking brake assembly.

Tighten

« Parking brake bolt to 83 N-m (61 ib-ft)

. Parking brake cable joint.

“On

12. Rear Cover . Drive coupling (6) (figure 18).

13. J-41734 . O-ring (14) and conical washer (15) (figure 18).
» The conical washer is to be set up with its
Figure 16. Rear Oil Seal Installation identification groove to the nut sice.
. New lock nut (5) (figure 18).

CAUTION: Do not reuse the lock nut.

+ Apply the engine oil to the setting face of the

new lock nut and tighten.

Tighten
* Drive coupling lock nut to 226 N-m (166 lb-ft)

* Stake nut by chisel, align the lock nut with the

V-shaped groove at the tip of the main shaft,
and stake the nut lip partion by using a chisel.
(Round edge 1 mm (0.04 in) x 60°).
* As shown figure 18, be sure to stake the nut
lip so that the clearance between the V-
shaped groove portion at the tip of the main
12. Rear Cover shaft and the staked up lip (A) is less than 1.5
G. Liquid Gasket mm (0.06 in), and the staking length (B) is 5
mm (0.2 in) or more.
Figure 17. Rear Cover installation
NOTICE: Be sure to confirm that there is no
+ Remove moisture and oil etc. on the mating crack at the staked portion of the lock nut after
face. staking.
* Apply a 2 mm (0.1 in) bead of the liquid
gasket (G) Three Bond 1215 or equivalent to
the rear cover surface (figure 17).
 MANUAL TRANSMISSION 781-13

VEHICLE SPEED SENSOR DRIVE GEAR

REPLACEMENT
15
| Remove or Disconnect (Figure 19)
8 More than « Block the vehicle so it cannot move.
5.0mm
« Disconnect the ground cable from the battery
~ (0.2in)
negative (—) post.
* Raise vehicle and support with suitable safety
stands.
More than 1. Transmission rear cover.
5.0mm
B .2in) Refer to TRANSMISSION REAR COVER
GASKET REPLACEMENT given previously in
this section.

a 2. Vehicle speed sensor drive gear

1. Transmission
(2).

2. Vehicle Speed Sensor Drive Gear

Less than
15mm
(0.06in)

Less than
15mm
A (0.06in)

5. Lock Nut 14. O-ring

6 Drive Coupling 15. Conical Washer

Figure 18. Drive Coupling and Lock Nut

9. Parking brake drum.

* Adjust the parking brake after installation.
1) Rotate the brake drum to align the adjust
hole with the adjuster.
2) Move the camshaft lever from side to side
several times to center the brake shoes. Figure 19. Vehicle Speed Sensor Drive Gear
3) Insert a screwdriver into the hole and rotate
the adjuster by pushing it upward until the
shoes drag on the drum. | install or Connect (Figure 19)
4) Back off the adjuster 30 notches. 1. Vehicle speed sensor drive gear (2).
* Install the adjust hole cover. 2. Transmission rear cover.
Refer to TRANSMISSION REAR COVER
Tighten GASKET REPLACEMENT given previously in
this section.
* Adjust hole cover bolt to 8 N-m (69 Ib-in)
« Connect the battery negative cable and
10. Propeller shaft. remove the wheel blocks.
» Line up reference mark. * Remove the safety stands.
Tighten
« Propeller shaft bolt to 103 N-m (76 lb-ft).

* Connect the battery negative cable and

remove the wheel blocks.
» Remove the safety stands.
 7B1-14 MANUAL TRANSMISSION

REAR OIL SEAL REPLACEMENT 2. parking brake drum (4) (figure 21).
* Remove the screw and the adjust hole cover.
[es] Remove or Disconnect (Figures 20- 25) « It may be necessary to back off the shoe
adjuster.
* Block the vehicle so it cannot move. 3. Lock nut (5).
» Disconnect the ground cable from the battery * Make sure to raise the staking of the lock nut,
negative (-) post. then remove the lock nut.
* Raise vehicle and support with suitable safety 4. Drive coupling (6) (figure 22).
stands. « Remove drive coupling using the puller
1. Propeller shaft (figure 20).
* Reference mark the flange yoke (3) to the
parking brake drum (4).
* Disconnect the propeller shaft (2) at flange
yoke (3).
* Put aside the propeller shaft and tie it to the
frame so it does not interfere with servicing
work.

6. Drive Coupling
7. Parking Brake Assembly

Figure 22. Removing Drive Coupling

5. Parking brake cable joint (figure 23).

1. Transmission » Move the joint cover (8) and disconnect the
2. Propeller Shaft cable joint.(9).
3. Flange Yoke « Remove the C-clip (10) then disconnect the
4. Brake Drum cable (11) from the bracket.
6. Parking brake assembly.
Figure 20. Removing Propeller Shaft

8. Joint Cover ____ ©

9. Joint SI
10. C-clip
11. Parking Brake Cable
4. Parking Brake Drum
5. Lock Nut Figure 23. Parking Brake Cable Joint
Figure 21. Removing Parking Brake Drum
 MANUAL TRANSMISSION 7B1-15

7.Oil seal. * Apply the engine oil to the setting face of the
* Use the screwdriver to remove the oil seal new lock nut and tighten.
from the rear cover.
Tighten
CAUTION: Take care not to damage the sealing
seat of the rear cover with screwdriver. + Drive coupling lock nut to 226 N-m (166 lb-ft)

25) or Connect (Figures 20, 21, 23, 24 and * Stake nut by chisel, align the lock nut with the
V-shaped groove at the tip of the main shaft,
Tool Required: and stake the nut lip portion by using a chisel.
J-41734 Oil Seal Installer (Round edge 1 mm (0.04 in) x 60°).
1. Oil seal. * As shown figure 25, be sure to stake the nut
* Apply engine oil to the new oil seal outer lip so that the clearance between the V-
circumference and apply multi-purpose grease shaped groove portion at the tip of the main
to the oil seal lip. shaft and the staked up lip (A) is less than 1.5
* Use the oil seal installer install the oil seal to mm (0.06 in), and the staking length (B) is 5
mm (0.2 in) or more.
the rear cover.
NOTICE: Be sure to confirm that there is no
crack at the staked portion of the lock nut after
staking.

13 "4

Me f More than
T §.0mm
| | (0.2in)

é } More than
J

R
i 5.0mm
* B (0.2in)}
12. J-41734
al
Figure 24. Rear Oil Seal Installation
5
2.Parking brake assembly.
—

Tighten
Less than
15mm
* Parking brake bolt to 83 N-m (61 Ib-ft) (0.06in)

Less than
3. Parking brake cable joint (figure 23). 1.5mm
4, Drive coupling (6) (figure 25). (0.06in}
5. O-ring (13) and conical washer (14).
¢ The conical washer is to be set up with its 5. Lock Nut 13. O-ring
identification groove to the nut side. 6 Drive Coupling 14. Conical Washer
6. New lock nut (5) (figure 25).
Figure 25. Drive Coupling and Lock Nut
CAUTION: Do not reuse the lock nut.
7B1-16 MANUAL TRANSMISSION

7. Parking brake drum.

+ Adjust the parking brake after installation.
1) Rotate the brake drum to align the adjust
hole with the adjuster (figure 21).
2) Move the camshaft lever from side to side
several times to center the brake shoes.
3} Insert a screwdriver into the hole and rotate
the adjuster by pushing it upward until the
shoes drag on the drum.
4) Back off the adjuster 30 notches.
« Install the adjust hole cover.

[Q)] Tighten 1. Transmission

2. Propeller Shaft
« Adjust hole cover bolt to 8 N-m (69 Ib-in) 3. Flange Yoke
4. Brake Drum
8. Propeller shaft.
* Line up reference mark (figure 20). Figure 26. Removing Propeller Shaft

FR] Tighten

+ Propeller shaft bolt to 103 N-m (76 ib-ft).

+ Connect the battery negative cable and

remove the wheel blocks.
« Remove the safety stands.

TRANSMISSION ASSEMBLY
REPLACEMENT
| Remove or Disconnect (Figures 26 - 33)

* Block the vehicle so it cannot move.

8. Joint cover
* Disconnect the ground cable from the battery
9. Joint
negative (-) post.
10. C-clip
» Raise vehicle and support with suitable safety
11. Parking Brake Cable
stands.
1. Propeller shaft (figure 26). Figure 27. Parking Brake Cable Joint
+ Reference mark the flange yoke (3) to the
parking brake drum (4). 4. Shift cable and select cable (figure 28).
» Disconnect the propeller shaft (2) at flange « Disconnect the shift cable (12) and select
yoke (3). cable (13) on the transmission side.
- Put aside the propeller shaft and tie it to the 5. Clutch slave cylinder (14) (figure 29).
frame so it does not interfere with servicing + Remove the slave cylinder assembly with the
work. flexible hose attached and then tie it to the
2. Parking brake cable joint (figure 27). frame so that it does not interfere with
« Move the joint cover (8) and disconnect the servicing works.
cabie joint. (9). 6. Middie exhaust pipe (16) and exhaust brake
« Remove the C-clip (10) then disconnect the valve (15) (figure 30).
cable (11) from the bracket.
3. Wiring connector.
* Disconnect the wiring connectors from the
vehicle speed sensor, the neutral switch and
the back-up light switch.
 MANUAL TRANSMISSION 7B1-17

<= ww

‘ fs B 5 10.

_ ES
12
OCo

O() 1 © Qo jy °
10. C-cilip 13. Select Cable 43 15. Exhaust Brake Valve
12. Shift Cable 16. Middie Exhaust Pipe

Figure 28. Gearshift Cable Figure 30. Removing Exhaust Brake Valve

17

14. Slave cylinder 17. Chain or Belt

Figure 29. Removing Clutch Slave Cylinder Figure 31. Transmission Assembly

7. Transmission assembly. * Remove the nuts of the transmission

mounting bracket on the crossmember side.
NOTICE: The exhaust pipe bracket, the gear « Engine and transmission angle may need to
control bracket and the clip are sometimes be adjusted for removal.
installed in the wrong position or direction * Hold the rear section of the engine by the jack
confusedly. To prevent incorrect installation of or hoist.
these parts, put correct installation mark on
them. CAUTION: When lifting the engine by the jack,
use wood biocks to prevent any possible
+ Support the transmission with mission jack. damage to the oil pan.

CAUTION: To prevent the falling of the * Remove transmission fastening boits.

transmission, tie it securely to the mission » Pull out the transmission assembly rearward.
jack with a chain or belt (figure 31). 8. Mounting bracket.
Do not allow transmission to hang
unsupported from clutch. Damage to the
clutch assembly will result.
 7B1-18 MANUAL TRANSMISSION

foe] Install or Connect (Figures 32 and 33)

1. Mounting bracket.

Tighten oN
+ Mounting bracket nut to 69 N-m (51 Ib-ft) i -

2. Transmission assembly.
- Support the transmission with mission jack. ;

CAUTION: To prevent the falling of the

transmission, tie it securely to the mission 17 =
jack with a chain or belt (figure 32). |

- Shift the transmission into high gear. 17. Chain or Belt

- Align the transmission with the engine slope.
* Turn the output parking brake drum to aid Figure 32. Transmission Assembly
clutch spline engagement.
* Instali the clutch housing to flywheel housing
fixing bolts (Figure 33). mm (in)

Tighten 30 (1.2) 35 (1.4)

* Clutch housing to flywheel housing bolt to
46 N-m (34 Ib-ft)

» Rise the engine and the transmission up into

the rear transmission mount.
* Install the engine rear mounting fixing nuts
and boits.

FQ] Tighten

+ Engine rear mounting nuts and bolts to

M10: 40 N-m (30 Ib-ft)
M12: 69 N-m (51 Ib-ft)

3. Exhaust brake valve (15) and Middie exhaust

pipe (16) (figure 30).

[Q] Tighten
- Exhaust brake valve bolt to 17 N-m (12 Ib-ft)
- Middle exhaust pipe bolt to 37 N-m (27 Ib-ft)
18. Clutch Housing
4. Clutch slave cylinder.
, Figure 33. Clutch Housing Bolts Location
FR] Tighten

* Slave cylinder bolt to 19 N-m (14 Ib-ft)

5. Shift cable and select cable.

 MANUAL TRANSMISSION 7B1-19

6. Wiring connector. [oe] Install or Connect (Figures 35 and 36)

« Color of connector.
Back-up light switch: Brown Tool Required:
Neutral switch: Gray J24254 Oil Seal Installer
7. Parking brake cable joint (figure 27). 1. Oil seal.
8. Propeller shaft. « Apply engine oil to the new oil seal outer
» Line up reference mark. circumference and apply multi-purpose grease
to the oil seal lip.
Tighten » Use the oil seal installer to install the oil seal
to the clutch housing (figure 35).
» Propeller shaft nuts to 103 N-m (76 Ib-ft)

* Connect the battery ground cable and remove

the wheel blocks.
« Remove the safety stands.

FRONT OIL SEAL REPLACEMENT

| Remove or Disconnect (Figure 34)

« Block the vehicle so it cannot move.

« Disconnect the ground cable from the battery
negative (~) post.
* Raise vehicle and support with suitable safety
stands.
1. Transmission assembly. 1. Clutch housing
Refer to TRANSMISSION ASSEMBLY 2. J-24254
REPLACEMENT previously in this section.
2 Clutch housing Figure 35. Front Oil Seai Installation
3 Oil seal.
« Use the screwdriver to remove the oil seal
from the rear cover.

1. Clutch housing
G. Liquid Gasket
4. Clutch housing
Figure 36. Clutch Housing
2. Oil Seal

Figure 34. Clutch Housing and Oil Seal 2. Clutch housing.

« Remove moisture and oil etc. on the mating
face.
CAUTION: Take care not to damage the sealing « Apply a2 mm (0.1 in) bead of the liquid
seat of the clutch housing with screwdriver. gasket (G) Three Bond 1215 or equivalent to
the clutch housing surface (figure 36).
 7B1-20 MANUAL TRANSMISSION

[3] important [F] Important

* Install the rear cover on the transmission case + Install the control box assembly on the
within 30 minutes after liquid gasket transmission case within 30 minutes after
application. liquid gasket application.

* Instali the clutch housing to the transmission 2. Transmission assembly.

case and tighten. Refer to TRANSMISSION ASSEMBLY
REPLACEMENT previously in this section.
Tighten
* Clutch housing bolts to 81 N-m (60 Ib-ft)

3. Transmission assembly.
Refer to TRANSMISSION ASSEMBLY
REPLACEMENT previously in this section.

* Connect the battery negative cable and

remove the wheel blocks.
* Remove the safety stands.

CONTROL BOX GASKET REPLACEMENT

| Remove or Disconnect (Figure 37)

* Block the vehicle so it cannot move.

* Disconnect the ground cable from the battery 1. Control box assembly
negative (—) post.
» Raise vehicle and support with suitable safety Figure 37. Removing Control Box Assembly
stands.
1. Transmission assembly.
Refer to TRANSMISSION ASSEMBLY
REPLACEMENT previously in this section.
2. Control box assembly
* Remove the 10 contro! box fixing bolts, and
then prize open the four corners of the control
box with a screwdriver to remove the control
box assembly (figure 37).

fd Install or Connect (Figure 38)

1. Control box assembly

* Remove moisture and oil etc. on the mating
face.
* Apply a 2 mm (0.1 in) bead of the liquid 1. Control Box Assembly
gasket (G} Three Bond 1215 or equivalent to G. Liquid Gasket
the control box surface (figure 38).
* Install the control box to the transmission Figure 38. Control Box Assembly Installation
case and tighten.
* Connect the battery negative cable and
Tighten remove the wheel blocks.
* Remove the safety stands.
« Control box bolt to 20 N-m (14 Ib-ft}
 MANUAL TRANSMISSION 7B1-21

MEMO
7B1-22 MANUAL TRANSMISSION

UNIT REPAIR
MAJOR PARTS ASSEMBLIES

Figure 41. Transmission Major Parts Assembly

 MANUAL TRANSMISSION 7B1-23

— . Parking Brake Drum 12. Mounting Bracket

. Lock Nut 13. Control Box Assembly
WN

. Drive Coupling 14. Countershaft Rear Bearing

Parking Brake Assembly 15. Countershaft Front Bearing
16. Input Gear Shaft Assembly
OAA

. Shift Block Assembly

. Shift Fork and Support Bolt 17. Mainshaft Rear Bearing
. Clutch Housing 18. Mainshaft Assembly
. Vehicle Speed Sensor Driven Gear Assembly 19, Countershaft Assembly
“DOAN

. Rear Cover 20. Reverse idle Gear Shaft

. Vehicle Speed Sensor Drive Gear 21. Reverse Idle Gear
. Spacer

Figure 41. Transmission Major Parts Assembly (Cont.)

9. Rear cover (9).

[eo] Remove or Disconnect + Remove 7 fixing bolts. Tap the rear cover with
Refer to “TRANSMISSION ASSEMBLY a copper or plastic hammer to remove it. The
REPLACEMENT?” earlier in this section.
rear cover is provided with lugs for hammering
both side.
[S] Disassemble (Figures 41- 48) « Use screwdriver to remove the oil seal from
the rear cover.
Tools Required:
J-35700 Bearing Remover CAUTION: Take care not to damage the sealing
J-41735 Bearing Remover seat of the cluich housing.
J-35699 Universal Puller
. Parking brake drum (1}. 10. Vehicle speed sensor drive gear (10) and
« Remove the screw and the adjust hole cover. Spacer (11).
« It may be necessary to back off the shoe 11. Mounting bracket (12).
adjuster. 12. Control box assembly (13).
. Lock nut (2). « Remove 10 control box fixing bolts, and then
- Make sure to rise the staking of the drive prize open the four corners of the control box
coupling lock nut. with a screwdriver to remove the control box
. Drive Coupling (3). assembly (figure 42).
* Remove the drive coupling using the universal
puller.
> Remove the conical washer and O-ring.
. Parking brake assembly.
Ob

. Shift block assembly (5).

. Shift fork and support bolt (6).
sO

. Clutch housing (7).

* Remove the clutch housing from the
transmission case.
- Use screwdriver to remove the oil seal from
the clutch housing.

CAUTION: Take care not to damage the sealing

seat of the clutch housing.
13. Control Box Assembly
. Vehicle speed sensor driven gear assembly (8). 22. Transmission Case
* Remove the vehicle speed sensor with key
rod. Figure 42. Removing Control Box Assembly
« Remove the fixing screw.
> Remove the driven gear assembly.
7B1-24 MANUAL TRANSMISSION

13. Countershaft rear bearing 14. Countershaft front bearing (15).

* Remove the snap ring from the countershaft - Move the countershaft approximately 3 mm
rear bearing. (0.1 in) forward by tapping on its rear end with
* Remove the snap ring from the input gear brass or plastic hammer.
shaft bearing outer circumference. + Remove the snap ring from the countershaft
* Move the countershaft approximately 3 mm front end.
(0.1 in) rearward by tapping on its front end * Set the bearing remover to the snap ring
with brass or piastic hammer (figure 43). groove to remove the front bearing (figure 45).
+ Remove the snap ring from the rear bearing
outer circumference.
+ Set the bearing remover to the snap ring
groove to remove the rear bearing (figure 44).

22. Transmission Case

23. J-35699
24. J-35700

Figure 45. Removing Countershaft Front Bearing

19. Countershaft
22. Transmission Case 15. Input gear shaft assembly (16).
» Remove the input gear shaft bearing outer
Figure 43. Moving Countershaft
race toward front end using a hammer and
soft metal bar.
* Remove the block ring and needle bearing.
16. Mainshaft rear bearing (17).
» Move the mainshaft approximately 3 mm
(0.1 in) rearward by tapping on its front end
with brass or plastic hammer.
* Remove the snap ring and set the bearing
remover io the snap ring groove to remove the
bearing (figure 46).
17. Mainshaft assembly (18).
* Use a strong cord to lift the mainshaft
assembly (figure 47).
18. Countershaft assembly (19).
19. Reverse Idle gear shaft (20) and reverse idle
gear (21).
22. Transmission Case
+ Drive out reverse gear shaft by tapping on its
23. J-35699
front end with suitable and hammer
24. J-35700
(figure 48).
Figure 44. Removing Countershaft Rear Bearing * Be careful not to lose the lock ball.
 MANUAL TRANSMISSION 7B1-25

[a] Assemble (Figures 41, 49 - 56)

a2
NOTICE: For steps 11, 12, 13, 14, 16, 17, 18, 19
Ty _ and 20, see “NOTICE” on page 7B1-1 of this
ne
“We~-A ! section.
\ Sse). [| 24
[3] Important
ay rae] 0
YL f EK | * Clean each part thoroughly.
« When assembling parts, apply clean engine
Np oe oil (SAE 5W-30) to their sliding and mating
sections.
= 22
Tool Required:
17. Mainshaft Rear Bearing 23. J-35699
J-41736 Bearing Installer
22. Transmission Case a4, J-41735
J-35010-A Bearing Installer
J-24254 Oil Seal Installer
Figure 46. Removing Mainshaft Rear Bearing
J-41734 Oil Seai Installer
1. Reverse idle gear (21) and idle gear shaft (20).
« The reverse idle gear should be installed with
longer boss side turned to the forward.
* With the lock ball in the idle gear shaft rear
section, install the idle gear shaft from the
rear side of the transmission.
2. Countershaft assembly (19).
+ Place the countershaft assembly in the bottom
of the transmission.
3. Mainshaft assembly (18).
* Take care that the thrust washer of the
reverse gear does not drop off.
« Use a strong cord when inserting mainshaft
assembly into transmission case.
4, Mainshaft rear bearing (17).
Assembly
« Install the snap ring to the rear bearing outer
22. Transmission Case
circumference.
«install the rear bearing using the bearing
Figure 47. Removing Main Shaft Assembly
installer.
5. Input gear shaft assembly(16).
+ Install the needle bearing (30) to the input
gear shaft (figure 50).
« Install the input gear shaft assembly into the
transmission case.
* Check to be certain the block ring on the Sth
gear side fitted properly to the inserts.
» Press in the bearing until the snap ring of the
bearing outer circumference comes into
contact with the transmission case.
6. Countershaft front bearing (15).
« Use the bearing installer to install the front
bearing (figure 51).
» Install the counter shaft snap ring.

21. Reverse Idle Gear

22. Transmission Case

Figure 48. Removing Reverse Idle Gear Shaft

7B1-26 MANUAL TRANSMISSION

22. Transmission Case 22. Transmission Case

26. J-41736 27. J-35010-A

Figure 49. Installing Mainshaft Rear Bearing Figure 51. Installing Countershaft Front Bearing

16. Input Gear Shaft

22. Transmission Case 22. Transmission Case
30. Needle Bearing 27. J-35010-A

Figure 50. Installing Input Gear Shaft Assembly Figure 52. Installing Countershaft Rear Bearing

7. Countershaft rear bearing (14). 8. Spacer (11).

» Install the snap ring to the rear bearing outer 9. Vehicle speed sensor drive gear (10).
circumference. 10. Rear cover (9).
» install the rear bearing using bearing installer ¢ Apply engine oil to the new oil seal outer
and install the snap ring (figure 52). circumference and apply multi-purpose grease
to the oil seal lip.
fy] Important * Use the oil seal installer (J-41734) to install
the oil seal to the rear cover.
- With each gear set to the neutral position, + Remove moisture and oil etc. on the mating
check to see if the shaft and each gear rotate face.
smoothly. * Apply a 2 mm (0.1 in) bead of the liquid
* Check to see if each block ring is free. When gasket Three Bond 1215, or equivalent, to the
it gets caught and stuck in the tapper cone, rear cover (figure.53).
use a screwdriver to make it free.
 MANUAL TRANSMISSION 7B1-27

11. Clutch housing (7).

[3] Important « Apply engine oil to the new oil seal outer
* Install the rear cover on the transmission case
circumference and apply multi-purpose grease
within 30 minutes after liquid gasket to the oil seal lip.
» Use the oil seal installer (J-24245) to install
application.
the oil seal to the clutch housing.
* Install the rear cover to the transmission case « Remove moisture and oi! etc.on the mating
and tighten. face.
* Apply a 2 mm (0.1 in) bead of the liquid
gasket Three Bond 1215, or equivalent, to the
Tighten
clutch housing surface (figure.54).
« Rear cover bolts to 40 N-m (30 Ib-ft)
[] important
* Install the clutch housing on the transmission
case within 30 minutes after liquid gasket
application.

* Install the clutch housing to the transmission

case and tighten.

Tighten

« Clutch housing bolts to 81 N-m (60 lb-ft)

12. Vehicle speed sensor driven gear assembly (8).

« Install the driven gear assembly to the rear
cover and tighten fixing screw.
9. Rear Cover
G. Liquid Gasket Tighten
Figure 53. Installing Rear Cover » Driven gear fixing screw to 15 N-m (11 Ib-ft)

* Install the vehicle speed sensor and tighten.

Tighten

* Vehicle speed sensor to 25 N-m (18 lb-ft)

13. Parking brake assembly (4).

Tighten

« Parking brake bolts to 83 N-m (81 Ib-ft)

14, Drive coupling (3).

> Install the O-ring (31) and the conical washer
(32) (figure 55).
7. Clutch Housing The conical washer is to be set up with its
G. Liquid Gasket identification groove to the nut side
(figure 55).
Figure 54. Installing Clutch Housing
7B1-28 MANUAL TRANSMISSION

15. Lock nut (2). 16. Parking brake drum.

« Apply the engine oil to the setting face of the + Adjust the parking brake after installation.
new lock nut and tighten. 1) Rotate the brake drum to align the adjust
nole with the adjuster.
CAUTION: Do not reuse the lock nut. 2) Move the camshaft lever from side to side
several times to center the brake shoes.
By Tighten 3) Insert a screwdriver into the hole and rotate
the adjuster by pushing it upward until the
* Drive coupling lock nut to 226 N-m (166 lb-ft) shoes drag on the drum.
4) Back off the adjuster 30 notches.
* Stake nut by chisel, align the lock nut with the * Install the adjust hole cover.
V-shaped groove at the tip of the main shaft,
and stake the nut lip portion by using a chisel. FQ] Tighten
(Round edge 1 mm (0.04 in) x 60°).
* As shown figure 55, be sure to stake the nut * Adjust hole cover bolt to 8 N-m (69 Ib-in)
lip so that the clearance between the V-
shaped groove portion at the tip of the main 17. Control box assembly (13).
shaft and the staked up lip (A) is less than 1.5 * Remove moisture and oil etc. on the mating
mm (0.06 in}, and the staking length (B) is 5 face.
mm (0.2 in) or more (figure 55). * Apply a 2 mm (0.1 in) bead of the liquid
gasket Three Bond 1215, or equivalent, to the
NOTICE: Be sure to confirm that there is no control box surface (figure.56).
crack at the staked portion of the lock nut after
staking. Y | Important
« Install the control box on the transmission
case within 30 minutes after liquid gasket
31 application.
32

8B More than
5.0mm _ G 13
% (0.2in) ° © 9D (

More than
5.0mm
TL D O) 6
{0.2in)
~ |
\ ~ QO
tJ CF

Less than 13. Control Box Assembly

1.5mm
(0.06in) G. Liquid Gasket

Less than Figure 56. Installing Control Box Assembly

15mm
A (0.06in} * Fixing bolt length
Front side (2 pieces): 45 mm (1.77 in)
2. Lock Nut 31. O-ring Rear side (5 pieces): 25 mm (0.98 in)
3 Drive Goupling 32. Conical Washer
Tighten
Figure 55. Stake Lock Nut
* Control box bolts to 20 N-m (14 ib-ft)
 MANUAL TRANSMISSION 7B 1-29

[3] Important

« Operating the shift lever and the select lever,

make sure that they shift to each position
smoothly.

18. Mounting bracket (12).

Tighten
* Mounting bracket nuts to 69 N-m (51 Ib-ft)

19. Shift fork and support bolt (6).

Tighten

* Support bolt to 52 N-m (38 lb-ft)

20. Shift block assembly (5).

7B1-30 MANUAL TRANSMISSION

INPUT GEAR SHAFT, MAINSHAFT,

AND COUNTERSHAFT ASSEMBLIES

Mainshaft

input Gear Shaft

Input Gear Shaft Assembly 14. Needle Bearing

1. Snap Ring 15. Snap Ring
2. Ball Bearing 16. Collar
17. 3rd Gear
Mainshaft Assembly 18. Needle Bearing
3. Collar 19. Block Ring
4. Reverse Gear 20 2nd/3rd Synchronizer Assembly
5. Needle Bearing 21. Block Ring
6. 1st/Rev. Synchronizer Assembly 22. 2nd Gear
7. Block Ring 23. Needle Bearing
8. ist Gear
9. Needle Bearing Countershaft Assembly
10. Snap Ring 24. Snap Ring
11. 5th/4th Synchronizer Assembly 25. Conical Spring
12. Block Ring 26. Anti-Lash Plate
13. 4th Gear 27. Anti-Lash Springs

Figure 57. Input, Main and Countershaft Assemblies

 MANUAL TRANSMISSION 7B1-31

Remove or Disconnect
Refer to “MAJOR PARTS ASSEMBLIES”
earlier in this section.

[S] Disassemble (Figures 57-65)

Tool Required:
J-22912-01 Bearing Remover
50
Input Gear Shaft Assembly
1. Snap ring (1).
2. Ball bearing (2) 3. Collar
» Use the bearing remover to remove the ball 4. Reverse Gear
bearing from input gear shaft (figure 58).
8. ist Gear
36. Mainshaft
50. J-22912-01

Figure 59. Removing 1st Gear

- Attach a backing plate to the vise, secure the

mainshaft at the spline end.
5. Snap ring (10).

important

« Snap ring of appropriate sizes are combined

to fill the gap to the clutch hub. Never mix
them with other snap ring.
2. Ball Bearing
35. Input Gear Shaft 6. 4th/Sth synchronizer assembly (11).
50. J-22912-01 Block ring (12).
4th gear (13).
Figure 58. Removing Bail Bearing Needle bearing (14).
+ Use a bench press and the bearing remover
Mainshaft Assembly to remove the 4th gear (13) together with the
3. Collar (3). 4th/5th synchronizer assembly (11), the block
Reverse gear (4). ring (12) and the needle bearing (14)
Needle bearing (5). (figure 60).
1st/reverse synchronizer assembly (6). + Disassembly synchronizer assemblies into the
Block ring (7). clutch hub, sleeve, inserts (3 pieces) and
1st gear (8). insert springs (2 pieces).
» Use a bench press and the bearing remover
to remove the 1st gear (8) together with the 7. Snap ring (15)
collar (3), the reverse gear (4) the needle
bearing (5), the 1st/reverse synchronizer Important
assembly (6), and the block ring (7) « Snap ring of appropriate sizes are combined
(figure 59). to fill the gap to the clutch hub. Never mix
* Disassembly synchronizer assemblies into the them with other snap ring.
clutch hub, sleeve, inserts (3 pieces) and
insert springs (2 pieces).
4. Needle Bearing (9).
7B1-32 MANUAL TRANSMISSION

Countershaft Assembly
10. Snap ring (24).
11. Conical spring (25).
12. Anti-lash plate (26).
a 36 * Insert a flat-end screwdriver between the
13 anti-lash plate and the counter drive gear, and
~_-50 remove the anti-lash plate (figure 62).

WARNING: THE ANTI-LASH PLATE SHOULD

BE REMOVED VERY SLOWLY WITH SPECIAL
CARE OTHERWISE SOME SPRING INSTALLED
INSIDE THE PLATE COULD POP OUT AND
CAUSE INJURY.

13. 4th Gear 13. Anti-lash Springs (27).

36. Mainshaft * Remove the 3 springs that are assembled to
50. J-22912-01 the counter drive gear side.
Figure 60. Removing 4th Gear

8. Collar (16).
3rd gear (17).
Needle bearing (18).
Block ring (19).
2nd/3rd synchronizer assembly (20).
Biock ring (21).
2nd gear (22).
- Use a bench press to remove the 2nd gear
(22) together with the collar (16), needie
bearing (18), block ring (19), 2nd/8rd
synchronizer assembly (20) and the block ring
(21) (figure 61).
* Disassembly synchronizer assemblies into the 26. Anti-lash Plate
clutch hub, sleeve, inserts (3 pieces) and 37. Countershaftt
insert springs (2 pieces).
9. Needle bearing (23). Figure 62. Removing Anti-lash Plate

16. Collar
17. 3rd Gear
22. 2nd Gear
36. Mainshaft

Figure 61. Removing 2nd Gear

 MANUAL TRANSMISSION 7B1-33

Inspect

+ All disassembled parts for wear, damage or other

abnormal conditions.
* Replace parts that are found worn.

Measure (Figures 63-69)

- Ball bearing runout must not exceed 0.2 mm
(0.008 in) (figure 63).

41. Reverse Idle Gear

42. Reverse Idle Gear Shaft

Figure 64. Clearance Between Reverse idle Gear

Bushing and Shaft

» Clearance between the reverse idie gear bushing

and reverse idle gear shaft must not exceed
0.2 mm (0.008 in) (figure 64).
* Mainshaft runout must not exceed 0.1 mm
{0.004 in) (figure 65).
40. Ball Bearing * Clearance between the block rings and dog gear
toothed for the ist, 4th, and 5th gears should not
Figure 63. Ball Bearing Runout be less than 0.5 mm (0.020 in} (figure 66).
+ Clearance between the biock rings and dog gear
toothed for the 2nd and 3rd gears should not be
* Gear inside diameter for the ist, 2nd, 3rd and
less than 1.0 mm (0.039 in) (figure 66).
reverse gears must not exceed 61.1 mm
(2.41 in).
* Gear inside diameter for the 4th gear must not
exceed 42.1 mm (1.657 in).

36. Mainshatt

Figure 65. Mainshaft Runout

7B1-34 MANUAL TRANSMISSION

43. Dog Gear

44, Block Ring 45. Clutch Hub

Figure 66. Clearance Between Dog Gear and Figure 68. Clearance Between Clutch Hub and
Block Ring Insert

* Glutch hub spline play between mainshaft spline « Clearance between the block ring and inserts for
and clutch hub spline at clutch hub outer the 2nd, 3rd, 4th and 5th gear synchronizer
circumference must not exceed 0.3 mm (0.012 in) assemblies must not exceed 4.1 mm (0.161 in)
(figure 67). (figure 69).
- Clearance between the clutch hub groove and + Clearance between the block ring and inserts for
insert must not exceed 0.4 mm (0.016 in) the 1st gear synchronizer assembly must not
(figure 68). exceed 4.0 mm (0.157 in) (figure 69).
ee end ee

36. Mainshaft 44. Block Ring

45. Ciutch Hub 46. Insert

Figure 67. Clutch Hub Spline Play Figure 69. Clearance Between Block Ring and
Insert
 MANUAL TRANSMISSION 7B1-35

Assemble (Figures 57 and 70-83)

97.7mm(0.3in)
27
[2] important
« Clean each part thoroughly.
+ When assembling parts, apply clean engine
oil (SAE 5W-30) to their sliding and mating
sections.

Tool Required:
J-35704 Anti-iash Plate Replacer
J-41736 Bearing Installer
J-35010-A Bearing Installer
26. Anti-lash Plate
Countershaft Assembly
27. Anti-lash Spring
1. Anti-lash springs (27).
* The anti-lash springs shouid be installed to
Figure 70. Installing Anti-lash Spring and Plate
the left of the inside counter drive gear pin
(figure 70).

NOTICE: When replacing the anti-lash spring

pin with a new one, hammer it in until its
height becomes 3 mm (0.12 in) from the gear
end face.

2. Anti-lash plate (26).

* Assembie the anti-lash plate to the drive gear
so that the drive gear hole (o 7.7 mm/0.3 in)
comes roughly in line with the hole
(6 7.7 mm/0.3 in) of the anti-lash plate
(figure 70).
* With the guide pin aligned with the drive gear
hole (o 7.7 mm/0.3 in), set the installer to the 26. Anti-lash Plate
guide pin. 51. J-35704
* Turn the installer clockwise. When the drive
gear pin comes to the position where it can be Figure 71. Installing Anti-lash Plate
seen fully, put the installer into the drive gear
side to fix the anti-lash plate to the drive gear
(figure 71).
3. Conical spring (25).
+ Install the conical spring above the anti-lash
plate with the convex side up (front side)
(figure 72).
4. Snap ring (24).
» Use a new snap ring to fix the conical spring.

NOTICE: Avoid the reuse snap ring.

Check visually the anti-lash plate for a warp or
curve after assembly.
C4 ormny UU

25. Conical Spring

26. Anti-lash Plate

Figure 72. Installing Conical Spring

7B1-36 MANUAL TRANSMISSION

Mainshaft Assembly
+ Attach a backing plate to the vise, secure the
mainshaft at the spline end.
5. Needle bearing (23).
6. 2nd gear (22).
« install the 2nd gear with its taper cone side
upward (front of transmission).
7. Block ring (21).
8. 2nd/3rd synchronizer assembly (20).
* Assemble the sleeve to the clutch hub. The
clutch hub has no specific directionality.
« Put the inserts into the clutch hub groove,
insert has no specific directionality and install
the insert spring (figure 73).
Assemble the insert springs so that the 46. Insert
distances (A and B) between inserts and the 48. Insert Spring
opening of the spring can be nearly equal,
and also this opening may not be the same
Figure 74. Installing Insert Spring
direction on both side (figure 74).
» Larger diameter side of the sleeve outer
circumference should be positioned toward
the 3rd gear side (front of transmission)
3rd gear side

we 0
(figure 75).
« Align the inserts with the insert groove of the
block ring.
¢ Tap the clutch hub boss section with the
bearing installer and a hammer to press it in
until it contacts closely with the mainshaft
stepped section (figure 76).
» When it is difficult to engage the clutch hub
boss with the mainshaft spline, heat the clutch
hub boss section to a temperature between 80 U
and 120 °C (176 and 248 °F) with the piston 2nd gear side
heater before assembling.
* Check to see if the 2nd gear rotates smoothly.
Figure 75. Aligning Sleeve and Clutch Hub

45. Clutch Hub

46. Insert
22. 2nd Gear
47. Sleeve
45. Clutch Hub
52. J-41736
Figure 73. Clutch Hub and Sleeve Assembly
Figure 76. Installing 2nd/3rd Clutch Hub
 MANUAL TRANSMISSION 7B1-37

9. Block ring (19).

* Align the inserts with the insert groove of the T 22
block ring.
10. 3rd gear (17)
» Install the 3rd gear with the taper cone side
turned to the 2nd gear side (to the bottom).
11. Needle bearing (18).
12. Collar (16).
* Install with the flange side turned upward
(front of transmission).
* Tap the collar with the bearing installer and a
hammer to press it in until it contacts closely
with the mainshaft stepped section (figure 77).
When it is difficult to engage the collar with 16. Collar
the mainshaft, heat the collar to a temperature 17. 3rd Gear
between 80 and 120 °C (176 and 248 °F) with 22. 2nd Gear
the piston heater before assembling.
Figure 78. Distance Between Thrust Washer and
Snap Ring Groove

14. Needie Bearing(14).

15. 4th gear (13).
« Install with the taper cone side turned upward
(front of transmission).
16. Block ring(12)
17. 4th/Sth synchronizer assembly (11).
* Mate the clutch hub and the sleeve so that the
larger diameter side of the clutch hub boss
and the identification groove of the sleeve
outer circumference point to the same
direction (figure 79).
16. Collar * Put the inserts into the clutch hub groove, and
17. 3rd Gear install the insert spring.
52. J-41736 Assemble the insert springs so that the
distances (A and B) between inserts and the
Figure 77. installing 3rd Gear Collar opening of the spring can be nearly equal,
and also this opening may not be the same
13. Snap ring (15) direction on both side (figure 74).
* Grooved side of the sleeve and the larger
Measure boss of clutch hub should be positioned
toward the 4th gear side (rear of
+ Measure distance "T" (figure 78) and select transmission) (fiqure 79).
the optimum snap ring frorn the table. > Align the inserts with the insert groove of the
Snap ring block ring.
* Tap the clutch hub boss section with the
Distance "T" Color Thickness mm (in) bearing installer and a hammer to press it in
mm (in) [reference] until it contacts closely with the mainshaft
stepped section (figure 80).
2.20-2.27 Yellow 1.85-1.90 ¢ When it is difficult to engage the cluich hub
(0.087-0.089) (0.073-0.075) boss with the mainshaft spline, heat the clutch
2.27-2.32 Blue 1.90-1.95 hub boss section to a temperature between 80
(0.089-0.091) (0.075-0.077) and 120°C (176 and 248 °F) with the piston
2.32-2.37 Brown 1.95-2.00 heater before assembling.
(0.091-0.093) (0.077-0.079) « Check to see if the 4th gear rotates smoothly.
2.37-2.43 Green 2.00-2.05
(0.093-0.096) (0.079-0.081)
7B1-38 MANUAL TRANSMISSION

Snap ring
input gear shaft side
color mark Thickness [reference] mm {in)

C Pink 1.75-1.80 (0.069-0.071)

BL
White 1.80-1.85 (0.071-0.073)
Yellow 1.85-1.90 (0.073-0.075)

Attach a backing plate to the vise, secure the

mainshaft at the top end.
19. Needle bearing (9).
Oil groove 20. ist gear (8).

U
Install with the taper cone side turned upward
(rear of transmission).
21. Block ring (7).
4th gear side
22. isi/Reverse synchronizer assembly (6).
°
Mate the clutch hub and the sleeve so that the
Figure 79. Aligning Sleeve and Clutch Hub oil grooves of the clutch hub boss end face
points to the direction opposite to that of the
chamfer of the sleeve outer circumference.
(figure 81).
Put the inserts into the clutch hub groove so
that the larger catch of the insert should be
positioned toward the 1st gear (oil groove side
of the clutch hub boss) and instail the insert
springs.
Assemble the insert springs so that the
distances (A and B) between inserts and the
opening of the spring can be nearly equal,
and also this opening may not be the same
direction on bath side (figure 74).
13. 4th Gear Face of the clutch hub with longer boss and
17. 3rd Gear two-oil grooves should be positioned toward
22. 2nd Gear the ist gear (front of transmission) (figure 81).
45. Clutch Hub Align the inserts with the insert groove of the
53. J-35010-A block ring,
Tap the clutch hub boss section with the
Figure 80. Installing 4th/Sth Clutch Hub bearing installer and a hammer to press it in
until it contacts closely with the mainshaft
18. Snap ring (11}. stepped section (figure 82).
When it is difficult to engage the clutch hub
Measure boss with the mainshaft spline, heat the clutch
hub boss section to a temperature between 80
+ Install the built-in snap ring and measure the and 120 °C (176 and 248 °F) with the piston
clearance between the snap ring and the heater before assembling.
clutch hub. Check to see if the 1st gear rotates smoothly.
« When the clearance is more than 0.09 mm
(0.004 in}, select a snap ring with the
maximum thickness that can be inserted from
among the following three types, and built it
in.
 MANUAL TRANSMISSION 7B1-39

Reverse> side

Chamfer an Larger

|
co" !

. ala
ae fa
Oil groove riz!

i 4. Reverse Gear
Ist gear side
52. J-41736

Figure 81. Aligning Sleeve and Clutch Hub Figure 83. Installing Reverse Gear Collar

input Gear Shaft Assembly

26. Balt bearing (2).
* Install the ball bearing to the input gear shaft
and press it in so that the outer circumference
snap ring side turns to the outside (in the
direction opposite to the gear).
27. Snap ring (1).

8. 1st Gear
45. Clutch Hub
52. J-41736

Figure 82. Installing 1st/Rev. Clutch Hub

23. Needle bearing (5).

24, Reverse gear (4}.
25. Collar (3).
+ Install with the flange side turned upward
(rear of transmission).
* Tap the collar with the bearing installer and a
hammer to press it in until it contacts the
clutch hub (figure 83).
7B1-40 MANUAL TRANSMISSION

CONTROL BOX ASSEMBLY

. Back-up Light Switch . Interlock Ball

=

. Neutral Switch . Spring Pin

OO PWN

. Shift Rod Cap

OOnN

. Plug and Gasket

. Detent Spring . 4th/5th Shift Arm
. Detent Ball . 4th/5th Shift Rod
. Spring Pin . Detent Ball
. Spring Pin . Detent Spring
. Shift Rod Cap . Spring Pin
. 1st/Reverse Shift Arm . Select External Lever
. tst/Reverse Shift Block . Select Internal Lever
©

. 1st/Reverse Shift Rod . Washer

tet
+

. Interiock Ball . Spring Pin

ON

. Spring Pin . Stopper Ring

. Spring Pin . Spring (Long)
nak

. Shift Rod Cap . Washer

week

. Interlock Pin . Shift internal Lever

. 2nd/3rd Shift Arm . Spring (Short)
“=~OOOAnN

. 2nd/3rd Shift Block . Shift External Lever

. 2nd/3rd Shift Rod . Select Lever Shaft Oil Seal
INS we

. Detent Bail . Shift Lever Shaft Oi! Seal

. Detent Spring
I

Figure 84. Control Box Assembly

 MANUAL TRANSMISSION 7B 1-41

[es] Remove or Disconnect

Refer to “MAJOR PARTS ASSEMBLIES” earlier

in this section.

[S] Disassemble (Figures 84-91)

Tools Required:
J-35703 Spring Pin Remover
. Back-up light switch (1).
fan —

. Neutral switch (2).

. Plug and gasket (3).
. Detent spring (4).and detent ball (5).

NOTICE: Be careful not to lose the detent ball

and spring.
11. 1st/Reverse Shift Rod
§. Spring pin (6),(7) using J35703 (figure 85).
Pring pin (©),(7) 9 (rg Figure 86. Removing Shift Rod and Cap

11. 1st/Reverse Shift Rod

42, J-35703
12. interlock Bails
Figure 85. Removing Spring Pin

6. 1st/reverse shift rod (11) and cap (8). Figure 87. Removing Interlock Ball
+ Set shift rod to ;neutral. ; ,
. 9. Spring pin (13), (14) using J-35703.
* Remove the shift rod and cap by tapping on 40. 2nd/3rd shift rod (19) and cap (15).
» Set shift rod to neutral.
its rear end to drive the rod and cap out the
end of the control box (figure 86). » Remove the shift rod and cap by tapping on
its rear end to drive the rod and cap out the
CAUTION: Take care not to damage the shift end of the control box (figure 86).
rod hole of the control box. 11. Interlock pin (16) from the 2nd/3rd shift rod (19)
os . (figure 88).
7. 1st/reverse shift arm (9) and shift block(10). 42. onalard Shift arm (17) and shift block (18).

8. Interlock balls (12). 13. Detent ball (20) and detent spring (21) from
* Take out the 2 interlock balls from between t .
the ist/reverse shift rod and the 2nd/Srd shift control box
rod (figure 87). NOTICE: Be careful not to lose the detent ball
and spring.
NOTICE: Be careful not to lose the detent
balls..
7B1-42 MANUAL TRANSMISSION

29

i|
| eo .
=
oO
—
29. Spring Pin
16. Interlock Pin
Figure 89. Select External Lever Spring Pin
19. 2nd/3rd Shift Rod

Figure 88. Removing Interlock Pin

14. Interlock balls (22).

* Take out the 3 interlock balls from between
the 2nd/3rd shift rod and the 4th/5th shift rod.
15. Spring pin (23) using J-35703.
16. 4th/5th shift rod (26) and cap (24).
* Set shift rod to neutral.
* Remove the shift rod and cap by tapping on
its rear end to drive the rod and cap out the
end of the control box.

CAUTION: Take care not to damage the shift

rod hole of the control box.
34. Stopper ring 37. Shift Internal Lever
17. 4th/Sth shift arm (25) 35. Spring (Long) 38. Spring (Short)
18. Detent ball (27).and detent spring (28). 36. Washer

Figure 90. Removing Shift Control Mechanism

NOTICE: Be careful not to lose the detent ball
and spring.

19. Spring pin (29) from the select external lever

(30) using J-35703 (figure 89).
20. Select external lever (30), select internal lever
(31) and washer (32).
21. Spring pin (33) from stopper ring (34) using
J-35703.
22. Stopper ring (33), spring-long (35), washer (36),
shift internal lever (37), spring-short (38) and
shift external lever (39) (figure 90).
23. Select lever shaft oil seal (40).(figure 91).
24. Shift lever shaft oil seal (41).(figure 91).
+ Use the screwdriver to remove the oil seai
from the control box.
40. Select Lever Shaft Oi! Seal
CAUTION: Take care not to damage the sealing 41. Shift Lever Shaft Oil Seal
seat of the control box.
Figure 91. Select and Shift Lever Shaft Oil Seal
 MANUAL TRANSMISSION 7B1-43

Inspect Assemble (Figures 84 and 94-98)

« All disassembled parts for wear, damage or other NOTICE: For steps 23 and 24, see “NOTICE”
abnormal conditions. on page 7B1-1 of this section.
* Check detent shoulders for rounding. Rounding
can cause gear slip out. [¥] Important
* Replace parts that are found worn.
* Clean each part thoroughly.
Measure (Figures 92 and 93) « When assembling parts, apply clean engine
oil (SAE 5W-30) to their sliding and mating
Shift arm thickness should not be less than 9 mm sections.
{0.35 in) (figure 92).
* Free length of the detent spring should not be Tool Required:
less than 30.1 mm (1.19 in) (figure 93). J-35009 Oil Seal Installer
1. Shift lever shaft oil seal (41) using J35009
(figure 94). ,
« Apply engine oil to the new oil seal outer
circumference and apply multi-purpose grease
on the oil seal lips.

43. Shift Arm

Figure 92. Shift Arm Thickness

45. J-35009

Figure 94. Installing Shift Lever Shaft Oil Seal

2. Select lever shaft oil seal (40) using J35009

(figure 94),
* Apply engine oil to the new oil seal outer
circumference and apply multi-purpose grease
on the oil seal lips.
3. Shift external lever (89), spring-short (38) and
shift internal lever (37) (figure 95).

INK
« With the shift external lever turned down (to
the transmission side), insert it into the control
box,
- Assemble the shift internal lever so that its
44, Detent Spring direction points to the same direction as that
of the stopper ring fixing pin hole (in the same
Figure 93. Free Length of Detent Spring direction as the external lever).
7B1-44 MANUAL TRANSMISSION

4. Washer (36), spring-tong (35), stopper ring (34) 5. Select internal lever (31), washer (32), select
and spring pin (33) (figure 96). external lever (30) and spring pin (29)
» With the stopper ring pin hole set on that of (figure 97).
the shift lever shaft, hammer a new spring pin * With the select internal lever paired with the
into the holes. shift internal lever, build them into the control
* Setting the control box pin hole to the shift box.
lever shaft groove, hammer a new spring pin « With the select external lever turned to the
into the hole. shift external lever side, fix it with a new pin
after assembling.

37. Shift Internal Lever

38. Spring -Short
31. Select Internal Lever
Figure 95. Direction of Shift Internal Lever
Figure 97. Installing Select Internal Lever

6. Detent spring (28) and detent ball (27).

» Apply small amount of multi-purpose grease
to the detent ball.
7. 4th/Sth shift rod (26).
« Press down the detent ball with a screwdriver
to prevent it from jumping out.
- Turning the detent groove to the detent bail
a7 side, insert the shift rod with the detent groove
side at the rear.
8 4th/5th shift arm (25).
« With the projection side of the boss set to the
rear, put the shift arm through the shift rod.
9. Spring pin (23).
« Setting the hole of the shift arm to that of the
34. Stopper ring 37. Shift Internal Lever
shift rod, fix them with new spring pin
35. Spring (Long) 38. Spring (Short)
(langth=25 mm/0.98 in).
36. Washer

Figure 96. Installing Shift Control Mechanism NOTICE: install spring pin properly with the
slit in line with the shaft center line.
 MANUAL TRANSMISSION 7B1-45

10. Detent spring (21) and detent ball (20). 22. Detent ball (5) and detent spring (4).
* Apply small amount of multi-purpose grease * Apply small amount of multi-purpose grease
to the detent ball. to the detent ball.
14. 2nd/3rd shift rod (19) and shift arm (17) and 23. Plug and gasket (3).
shift block (18).
* Press down the detent ball with a screwdriver Tighten
to prevent it from jumping out.
« Turning the detent groove to the detent ball * Detent ball plug to 25 N-m (18 Ib-ft)
side, insert the shift rod with the detent groove
side at the rear. 24. Shift rod caps (8), (15) and (24).
12. 2nd/3rd shift block (18). » Apply liquid gasket Three Bond 1141 or
« Assemble the shift block so that the shift block equivalent to the cap outer circumference,
pin hole is inclined to the 4th/5th shift rod and hammer it in with something soft such as
side. a rubber hammer.
13. 2nd/8rd shift arm (17).
+ With the projection side of the boss set to the CAUTION: When there is any warp or flaw
front, put the shift arm through the shift rod. found with the shift rod cap, replace it with
14. Interlock ball(22). new one.
* Apply small amount of multi-purpose grease
to the interlock balls. 25. Neutral switch (2) and back-up light switch (1).
« Install 3 interlock balls in position between the * Apply liquid gasket Three Bond 1141 or
4th/Sth shift rod and 2nd/Srd shift rod. equivalent to the switch's threaded portion
15. Interlock pin (16). and install the switches to the control box.
* Apply small amount of multi-purpose grease * Golor of connector
to the interlock pin. Back-up light switch: Brown
* Install interlock pin in position the pin hole of Neutral switch : Gray
2nd/3rd shift rod.
16. New spring pin (13: length=32 mm/1.26 in) and Tighten
(14: length=25 mm/0.98 in).
* Switch to 34 N-m (265 lb-ft)
NOTICE: Install spring pin properly with the
slit in line with the shaft center line.

17. 1st/reverse shift rod (11).

* Before assembly, set the 4th/5th and 2nd/3rd
shift rods already reassembled in neutral
position.
° Insert the 1st/reverse shift rod so that the
detent ball groove comes to the left and the
rear side at the same time.
18. 1st/reverse shift block (10).
* Put the shift block through the rod so that the
catch turns up.
19. Interlock ball(12).
« Apply small amount of multi-purpose grease
to the interlock balls. 1. Back-up Light Switch
« fnstail 2 interlock balls in position between the 2. Neutral Switch
2nd/3rd shift rod and 1st/reverse shift rod.
20. 1st/reverse shift arm (9) Figure 98. Installing Back-up Light and Neutral
+ With the wider side of the arm section turned Switch
to the 2nd/3rd shift rod side, put the shift arm
through the shift rod.
21. New spring pin (6: length=32 mm/1.26 in) and
(7: length=25 mm/0.98 in).

NOTICE: Install spring pin properly with the

slit in line with the shaft center line.
7B1-46 MANUAL TRANSMISSION

SPECIFICATIONS
TranSMiSSiON TYP@ .........cceeccceteesscesceseeessenenccaeusesneneesunmeseaanecssuenenstsenevesenenenteasnecseesanies MXA-5C Direct Drive 5-Speed
Gear Mesh Type.......0...-s0 gucaesacusanscececsterenseenseaenscenseeeesnsenueesscensetveneamanasensesneneneaeneaness 1st to 5th: Synchro-mesh
Reverse: Constant-mesh
Gear Ratio... cccccccesecccecsscsssssseceenseessuetecueeasensneneeaeesasessaeeegersaneentees pasecacaesauessceecdeeesdneseaneneqasesteaseassecsaesnsentens ist 6.020
2nd 3.626
3rd 2.017
4th 1.367
5th 1.000
Reverse 6.030
Lubricating Oi)... cee tee ceeeeeseeeesserseenssensensesengenseonessseneeseanuevsesersssasseneauees coceeeeeesedessneesaueneaes Engine Oii SAE 5W-30
Oil Capacity oo... cee ccceeceeceeeeeeeessusenesancauseesseanssenenasenanenessenanesesoessensenseenesaceneeneeseueesenesanseees Approx. 3.2 Liters (6.8 pints)
Weight without Lubricating Oil .........cceseseseessseceseeteeseceeneneneceesnssneascressneeeusnesssesnecansesavaneanteneesaeataneas 75 kg (168 Ib)
Distance between Center of Shift Lever Play and Center Cluster... ecessreeseenees 283 + 15 mm (11.1 + 0.6 in)
Ball Bearing RUMOUt ...........ccceceeceercsseserseeeeeesneeceusenseeseesesnensessnneseneceneseneusessaeaeeassessesaeanteres Less than 0.2 mm (0.01 in)
Gear Inside Diameter (ist, 2nd, 3rd and Reverse Gear) .....eecsccsseccssenreersseneesarenees Less than 61.1 mm (2.41 in)
(4tN Gear) oo... eccceeseeceseeeseaeeenceeeeseeaneseunonsdesenenmaseuseseanuasennensesenss Less than 54.1 mm (2.13 in)
Clearance between 4th Gear Bushing and Mainshalft........... cc cccssesssuneussssaeeeseeers 0.05-0.20 mm (0.0020-0.0079 in)
Clearance between Reverse Idie Gear and Reverse Idie Gear Shaft ..............00+ 0.04-0.20 mm (0.0016-0.0079 in)
Mainshaft RUNOUt. 0.0.0... ccssecsenseeceteereecnereneeerescnnsesaceeeeseucusdenseussuesseasuaseuseeensenvannesseaees Less than 0.1 mm (0.004 in)
Clearance between Block Ring and Dog Gea... cee cccsecnesseeenseneeertnetressnenaneneseaaesnees More than 0.5 mm (0.02 in)
Spline Play between Clutch Hub and Mainshalft ..........ccseescessestsnseeetsesetesseaseeneranseeneas Less than 0.3 mm (0.01 in)
Clearance between Block Ring Groove and Insert (1St G@ar) occ ee cceesecsenserreeee 3.54-4.00 mm (0.139-0.157 in)
(2nd, 3rd, 4th and 5th Gear)........ 3.59-4.10 mm (0.141-0.161 in)
Clearance between Clutch Hub Groove and Insert... cectotsosonsanerenseeaanesaneesouss 0.09-0.40 mm (0.004-0.016 in)
Clearance between Clutch Hub and Snap Ring 2.0... ceescseeesesssesenessseesseresnsessenenenees Less than 0.09 mm (0.004 in)
Shift Arm Thickness ......c.cccccccccsenceccssesssanececeeetereereessenesusesuuesenuenssnsessucuvenseaeseaseasenetasenees More than 9.0 mm (0.35 in)
Free Length of Detent Spring... ccccccsccseseeneessneerenensseneesneeenetsecetercnaneveneaeiticensesseieees More than 30.1 mm (1.19 in)

FASTENER TORQUES

Clutch Housing to Flywheel Housing Bolt .............ccsscneeneeeeeeeseerenteeieenerennenernsentes beenaneeanesnseesaneeees 46 N-m (34 Ib-ft)
Clutch Housing to Transmission Case Bolt............ccsssssseessenessesceeeteesecesseetennsereaneanentanennesstrasscasaas 81 N-m (60 Ib-ft)
Support Bolt of Clutch Shift Fork.........ccccccceeeeeeeessceseesenennsseseensestenecavsuseseateeneteseceaeseeanesananensenenees 52 N-m (38 lb-ft)
Rear Cover Bolt .....0..:0.cccsccesccccessseessensessnssnnessccesesaeneesdaeesseseusseuusscuuaeceesecaunaesanesessenamsedsensenessaneeneaean 40 N-m (30 lb-ft)
Side Cover Bolit......ccccccccccccescessstscessesersvesenessneetensnneesessecneeesessaneoneceeneseseeseustaauecansaveuneuenneseeanees eevetnceeeens 18 N-m (13 Ib-ft)
Control Box Nut.......cccccccccececcessessseeccsnseeensneesscecnsssereessnucssesseencespesedeuenssanuoesenanasegeneusscesenssssseeedanneniaeens 69 N-m (51 Ib-ft)
BOlt ..ccccccccecccecsveceesessceusessueesensenssueceseescnesesscessaceeneesscesansesustnaceeessesesaesesuasuasansoseesseuesuseeenseas 20 N-m (14 ib-ft)
Filler PIU ........ccccscsscesecesestseceserssesssnsescsesseasnsusensesanensenecesseneruaceeneeenenerseenssseediansssenereceasageasseseaanesesaenees 49 N-m (36 Ib-ft)
Drain PIUG oe ccccesceseeseeeseceetsessnseessuscscanaesanenescsnanasesscecarenenenseanaeaeneeanensusensecesaenesteuseeseuseeseaseasteaarssesanes 49 N-m (36 Ib-ft)
Drive Coupling LOCK Nut ........ccccccssessesenescesessneseneessenseeeseseesenessnenarsensecssniasasenimissassnenenanenecsnenenes 226 N-m (166 lb-ft)
Backup Light SwitCh...........-ccscesesseccenseresscesseesnesseeemenreneasamnesseucaescansvasensseenenseeseaaseassenensaaenetenenanenenats 34 N-m (25 lb-ft)
Neutral SWIitch .....ccc.ccccccccceccssccccccvesecceesesesessussnsnunenenenseeeseneeasesseaedeasvaueeeesensseasausecnasasenaeeeesesensenaestemeui 34 N-m (25 Ib-ft}
Transmission Rear Mount Nut and Bolt (M10).......... cee seeeecerenensseesesuensssseuueeseeceseessennsessneesssenevssigees 40 N-m (80 Ib-ft)
(M12) ...cccecsccesscccesceneeoesecseecaeneneeseeusssssusesesssasenssensesnerensenenasaes 69 N-m (51 Ib-ft)
Detent Ball PIUQ uo... cece csesseesssnseccseranssennerecaessnesececacesiseceenensasasieansesesnseesscansentaenesaesanesenensnesuagnentees 25 N-m (18 Ib-ft)
Gearshift Cable Lock Nut... cece ecsescencersscersseesnsersenterenenens vesteceantecsensseneneenecacerseseenmenenenensenecuassaness 6 N-m (82 Ib-in)
Gearshift Cable Mass Damper Nut ............ccccesesssseenessessenseeneecseneeseenteeteecesertenmseanaaesetaearessasseesncesenes 103 N-m (76 Ib-ft)
Clutch Slave Cylinder Mounting Bolt...........cescssssssesessssensseesrsnserissressnsaseaneversaensceessesenscnsatennentes 19 N-m (14 Ib-ft)
Vehicle Speed Sensor Driven Gear Mounting Bolt .........-:. see eeeseeeeersnceesntneneesnsesescenecetencenennteeeaneney 15 N-m (11 Ib-ft)
Vehicle Speed SENSO... sess es eseessnesescneseensseneeeeaseeeereenseatssaracsussnsenaneessanaseasanansannerscnneasercenaneataneness 25 N-m (18 lb-ft)
 MANUAL TRANSMISSION 7B 1-47

SPECIAL TOOLS

TOOL NO.
ILLUSTRATION
TOOL NAME

J
J-41734
Oil Seal Installer (Rear
Cover)

oo J-24254
Oil Seal Installer (Clutch
Housing)

cS J-35700
Bearing Remover

(OF
J-41735
Bearing Remover

+ J-35699
Universal! Puller

CZ
\3

J-41736
Bearing Installer

> J-35010-A
Bearing Installer

Q) J-22912-01
Bearing Remover

(OF> J-35704
Anti-lash Plate Replacer

“ J-35703
Spring Pin Remover

oa
J-35009
Oil Seal Installer (Contro!
Box)
MEMO
 MANUAL TRANSMISSION 7B2-1

SECTION 7B2

MANUAL TRANSMISSION (MBP)

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

D@SCIIPtION .........ccssscsscrsscnevoncsevsnsensssveussusssontssosnsnasonerasussaeuecaueneuscenaeacnsnsosssavenesoreceousaanesouseucenscusaseassueceuanesneeene 7B2- 2

Diagnosis of Manual TransmMisSSion...........cccssssscessscersnessscsssssssnseeecneerseneeneetssesncesnssesaeseesaeusansensansecuasreseneys 7B2- 2
On-Vehicle Service .........::csccesssssessensrsenessetsonsensecnssuenaeasnueceusoueseesensersoguastescecanteseesaesnuorsesoces sueeasesnesuccensseseeenss 7B2- 6
Transmission Oil Level Check...........ccscscossssessesssrsesessrenensserssensassenssensecesesevecessoesanescetenssecensussensoasssontes 7B2- 6
Changing Transmission Oil ..........:csssscsssseecssessceeeaesceresssonmuessspssncecensnassesseenesensesceasnnesseusesteneserentenses 7B2- 6
Gearshift Lever Replacement ...............csssccccrsessnsssesnesresesnanssesntscorsaevoraconsaneasussonsusesorseueensovantunnevaneauenaees 7B2- 6
Gearshift Cable Adjustment............cccssecsrsssserssseceracsoeserossareesersasessasasnansuansasensaseoasueneeasuaseccoaneenetes anaeensees 7B2- 7
Gearshift Cable Replacementt.............::ccccsscscsssersnecssersseeneronseesinssaorsennecatsssoncevaneausussunsenessoesadaseavastoseezece 7B2- 8
Rear Cover Gasket and Oil Seal Replacement............:cc:cscssssssessevssensestaevasenensensnersarsnecseonssenesusesecnsens 7B2-10
Transmission Assembly Replacement ............:ccssscssseserssessessssssvensonsonseonanensenaneseesuenssencouseanenusnusutneone 7B2-12
Front Oil Seal Replacement ............cccssccssesesssssystosevsuscessnsssusesesessuanenecssuneusousosconsseacsnssuessonsuuneassuceesansns 7B2-15
Quadrant Box Gasket Replacement..............::csssenesssseesessnseensensetenesenssenedensesuasnensersaeseeusuesusseunennersneunvensees 7B2-17
Unit Repair...........scccsssssssssssssscsstssnesseensenssererseenansseenseensaeones eseeeusaseonseaeseuaneaausaeseunusuasscaraceussarsassenscascansuegosazens 7B2-20
Major Parts ASSeMDDIy ...........c:sessccessssssensseseteeersersecrsenresenensenescestorasaseneaenauaesnneenaecanassasssnenensenssney sevseenerene 7B2-20
Top Gear Shaft ASSOMDIy .........::ccssseesccsssseerssssearecsecsnseacessuenenensesauannensssnenesianseonasensgesesunsensanssonenstansesnennonaneas 7B2-31
Main Shaft ASSEMDIY..........cccecssrcsccsssersnsusesssenenssevsenscuseuerarsecesusounstesesutencauacanenerseuseeansnsenssauenseusoessensenetsensets 7B2-33
Counter Shaft Assembly ...........s:cccsureesssares caeeaesnannouseaceneranansenserseusensonsaneeavarandapssassvansesessuveoaseacrscsensaussenuness 7B2-39
Upper Quadrant DOX ......ssccsiesscsrennserseseens sassersuenerseneenaceataues vonuenenssensansazausssuncesunvercanscanasaatensnneesceuteneuetonenesuats 7B2-41
Lower Quadrant DOX........sccsscsesscesssseeessoearecseusunseestsensnseaeacersanenateousouesussneausntauaysevandeeesonsaseustansasenuadesoareaaaaeseas 7B2-44
Specifications...........cssscscssecseessnesensensnesensseesesens susauececausensenvsonanseees seeeseseenvesaecunecansasusseasseaesatenseatuausecusane 7B2-50
Fastener TOrques.....scssscesseserassecneess saveceansaucsiasessnavaeussausuescecoussneasssceatuaussussusaenuesneaceatentecceusrsusensenenossaeta 7B2-50
Special TOOINS.........cccsscssssssssssssssesssensenrsscentresseseacaesesenseenenssensuneaseesesensrseessanscnseosaeensnsssnenaeensuaenensaeseensanseaeneasnans 7B2-51
7B2-2 MANUAL TRANSMISSION

DESCRIPTION

The transmission is part of the drive line and is transmissions will turn the drive line at the same
located behind the clutch assembly. Its job is to speed as the engine.
control the torque, or turning force, from the clutch The 6-speed transmissions have constant mesh
through a series of gears. These gears then first and reverse gears and the remaining gears are
transmit the torque to the vehicle driving wheels. synchronized. Shifting is done with a remote shift
The transmission increases engine torque to start control and two cables operating a shift quadrant
the vehicle moving. mounted on the top of the transmission.
In lower gears, the transmission turns the drive Both transmissions are equipped to drive a power
line slower than engine speed. in high gear, many take off unit. An identification plate is mounted on
the side of the transmission.

Figure 1. MBP 6 Speed Transmission

DIAGNOSIS OF MANUAL TRANSMISSION

The following diagnosis information is to be used transmission model may have a different correction
only as a guide to locating a transmission problem. for the same problem.
Corrective procedures are not included, as each
 MANUAL TRANSMISSION 7B2-3

DIAGNOSIS OF MANUAL TRANSMISSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Walking or Jumping . Improperly adjusted shift linkage. . Adjust.

m=
Out of Gear . Shift rod detent groove notches . Replace shift rod.
worn.
. Shift arm pads or groove in sliding . Replace.
5

sleeve worn excessively.

. Shift rod bent or sprung out of . Replace.
line.
. Worn taper on clutch gear teeth. . Replace.
Om

. Shift arm pads not square with . Replace.

shift rod bore.
. Excessive end play in drive gear, . Replace worn or loose parts.
mainshaft or countershaft.
8. Thrust washers or faces worn 8. Replace or install.
excessively, or missing.
9. Shift rod detent springs broken. 9. Replace.

Sticking in Gear 1. Clutch linkage improperly 1. Adjust.

adjusted.
2. Improperly adjusted shift linkage. 2. Adjust.
3. Sliding sleeve tight on splines. 3. Free up. Replace worn parts.
4. Misaligned mainshaft or 4. Align.
countershaft.
5. Chips wedged between spline of 5. Remove and lubricate splines.
clutch hub and sleeve.

Noise in Gear 1. Worn or rough mainshaft rear 1. Replace.

bearing.
2. Worn speedometer gears. 2. Replace.
3. Rough, chipped or tapered sliding 3. Replace.
gear teeth.
4. Excessive end play of mainshaft 4, Replace worn or loose parts.
gears.

Oil Leaks . Oil level too high. . Drain to correct level.

. Welch “seal” plugs loose or . Tighten or replace.
missing.
. Wrong lubricant in unit. . Use correct lubricant.
. Oil drain-back opening in . Tighten or replace.
transmission case.
. Defective or improperly installed . Replace or instal! properly.
gaskets.
. Seals defective or omitted from . Replace or install.
bearing caps.
. Cracks or holes in castings. . Repair or replace.
sod

. Transmission breather omitted, or . Replace or unplug.

plugged internally.
. Drain or filler plugs loose. . Tighten.
10. Housing bolts loose or missing. 10. Tighten or replace.
11. Screw-back threads in 14 . Replace.
transmission case.
7B2-4 MANUAL TRANSMISSION

DIAGNOSIS OF MANUAL TRANSMISSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Bearing Failures . Dirty bearing, dirt in lubricant or . Clean.

poor installation procedure.
. Acid etch due to water or other . Drain and install new lubricant.
contaminants in lubricant.
Varnish or sludge coated because . Use proper lubricant and change oil at
the wrong type or grade of scheduled intervals.
lubricant was used. Prolonged oil
change.
. Fatigue spots, cracks or spalling. . Don’t overload vehicle. Be sure proper
Vehicle overloaded or engine engine is installed in vehicle.
torque too high for transmission.
. Straw- or blue-colored metal. Lack . Fill to proper level. Replace loose or
of lubricant or internal parts worn parts.
interference.
. Rough rotation or frozen races. . Replace.
Improper installation-brinelling
bearing, improper fit of shafts or
bore.
. Rust-colored scoring. Fretting . Replace worn parts. Drain and add new
corrosion. fluid.
. Broken retainer or cage causing . Replace.
vibration.
. Chips in bearing. Look for . Repair or replace. Drain oil and add new
clashing clutch gear teeth or other lubricant.
internal damage.

Noisy Operation Fan out of balance or blades are . Replace or straighten.

oats

ah

(Noise Arising bent.

Outside . Defective vibration damper. . Replace.
© fh

& Gh

Transmission) . Crankshaft out of balance. . Machine to achieve balance.

On

. Flywheel out of balance. . Machine to achieve balance.

Ooh

. Flywheel mounting bolts loose. . Tighten.

. Engine rough at idle producing . Check engine and fuel system for
rattle in gear train. probiem.
. Clutch assembly out of balance. . Balance.
ons
oaON

. Engine mounts loose or broken. . Tighten or replace.

. Power take-off engaged. . Disengage.
©o

10. Universal joints worn out. 10 . Replace.

11. Propeller shaft out of balance. 11 . Balance.
. Universal joint angles out of plane 12 . Adjust.
or at excessive angle.
13. Center bearings in drive line dry— 13 . Lubricate or align.
not mounted properly.
14. Wheels out of balance. 14 . Balance.
15. Tire treads humming or vibrating 15 . Replace tires or balance them.
at certain speeds.
16. Air leaks on suction side of 16 . Repair leak.
induction system — especially
with turbochargers.
 MANUAL TRANSMISSION 7B2-5

DIAGNOSIS OF MANUAL TRANSMISSION (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Noisy Operation 1. Growl, hum or grinding because 1. Replace.

(Noise Arising in of worn, chipped or cracked
Transmission) gears.
2. Detective bearing causing hissing, | 2. Replace.
thumping or bumping.
3. Metallic rattles in transmission. 3, Replace or adjust backlash.
Engine torsional vibrations,
defective or faulty injector
excessive backlash in Power
Take Off mounting.
4, Metallic rattles caused by 4. Replace with proper lubricant or add to
improper lubricants, or lack of the proper level.
lubrication.
5. Free running gears seizing on 5. Free up thrust face.
thrust face or inside diameter
causing a squeal at high speeds.
6. Gear seizure at high speed 6. Free up gear(s).
accompanied by a loud squealing
noise.
7. Floating gear on mainshaft has 7. Free up gear(s).
seized.
8. Vibration in power train (engine, 8. Balance or repair.
propeller shafts, joint angle, rear
axle, differential)
g. Lack of backlash between mating 9. Adjust backlash.
gears, or improper shimming of
Power Take Off units producing a
gear whine.

Noise in Neutral 1. Defective anti-lash plate. 1. Replace.

2. Worn flywheel pilot bearing. 2. Replace bearing.
3. Worn or scored countershaft 3. Replace.
bearings.
4, Excessive end play in 4, Replace worn or loose parts.
countershaft or reverse idler gear.
5. Worn or rough reverse idler gear. 5. Replace.
6. Bent or worn countershaft. 6. Replace.
7. Excessive backlash in gears. 7. Adjust or replace worn or loose parts.
8. Incorrect clutch linkage 8. Adjust.
adjustment.
9. Worn mainshaft pilot bearing. 9. Replace.
10. Scuffed gear tooth contact 10. Check gear tooth pattern and align.
surface. Replace gear if worn.
11. Insufficient lubrication. 11. Add lubricant to proper ievel.
12. Incorrect grade of lubricant. 12. Use recommended grade.
13. Worn damper spring of clutch 13. Replace.
disc.
7B2-6 MANUAL TRANSMISSION

ON-VEHICLE SERVICE
TRANSMISSION OIL LEVEL CHECK CHANGING TRANSMISSION OIL
Measure (Figure 2) Drain the transmission oil after driving the vehicle.
The oil will drain more completely.
Biock the vehicle so it cannot move.
* Block the vehicle so it cannot move.
« Disconnect the ground cable from the battery
+ Disconnect the ground cable from the battery
negative (-) post.
negative (—) post.
1. Remove the filler plug (2) from the transmission
1. Remove the drain plug.(3) Provide a pan to
case (1).
catch oil.
2. Check oil level
2. install the drain plug and tighten.
* Add lubricant to within 0 to 10 mm (0 to 0.4 in)
of bottom edge of the filler hole if necessary
[RJ Tighten
(figure.2).
« Drain plug to 69 N-m (51 Ib-ft)
CAUTION: Use ENGINE OIL SAE 5W-30 for the
transmission case.
3. Remove the filler plug (2).
4. Fill the transmission case to level of the filler
3. Install the filler plug.
plug opening.
Tighten
CAUTION: Use ENGINE OIL SAE 5W-30 for the
transmission case.
+ Filler plug to 69 N-m (51 Ib-ft)
5. Install filler plug and tighten.
* Connect the battery ground cable and remove
the wheel blocks.
[RJ Tighten
* Filler plug to 69 N-m (51 Ib-ft)

« Connect the battery negative cable and

remove the wheel blocks.

GEARSHIFT LEVER REPLACEMENT

[es] Remove or Disconnect (Figure 3)

* Block the vehicle so it cannot move.

+ Disconnect the ground cable from the battery
negative (~) post.
1. Gearshift lever knob (4).
2. Cover assembly (5).
« Remove the fixing screw (6) and 3 clips (7).
3. Shift cable (8) and select cable (9).
1. Transmission Case * Disconnect the cables from the gearshift
2. Filler Plug lever.
3. Drain Plug « Remove the C-clips (10) and disconnect the
cables from bracket.
Figure 2. Transmission Oil Level 4. Gearshift lever assembly (11).
* Remove 2 screws (12) and 2 nuts (13).
 MANUAL TRANSMISSION 7B2-7

GEARSHIFT CABLE ADJUSTMENT

After connection of the select cable and the shift

cable, confirm if shift operation Is performed
smoothly. If any dragging or Improper stroke is
present, check and adjust In accordance with the
procedures shown below.

Measure (Figure 4)

Set the transmission in the neutral position, then

confirm if the dimension between the center of the
shift lever play and the instrument center cluster is
within the 283 + 15 mm (11.1 + 0.6 in) . If the
dimension is out of the reference value, adjust as
required.

C—

rw BA ——

.
Gearshift Lever Knob fe
.
Cover Assembly
OO

Screw .
Clip .
COON

.
Shift Cable
.
Select Cable
C-Clip .
om

11. Gearshift Lever Assembly

12. Screw Figure 4. Shift Lever Position Check
13. Nut

Figure 3. Gearshift Lever Replacement [A] Adjust (Figures.3 , 4 and 5)

« Block the vehicle so it cannot move.

[><] install or Connect (Figure 3) « Disconnect the ground cable from the battery
negative (—) post.
1. Gearshift lever assembly (71). 1. Remove the gearshift lever knob (4).
2. Shift cable (8) and select cable (9). 2, Remove the cover assembly (5).
* Connect the cables to the gearshift lever. 3. Disconnect the shift cable (8) and the select
+ Install the C-clips (10) to the bracket. cable (9) on the gearshift lever side.
4, Set the transmission in the neutral position,
[Al aqiust then adjust the dimension between the center of
the shift lever play and the instrument center
» When connecting the shift cable and select cluster to the 283 + 15 mm (11.1 + 0.6 in).
cable to the gearshift lever, adjust the cable. (figure 4).
Refer to GEARSHIFT CABLE ADJUSTMENT 5. Loosen the lock nut (15) of the shift cable (8)
in this section. and the select cable (9), then turn the bali joint
3. Cover assembly (5). (14) or turnbuckle (16) as necessary for
4. Gearshift lever knob (4). respective pins.
6. Fasten the lock nut (15) with specific torque.
» Connect the battery negative cable and
remove the wheel blocks. Tighten
« Lock nuts to 6 N-m (52 Ib-in)
7B2-8 MANUAL TRANSMISSION

7. Install the cover assembly (5).

8. Install the gearshift lever knob (4).

* Connect the battery negative cable and

remove the wheel blocks.

8. Shift Cable 15. Lock Nut 4, Gearshift Lever 10. C-Clip

9. Select Cable 16. Turnbuckie Knob 11. Gearshift Lever
14. Ball Joint 5. Cover Assembly Assembly
6. Screw 17. Grommet Retainer
Figure 5. Gearshift Cable (1) 7. Clip 18. Grommet Seal
8. Shift Cable 19. Grommet
9. Select Cable
GEARSHIFT CABLE REPLACEMENT
Figure 6. Gearshift Cable (2)
| Remove or Disconnect (Figures 6, 7 and 8)

« Block the vehicle so it cannot move.

+ Disconnect the ground cable from the battery 10
negative (-) post. f~ 4
. Gearshift lever knob (4). @
| gp
—

. Cover assembly (5).

aon

s
. Shift cable (8) and select cable (9).
« Disconnect the shift cable and select cable
from gearshift lever.
* Remove the C-clips (10) and disconnect the
cables from gearshift lever bracket.
* Remove the grommet retainer (17), grommet
seal (18) and grommet (19).
+ Tilt the cab.
* Disconnect the shift cable and the select
cable on the transmission side.
* Remove the C-clips (10) and disconnect the
8. Shift Cable 10. C-clip
shift cable and the select cable from the
9. Select cable 20. Bracket
bracket.(20).
* Remove the clips that fix the cables to the
Figure 7. Gearshift Cable (3)
frames or brackets.
« Remove the shift and select cable assemblies.
 MANUAL TRANSMISSION 7B2-9

8. Shift Cable
9. Select Cable
11. Gearshift Lever

Figure 8. Gearshift Cable (4)

tf Fasten the cables with C-clips to the brackets
Inspect on the transmission side.
Check the cables for any deformation, damage or + Fasten the cables with C-clips to the gearshift
lever bracket.
rust, and also check the sliding portion for any
+ Fasten the cables with clips to the frames and
abnormal condition.
When there is any abnormal condition found, brackets.
« Connect the cables to the transmission.
replace it with new one.
* Install the grommet (19), grommet seal (18)
fe] Install or Connect (Figures 6, 7 and 8) and grommet retainer(17).

1. Shift cable (7) and select cable(8). [A] adjust

* Install temporarily that the shift cable and
select cable. « When connecting the shift cable (8) and the
select cable (9) to the gearshift lever, adjust
[?] Important the cables.
Refer to GEARSHIFT CABLE ADJUSTMENT
« Never bend the cables to radius less than 450
given previously in this section.
mm (18 in) unless it is necessary to do so for
. Cover assembly (5).
wiring purposes. And never bend the cables to
A

. Gearshift lever knob (4).

radius less than 180 mm (7 in) even during
a

wiring.
« Connect the battery negative cable and
- install the cables carefully without
remove the wheel blocks.
unnecessary twisting the cable boots.
7B2-10 MANUAL TRANSMISSION

REAR COVER GASKET AND OIL SEAL

REPLACEMENT
| Remove or Disconnect (Figures 9 - 10)

+ Block the vehicle so it cannot move.

+ Disconnect the ground cable from the battery
negative (-) post.
+ Raise vehicle and support with suitable safety
stands.
1. Propeller shaft (figure 9).
* Reference mark the flange yoke (3) to the
parking brake drum (4).
* Disconnect the propeller shaft (2) at flange
yoke (3).
* Put aside the propeller shaft and tie it to the 6. Drive Coupling
frame so it does not interfere with servicing 7. Parking Brake Assembly
work.
Figure 10. Removing Drive Coupling

4, Parking brake drum

Remove the parking brake drum.
5, Drive coupling (Figure 10)
« Remove drive coupling (6) using the puller.
. Parking brake assembly
am oO

. Vehicle speed sensor wiring connector.

. Vehicle speed sensor and vehicle speed sensor
driven gear assembly
Refer to VEHICLE SPEED SENSOR DRIVEN
GEAR REPLACEMENT given previously in this
section.
9. Rear cover (10).
* Remove 11 fixing bolts. Tap the rear cover
with a copper or plastic hammer to remove it.
The rear cover is provided with lugs for
hammering both side.
« Remove the oil seal using the screw driver.

CAUTION: Take care not to damage the sealing

seat of the rear cover with screwdriver.
1. Transmission 3. Flange Yoke If the rear cover has been removed, the oil seal
2. Propeller Shaft 4. Brake Drum must be replaced with new one.

Figure 9. Removing Propeller Shaft

2. Lock nut
+ Apply the parking brake fully.
« Shift the transmission to first gear or reverse
gear.
* Make sure to raise the staking of the lock nut,
then remove the lock nut.
3. Parking brake cable
: Release the parking brake, then remove the
parking brake cable.
« Remove the lock nut from the parking brake
cable with bracket.
 MANUAL TRANSMISSION 7B2-11

[oe] Install or Connect (Figures 11, 12 and 13) [7] Important

1. Rear cover (figures 11, 12) » Install the rear cover on the transmission case
» Apply engine oil to the new oil seal outer within 30 minutes after liquid gasket
circumference and apply multi-purpose grease application.
to the oil seal lip.
- Use the oil seal installer install the oil seal (9) + Install the rear cover and tighten.
to the rear cover (8).
fa] Tighten

* Rear cover to 48 N-m (35 I[b-ft)

™ . Vehicle speed sensor and vehicle speed sensor

driven gear assembly
wu Refer to VEHICLE SPEED SENSOR DRIVEN

os
GEAR REPLACEMENT given previously in this
section.
. Vehicle speed sensor wiring connector.
. Parking brake assembly.

Tighten

« Parking brake bolt to 127 N-m (94 lb-ft)

8. Rear Cover
9. Oil Seal . Parking brake cable.
. Drive coupling (6).
Figure 11. Rear Oil Seal Installation . Parking brake brum
* Apply the parking brake fuily.
» Shift the transmission to first gear or reverse
gear.
. New lock nut (5) with O-ring (figure 13).
: Apply grease to O-ring, and in to the groove of
10 the flange.
* After tightening, caulk the flange nut against
slot in main shaft. When caulking, the nut
flange and the groove of the main shaft or/and
must touch at both shoulders and the bottom
of the grove even if small crack occurs on the
caulking flange of nut.

CAUTION: Do not reuse the lock nui.

Take care not to damage the oil seal.

Tighten

10. Rear Cover « Drive coupling lock nut to 588 N-m (433 Ib-ft)
G. Liquid Gasket

Figure 12. Rear Cover Installation

* Remove moisture and oil etc. on the mating

face.
+ Apply a 2 mm (0.1 in) bead of the liquid
gasket (G) Three Bond 1215 or equivalent to
the rear cover (10) surface (figure 12).
 7B2-12 MANUAL TRANSMISSION

1. Propeller shaft (figure 14).

* Reference mark the flange yoke (3) to the
parking brake drum (4).
+ Disconnect the propeller shaft (2) at flange
yoke (3).
* Put aside the propeller shaft and tie it to the
frame so it does not interfere with servicing
work.
2. Wiring connector.
« Disconnect the wiring connectors from the
vehicle speed sensor, the neutral switch and
the back-up fight switch.
3. Harness connecter (Figure 15)
¢ Remove the clip from the bracket.
Take care not to damage the clip.
Caulking tool
4, Parking brake cable (Figure 16)
NN « Remove the lock nut (5) and adjust nut from the
parking brake cable (6).
« Remove the parking brake cable with bracket
(8).

Figure 13. Drive Coupling and Lock Nut

9. Adjust the parking brake.

Refer to PARKING BRAKE in section 5C.
10. Propeller shaft.
» Line up reference mark.
1. Transmission Reference Mark
amatte

Tighten 2. Propeller Shaft

3. Flange Yoke
* Propeller shaft bolt to 103 N-m (76 lb-ft). 4. Brake Drum

+ Connect the battery negative cable and Figure 14. Removing Propeller Shaft
remove the wheel blocks.
- Remove the safety stands.

TRANSMISSION ASSEMBLY
REPLACEMENT
[+9] Remove or Disconnect (Figures 14 - 22) E
op IT
—— Sond — errr)

ej ap
+ Block the vehicle so it cannot move.
« Disconnect the ground cable from the battery
negative (-) post.
« Raise vehicle and support with suitabie safety
stands.

Figure 15. Harness connector

 MANUAL TRANSMISSION 7B2-13

Fat)
*=)))))))) Ld OED
ao |
ia
ee eee ; Ke :

VICK
ees /2.
AS (Si\
Loe)

u
Me ot

N oN
b

5. Lock nut
6. Parking brake cable
7. Adjust nut
8. Bracket 11. Slave cylinder

Figure 16. Parking Brake Cable Joint Figure 18. Removing Clutch Slave Cylinder

5. Shift cable and select cable (figure 17). 8. Exhaust pipe.

+ Disconnect the shift cable (10) and select 9. Mounting bracket bolts (Figure 19).
cable (9) on the transmission side. 10. Transmission assembly.
6. Clutch slave cylinder (figure 18). a, .
- Remove the slave cylinder (11) assembly with ® Support the transmission with transmission
the flexible hose attached and then tie it to the jack.
frame so that it does not interfere with
servicing works. CAUTION: To prevent the falling of the
7. Starter Motor assembly. transmission, tie it securely to the
- Remove the starter motor assembly then tie it transmission jack with a chain or belt (figure
to the frame so that it does not interfere with 20).
servicing works. Do not allow transmission to hang
unsupported from clutch. Damage to the
9 clutch assembly will result.
ifA
)
LS)XI
UU
)

_
YY
Cl

2s
—_
——

—
viEe 1woh
—

|
nS a

9. Select Cabie
10. Shift Cable

Figure 17. Gearshift Cable

Figure 19. Removing Exhaust Brake Valve
 7B2-14 MANUAL TRANSMISSION

fR] Tighten

* Clutch housing to flywheel housing bolts

(Figure 22)

* Rise the engine and the transmission up into

the rear transmission mount.

3. Exhaust pipe bracket.

Tighten
« Exhaust pipe bracket bolt (Figure 22)

4. Clutch slave cylinder.

12. Chain or Belt
[Q] Tighten
Figure 20. Transmission Assembly
* Slave cylinder bolt to 16 N-m (12 lb-ft)
* Remove the nuts of the transmission
mounting bracket on the crossmember side.
5. Shift cable and select cable.
» Engine and transmission angle may need to
be adjusted for removai.
¢ Hold the rear section of the engine by the jack
or hoist.

CAUTION: When lifting the engine by the jack,

use wood blocks to prevent any possible
damage to the oil pan.

« Remove transmission fastening bolts.

« Pull out the transmission assembly rearward.

[><] install or Connect (Figures 21 and 22)

1. Transmission assembly.
* Support the transmission with transmission
jack.
12. Chain or Beit
CAUTION: To prevent the falling of the
transmission, tie it securely to the Figure 21. Transmission Assembly
transmission jack with a chain or belt (figure
21).

* Shift the transmission into high gear.

« Align the transmission with the engine slope.
* Turn the output parking brake drum to aid
clutch spline engagement.
« Install the clutch housing to flywheel housing
fixing bolts (Figure 22).

2. Mounting bracket bolts.

FR] Tighten

¢ Mounting bracket nut to 97 N-m (72 Ib-ft)

 MANUAL TRANSMISSION 7B2-15

Nem {Ibsft}
(2) 30(1.18) mm (in)
3 5(0.44}

130(118 46{34}
46{34}
18.5
(9./3
oe
18.5 08 (oes; 6) (4) 6)
(0.73)
+
(0.012) Flywheel Housing “
4
3.5(0.14) , 35(1,38),
Flywheel Housing” oes) \Hamess Clip Clutch Housing
46{34}
Clutch Housing
18.5 6.6
(0.73) (0.24)
watt \
Flywheel Housing” 058) \ Gear Control
a) Clutch Housing
Cable Bracket

Pea

t | 76{56}
41 a
{161}

Flywheel Housing” | \ Starter Motor

Clutch Housing

(0)
Engine Ground Cable 0== —--—
7 3K29}

{ | i
4t
(1.61) \ 76056}
Flywheel Housing /” | \'starter Motor
Clutch Housing

4634} O® 88247}

or
14
¢q | 46{34}
(0.55}
Flywheel! Housing” 18.5 34 45
(0.73) (1.34) (0.18)
Ly 1
Clutch Housing Flywheel Housing” \ Exhaust
Pipe Bracket
Clutch Housing

Figure 22. Clutch Housing Bolts Location

6. Wiring connector. FRONT OIL SEAL REPLACEMENT

7. Parking brake cable (figure 16).
8. Propeller shaft. [-9| Remove or Disconnect (Figure 23)
« Line up reference mark. « Block the vehicle so it cannot move.
* Disconnect the ground cable from the battery
Tighten negative (—) post.
+ Raise vehicle and support with suitable safety
* Propeller shaft nuts to 103 N-m (76 !b-ft) stands.
1. Transmission assembly.
* Connect the battery ground cable and remove Refer to TRANSMISSION ASSEMBLY
the wheel blocks. REPLACEMENT previously in this section.
+ Remove the safety stands.
2. Clutch housing
3. Front cover
7B2-16 MANUAL TRANSMISSION

4. Oil seal.
« Use the screwdriver to remove the oil seal
from the front cover.

Oil Hole Oil groove

Figure 25. Front Cover

1. Front cover 2
2. Oil Seal

Figure 23. Front Cover and Oil Seal

CAUTION: Take care not to damage the front

cover.

[oe] Instail or Connect (Figures 24 and 25)

1. Oil seal.
« Apply engine oil to the new oil seal outer
circumference and apply multi-purpose grease
to the oil seal lip.

1. Clutch housing
G. Liquid Gasket

Figure 26. Clutch Housing

2. Front cover (Figure 25)

UP * Apply a liquid gasket (Loctite FMD-127 or
we) equivalent) to the front cover.
Do not apply a liquid gasket to the groove.
Ne

Fy] Important

* Instail the front cover on the transmission

case within 30 minutes after liquid gasket
1. Front cover
application.
2. Oil Seal
* Align the from cover oil groove and the
Figure 24. Front Oil Seal Installation
transmission case oil hole, install front cover.

CAUTION: Take care not to damage the oil seal.

Tighten

Front cover bolts with O-ring to 26 N-m (20 lb-ft)

 MANUAL TRANSMISSION 7B2-17

3. Clutch housing.
important
* Remove moisture and oil etc. on the mating
face. ¢ Install the lower quadrant box assembly on
* Apply a 2 mm (0.1 in) bead of the liquid the transmission case within 30 minutes after
gasket (G) Three Bond 1215 or equivalent to liquid gasket application.
the clutch housing surface (figure 26).
2. Upper quadrant box assembly.
Tighten * Remove moisture and oil etc. on the mating
face
» Clutch housing bolts to 118 N-m (87 Ib-ft) * Apply a 2 mm (0.1 in) bead of the liquid
gasket (G) Loctite FMD-127 or equivalent to
4. Transmission assembly. the upper quadrant box surface. (figure 28)
Refer to TRANSMISSION ASSEMBLY * Install the upper quadrant box to the lower
REPLACEMENT previously in this section. quadrant box and tighten.

* Connect the battery negative cable and [R] Tighten

remove the wheel blocks.
» Remove the safety stands. * Upper quadrant box boits to 53 N-m (39 Ib-ft)

QUADRANT BOX GASKET [¥] important

REPLACEMENT
« Install the upper quadrant box assembly on
[=] Remove or Disconnect the lower quadrant box within 30 minutes after
liquid gasket application.
* Block the vehicle so it cannot move.
« Disconnect the ground cable from the battery 3. Transmission assembly.
negative (—) posi. Refer to TRANSMISSION ASSEMBLY
* Raise vehicle and support with suitable safety REPLACEMENT previously in this section.
stands.
1. Transmission assembly.
Refer to TRANSMISSION ASSEMBLY
REPLACEMENT previously in this section.
2. Upper quadrant box assembly.
3. Lower quadrant box assembly.

| install or Connect (Figure 27 and 28)

1. Lower quadrant box assembly.

» Remove moisture and oil etc. on the mating
face.
* Apply a 2 mm (0.1 in) bead of the liquid
gasket (G) Three Bond 1215 or equivalent to
the control box surface (figure 27).
« Install the lower quadrant box to the
transmission case and tighten. 1. Lower Quadrant Box Assembly
G. Liquid Gasket
Tighten
Figure 27. Lower Quadrant Box Assembly
+ Lower quadrant box bolts to 53 N-m (39 lb-ft) Installation
7B2-18 MANUAL TRANSMISSION

G. Liquid Gasket

Figure 28. Upper Quadrant Box Assembly

Installation

* Connect the battery negative cable and

remove the wheel blocks.
* Remove the safety stands.
 MANUAL TRANSMISSION 7B2-19

MEMO
7B2-20 MANUAL TRANSMISSION

UNIT REPAIR
MAJOR PARTS ASSEMBLY

Figure 29. Transmission Major Parts Assembly

 MANUAL TRANSMISSION 7B2-21

ss
ss s,
»Y

29

. Upper quadrant box assembly . Needle roller bearing; 6th counter gear
OONOAARWD =

. Lower quadrant box assembly . Bearing retainer

. Parking brake drum and flange . Front cover assembly
. Parking brake assembly . Counter shaft front bearing cover
. Clutch housing assembly . Snap ring; counter shaft rear bearing
. Speedometer driven gear assembly . Counter shaft front bearing
. Rear cover assembly . Counter shaft rear bearing
. Speedometer drive gear . Reverse idie gear shait
. Main shaft rear bearing and distance piece . Top gear shaft assembly
. 6th relay lever and spindle . Main shaft rear bearing
©

. Main shaft assembly

kkk

. 6th shift arm and rod

—

. Snap ring; 6th synchronizer , Synchronizer clutch gear

. Reverse idle gear, thrust collar and washer
han

. 6th synchronizer assembly

. 6th blocking ring . Counter shaft assembly
wk

. 6th main shaft gear . Transmission case

oo

. 6th counter shaft gear

Figure 30 and 31. Transmission Major Parts Assembly (Cont.)

 7B2-22 MANUAL TRANSMISSION

7. Rear cover assembly.

[oe] Remove or Disconnect
8. Speedometer drive gear.
Refer to “TRANSMISSION ASSEMBLY 9. Main shaft rear bearing and distance piece.
REPLACEMENT” earlier in this section. 10. 6th relay lever and Spindle.
11. 6th shift arm and roa.
[S] Disassemble (Figures 30 - 44) * Remove the lock bolt (2), then pull out the 6th
shift arm and rod. (Figure 34)
Tools Required.
J-35833 Speedometer driven gear bushing
remover
J-35858 Bearing remover
J-34827 Bearing remover
J-34539 Reverse idle gear remover
1. Upper quadrant box assembly (1).
2. Lower quadrant box assembly (2).
3. Parking brake drum and frange (3).
+ Engage two gear sets or wedge a piece of
hard between the gears and case to prevent
turning of main shaft. (Figure 32)
2. Lock bolt

Figure 34, Removing 6th Shift Arm and Rod

12. Snap ring; 6th synchronizer.

13. 6th synchronizer assembly.
» Clutch hub (3) must be removed with sieeve
(4). (Figure 35)

NOTE:
Take care not to jose plungers and springs.

Figure 32. Removing Parking Brake Drum and

Flange

4. Parking brake assembly (4).

5. Clutch housing assembly (5).
6. Speedometer driven gear assembly (6).
« Disassembly these parts if necessary. (Figure
33)
Remover: J-35833

3. Clutch hub 4. Sleeve

Figure 35. Removing Synchronizer Assembly

14. 6th blocking ring.

15. 6th main shaft gear.
16. 6th counter shaft gear.
17. Needle roller bearing; 6th counter shaft gear.
18. Bearing retainer.
19. Front cover assembly.
1. J-35833

Figure 33. Removing Speedometer Driven Gear

Assembly
 MANUAL TRANSMISSION 7B2-23

20. Counter shaft front cover.

* Turn bolt into threaded hole in the shaft front
cover (5) to release counter shaft front cover.
(Figure 36)

8. J-34827

Figure 38. Removing Counter Shaft Rear Bearing

Threaded hold 24. Reverse idle gear shaft.

5. Front cover » Before removing the set screw. (Figure 39)
Remover: J-34539
Figure 36. Removing Counter Shaft Front Cover

21. Snap ring; Counter shaft rear bearing.

22. Counter shaft front bearing.
« Remove the counter shaft front bearing (7)
using a special tool. (Figure 37)
Remover: J-35858

Figure 39. Removing Reverse Idle Gear Shaft

25. Top gear shaft assembly.

« Insert “-” screwdriver between top gear and
6. J-35858 synchronizer gear, disconnect synchronizer
7. Counter shaft front bearing from retaining clip of top gear. (Figure 40)
* Remove the top gear shaft assembly.
Figure 37. Removing Counter Shaft Front Bearing
NOTE:
23. Counter shaft rear bearing. Take care not to damage to the synchronizer
- Remove the counter shaft rear bearing using blocking ring.
a special tool. (Figure 38)
Remover: J-34827
7B2-24 MANUAL TRANSMISSION

10. Blocking gear 11. Dog gear 13. Holding fixture

Figure 40. Removing Top Gear Shaft Assembly Figure 42. Attach a Holding Fixture

26. Main shaft rear bearing.

*« Remove the main shaft rear bearing using a
special tool. (figure 41)
Remover: J-34827

14. Main shaft assembly

Figure 43. Removing Main Shaft Assembly

28. Synchronizer clutch gear.

12. J-34827 29. Reverse idle gear, thrust collar and washer.
30. Counter shaft assembly.
Figure 41. Removing Main Shaft Rear Bearing * Remove the counter shaft assembly (15) from
the case using a suitable hook or wire. (Figure
27. Main shaft assembly. 44)
- Use a flange nut to attach a holding fixture
(13) to the rear of the main shaft.
This will prevent the reverse gear, and the
thrust washer from falling free during the
disassemble procedure. (Figure 42)

Holding fixture dimensions (reference).

Length: 210 mm (8.27 in)
Inside Dia. : 46 - 48 mm (1.81 - 1.89 in)
Thickness: 3 - 5 mm (0.12 - 0.20 in)

- Remove the main shaft assembly (14) from the 15. Counter shaft assembly
case using a suitable hook or wire. (Figure 43)
Figure 44. Removing Counter Shaft Assembly

31. Transmission case.

 MANUAL TRANSMISSION 7B2-25

5. Main shaft assembly.

Ea Assemble (Figures 45 - 68)

[] Important

* Clean each parts thoroughly.

+ Be sure to use a new O-ring and seal.
« Remove liquid gasket from each fitting surface.

Tools Required.
J-35835

. Transmission case.
4. Hoiding fixture
—

. Reverse idle gear, thrust collar and washer.

on

. Reverse idle gear shaft. (Figure 45)

Figure 47. Installing Main Shaft
+ Apply grease to needle roller bearing.
» Assemble each paris as figure. 6. Synchronizer clutch gear. (Figure 48)
* Align cutting groove of reverse idie gear shaft « Check that the gear and washer are installed
and lock plate installation position. (Figure 46) to the correct position.
* Install the reverse idle gear shaft by tapping « Install the holding fixture (6) to the main shaft,
lightly. then semi tighten the used flange nut (7).
« Set the synchronizer clutch gear (5).
« Remove the main shaft assembly from the
1, case using a suitable hook or wire.
Ve 2 CAUTION:
If i

Front The main shaft is very heavy. If it falls, it can

Side cause serious injury to service personnel.
Place supports beneath the main shaft assembly
Cc |. — ~2
to prevent it from falling.

1. Thrust collar 2. Washer

Figure 45. Installing Reverse Idle Gear Shaft

=a

6. Holding fixture 7. Flange nut

_

Figure 48. installing Synchronizer Clutch Gear

Ve co

7. Main shaft rear bearing. (Figure 49)

- Apply oil to the bearing.
3 Lock plate * Install the bearing to the main shaft.
CGhamfered side of inner race must be facing
Figure 46. Installing Lock Plate the thrust washer.
« Install snap ring to the groove of outer race.
4. Counter shaft assembly.

CAUTION:
The counter shaft is very heavy.
Always support the counter shaft assembly with a
hoist and wire.
7B2-26 MANUAL TRANSMISSION

12. Bearing retainer. (Figure 52)

Tighten

« Bearing retainer bolts to 48 Nem (35 Ibeft)

8. Inner race
9. ist gear 9

Figure 49. installing Main Shaft Rear Bearing

8. Top gear shaft assembly. (Figure 50)

* Apply grease to the pilot bearing.
« Install top gear shaft. 12. Bearing retainer
* Check that the synchronizer clutch gear is fitted
into the main shaft retaining clip correctly. Figure 52. Installing Bearing Retainer
« Check that the top gear shaft turns smoothly.
13. Counter shaft front bearing cover. (Figure 53)
« Use a plastic hammer to lightly drive the front
bearing cover into position in the transmission
case.

NOTE:
Take care not to damage bearing cover outside
rubber.

Figure 50. Installing Top Gear Shaft Assembly

9. Counter shaft front bearing.

10. Counter shaft rear bearing.
11. Snap ring; Counter shaft rear bearing. (Figure 51)
Instalier: J-35835
+ Turn the transmission case upside down.
« Use a hammer and the bearing installer to 13. Counter shaft bearing cover
install the bearing to the transmission case.
« Return the transmission case to its upright Figure 53. Installing Counter Shaft Front
position. Bearing Cover

14. Front cover assembly. (Figure 54)

« When installing the front cover.

NOTE:
Take care not to damage the oil seal lip.

« Apply grease to the oil seal lip.

« Align the main housing oil holes and the front
cover oil grooves.
* Apply recommended liquid gasket (Loctite
11. J-35853
FMD-127 or equivalent) to the front cover
fitting surface.
Figure 51.Installing Snap Ring: Counter Shaft
Rear Bearing
 MANUAL TRANSMISSION 7B2-27

19. 6th synchronizer assembly.

Tighten
* Install snap ring to the sleeve.
+ Install insert, spring and plunger to the clutch
* Front cover bolts to 26 Nem (20 Ibeft}
hub. (Figure 57)
* Align cut-out portion of sleeve spline and
clutch hub groove (except plunger installing

WH
position).
« Install the sleeve to the clutch hub with
pressing plunger.
* The clutch hub oil grooves must be facing the
ae front of the transmission case. (Figure 58)

Liquid gasket J 9
14. Front cover
18
>” “~
ie Cut-out
Portion
Figure 54. Installing Front Cover Assembly.

15. 6th main shajt gear. (Figure 55)

+ Install the 6th gear.

18. Insert
19. Insert

Figure 57. installing 6th Synchronizer Assembly (1)

c
15. 6th gear
Se)
Figure 55. Installing 6th Main Shaft Gear Front _
17
16. Needle roller bearing; 6th counter gear. N a
17. 6th counter shaft gear. (Figure 56)
+ Install the 6th gear as figure.

17. 6th synchronizer assembly

Figure 58. Installing 6th Synchronizer Assembly (2)

20. Snap ring; 6th synchronizer.

21. 6th shift arm and rod. (Figure 59)
* Apply liquid gasket (LOCTITE 262 or
equivalent) to threaded portion of the boit.

Tighten
16. Synchronizer gear
* Lock bolt to 20 Nem (14 Ibeft)
Figure 56. installing 6th Counter Shaft Gear.

18. 6th blocking ring.

* Apply grease to needle roller bearing.
» Install needle roller bearing and 6th counter
shaft gear. Synchronizer clutch gear side of
the 6th counter shaft gear must be facing rear
of the transmission case.
7B2-28 MANUAL TRANSMISSION

25. Rear cover.

+ Apply grease to the oil seal lip.
* Apply liquid gasket (Loctite FMD-127 or
equivalent) to the fitting surface of the rear
cover.
« Tighten rear cover bolts in the sequence
shown in the figure 62.

Tighten

» Rear cover bolts to 48 Nem (35 lb-ft)

Figure 59. Installing 6th Shift Arm and Rod

22, Relay lever and spindle. (Figure 60)

* Install O-ring to the spindle.
* Align the relay lever to the groove of shift arm
rod.

Tighten

* Spindie bolts to 51 Nem (38 lb-ft)

NOTE:
Take care not to damage to the O-ring. 22. Rear cover

Figure 62. installing Rear Cover

26. Speedometer driven gear assembly. (Figure 63

and 64)
1. Apply grease to the O-ring, then install it to
the bushing.

20. Relay lever

Apply grease
Figure 60. Installing Relay Lever and Spindle L/L

23. Main shaft rear bearing and distance piece.

24. Speedometer drive gear. (Figure 61)
» Apply grease to gear teeth surface.
+ Install speedometer drive gear. The spline
cutting portion of the speedometer drive gear
must be facing front of the transmission case.
23 Speedometer driven gear

Figure 63. Installing Speedometer Driven Gear

Assembly (1)

2. install the bushing to the rear cover, then

Front Side
adjust it for 0.1 - 0.3 mm (0.004 - 0.012 in)
clearance between the speedometer drive
\ gear and driven gear.
3. Apply screw hole mark to the bushing from
Apply grease 21
screw hole of the rear cover, then remove
21. Speedometer drive gear the bushing.
4. Make a screw hole to mark applied at step
Figure 61. Installing Speedometer Drive Gear No, 3.
 MANUAL TRANSMISSION 7B2-29

29. Parking brake drum and flange. (Figure 66 and

67)
* Apply grease to the O-ring, and install it to the
groove of the flange.

Tighten

« Flange nut to 588 Nem (434 Ibeft)

NOTE: Be sure use a new flange nut.

* After tightening, caulk the flange nut against

24. Speedometer driven gear slot in main shaft. When caulking, the nut
flange and the groove the main shaft or/and
Figure 64. installing Speedometer Driven Gear must touch at both shoulders and the bottom
Assembly (2) of the groove even if small crack occurs on
the caulking flange of nut.
Screw hole size
Diameter: 4.5 mm (0.177 in)
Depth: 3.5 - 4.0 mm (0.138 - 0.157 in)

5. Install the bushing to the rear cover, then

align screw holes.
6. Tighten set screw.

27. Clutch housing assembly. (Figure 65)

Tighten
* Clutch housing bolts to 118 N-m (87 Ibeft)

Figure 66. Installing Parking Brake Drum and

Flange Assembly (1)

Caulking tool
GB

25. Clutch housing

Figure 65. Installing Clutch Housing Assembly 26. Flange nut 3R

28. Parking brake assembly.

Figure 67. Installing Parking Brake Drum and
Tighten Flange Assembly (2)

30. Lower quadrant box assembly.

« Parking brake bolts to 127 Nem (94 Ibeft) 31. Upper quadrant box assembly. (Figure 68)
- Apply liquid gasket (Loctite FMD-127 or
Refer to PARKING BRAKE in section 5C. equivalent) to lower and upper quadrant box
fitting surface.
« At first fix a reamer bolt with mark (D), then fix
other bolts.
7B2-30 MANUAL TRANSMISSION

Tighten

* Quadrant box bolts to 53 N +m (39 Ibeft)

After assembling the transmission, refili the

case with the new specified transmission oil.

Lubricating Oil Capacity (reference):

5.3 Liters (11.20 pints)

Reamer Bolt

Figure 68. Installing Quadrant Box Assembly

 MANUAL TRANSMISSION 7B2-31

TOP GEAR SHAFT ASSEMBLY

mS)
©
Snap ring Snap ring
ON HOM

Thrust washer Top gear shaft bearing

RNs

Pilot bearing Retaining clip

Thrust washer Top gear shaft

Figure 69. Top Gear Shaft Assembly

7. Retaining clip
fe] Remove or Disconnect
8. Top gear shaft
Refer to “MAJOR PARTS ASSEMBLIES” earlier Inspect (Figure 71 and 72)
in this section.
Make necessary correction or parts replacement if
Disassemble (Figure 70) wear, damage or any other abnormal conditions are
found through inspection.
. Snap ring.
—

. Thrust washer. 1. Visuai check.

anh

. Pilot bearing. « Visually check each of the parts.

. Thrust washer. Check the bearing fittings, the faces, the
Omnb

. Snap ring. splines, and the gears for excessive wear and
. Top gear shaft bearing. damage.
« Use a bench press to remove the top gear
Top gear shaft
shaft bearing. (Figure 70) Top gear shaft bearing
Pilot bearing
Snap ring
Retaining clip
Thrust washer

2. Top gear shaft.

Visually check the oil seal lip sealing face and
C= DNS) ac the spline for excessive wear and distortion.
if there is excessive wear or distortion, the oil
seal lip sealing face and the spline should be
1. Top gear shaft bearing replaced. (Figure 71)

Figure 70. Top Gear Shaft Bearing

 7B2-32 MANUAL TRANSMISSION

Bearing inner Race, Snap Ring, Thickness

and Color mm (in.)
Width of Bearing Snap Ring Color
Inner Race Thickness (t)
21.85 - 21.89 2.64 Green
(0.8602 - 0.8618) (0.1039)
21.89 - 21.93 2.60 Blue
(0.8618 - 0.8634) (0.1024)
21.93 - 21.97 2.56 Yellow
{0.8634 - 0.8650) (0.1008)
Figure 71. Top Gear Shaft 21.97 - 22.00 2.53 White
(0.8650 - 0.8661) (0.0996)
3. Bearings. (Figure 72)
Visually check the balls and rollers for worn
contact surfaces and abrasion.
If there is wear and abrasion, the bearings jt

should be replaced.
pS

Widthof bearing
inner race
[-<t——_——~2o>-4

A eetit

Figure 73. Snap Ring

5. Thrust washer.
6. Pilot bearing. (Figure 74)
* Apply multi-purpose type grease to the
Figure 72. Bearings
bearing.
[+>] Install or Connect

Assemble (Figure 73 and 74)

. Top gear shaft.

&wWh

. Retaining clip.
. Top gear shaft bearing.
. Snap ring. (Figure 73)
» If the bearing is to be replaced with a new
one, measure the bearing inner race width to
determine the correct snap ring thickness.
« Attach a suitable bar and use a bench press. Figure 74. Pilot Bearing

7. Thrust washer.
8. Snap ring.
 MANUAL TRANSMISSION 7B2-33

MAIN SHAFT ASSEMBLY

1. Thrust washer 7. 4th gear and needle roller bearing

2. 1st gear, needle roller bearing and collar 8. Snap ring
3. 1st-reverse sleeve and clutch hub 9. Collar, 3rd gear and needle roller bearing
4. Reverse gear and needle roller bearing 10. 2nd - 3rd synchronizer assembly
5. Snap ring 11. 2nd gear and needle roller bearing
6. 4th - 5th synchronizer assembly 12. Main shaft

Figure 75. Main Shaft Assembly

1. Thrust washer.
[es] Remove or Disconnect 2. ist gear, needle roller bearing and collar.
. ist - Reverse sleeve and clutch hub.
ooh &

Refer to “MAJOR PARTS ASSEMBLIES” earlier

. Reverse gear and needle roller bearing.
in this section. . Snap ring.
. 4th - 5th synchronizer assembly (Figure 76).
[4] Disassemble (Figure 75, 76 and 77) « Remove the 4th - 5th synchronizer assembly
CAUTION: from the main shaft assembiy using a
The main shaft assembly is very heavy - If it falls, adequate puller.
it can cause serious injury to service personnel. « Remove the sleeve from the clutch hub. Be
Piace supports beneath the main shaft assembly careful not to lose plunger, spring and block
to prevent it from falling. after removal of the sleeve.
7B2-34 MANUAL TRANSMISSION

oa) hGD
eatin’

Synchronizer hint
Assembly

Figure 76. Synchronizer Assembly Figure 78. Visual Check

7. 4th gear and needle roller bearing. 2. Dual synchronizer assembly (2nd and 3rd).
8. Snap ring. (Figure 79)
9. Collar, 3rd gear and needle roller bearing.
10. 2nd - 3rd synchronizer assembly.
11. 2nd gear and needle roller bearing (Figure 77).
Duai synchro cone
- Use a bench press to remove each parts.
Outer ring Synchro cone Inner ring

3rd Gear

end Gear
Figure 79. Dual Synchronizer Assembly

3. Clutch hub. (Figure 80)

* Visually check for worn clutch hub inside and
Figure 77. 2nd Gear and Needle Roller Bearing outside if wear is discovered during
inspection, the clutch hub should be repiaced.
12. Main shaft. * Measure the clearance between the insert and
the clutch hub.
Inspect (Figure 78 - 83)
Insert and clutch hub clearance mm (in)
Make necessary correction or parts replacement if
Standard Limit
wear, damage or any other abnormal conditions are
found through inspection. 0.1 - 0.4 (0.004 - 0.016) 0.5 (0.020)

1. Visual check. (Figure 78)

* Inspect all disassembied parts for wear,
damage or inspect the following parts paying
particular attention to the points shown in the
illustrations.

Figure 80. Clutch Hub

 MANUAL TRANSMISSION 7B2-35

4. Insert spring 6. 2nd - 3rd synchronizer (Dual cone type). (Figure

Only the insert springs for the 6th synchronizer 83)
are different in free length from the 2nd - 3rd + Measure the clearance between the
and 4th - 5th synchronizer, so be careful to synchronizer cone and synchronizer gear
assemble correctly. teeth.
+ If the measured valve exceeds the specified
Spring free length mm (in.) limit, the synchronizer assembly must be
replaced.
2nd - 3rd and 4th - Sth 6th
19.9 (0.784) 18.7 (0.736) Gear teeth and synchronizer cone clearance mmi(in.)
Standard Limit
For identification, the 6th synchronizer insert 1.1 (0.043) 0
springs are painted white.

5. Blocking ring. (Figure 81 and 82)

+ Visually check for worn biocking ring inside
fine grooves.

Figure 83. 2nd - 3rd Synchronizer

foe] Install or Connect

Figure 81. Blocking Ring CAUTION:

The main shaft assembly is very heavy.
Measure the clearance between the if it falls, it can cause serious injury to service
synchronizer cone and the blocking ring. personnel.
Place supports beneath the main shaft assembly
Blocking ring and synchronizer clearance = mm(in) to prevent it from falling.
Standard Limit
1. Main shaft.
2.0 (0.079) 0
2. 2nd gear and needle roller bearing. (Figure 84)
1. Secure main shaft with a vice and supporter.
The top gear shaft side must be facing
upward.
2. Lubricate the main shaft with transmission
oil.
3. Apply grease to needle roller bearing.
4. Install the needle roller bearing and 2nd
gear.
The synchronizer gear teeth side of the 2nd
gear must be facing upward.

Figure 82. Blocking Ring and Synchronizer

Clearance
7B2-36 MANUAL TRANSMISSION

Insert
&
? * Cut-out
Portion
Plunger
Apply grease
Nn.

Apply grease

Figure 84. 2nd Gear and Needle Roller Bearing. Figure 86. Synchronizer Assembly (2)

NOTE:
Assemble (Figure 84 — 95) If the synchronizer cone claw and outer ring claw
3. 2nd - 3rd synchronizer assembly. (Figure 85 are not fit to holes or grooves, the synchronizer
and 86) assembly cannot be reassemble to the correct
position.
1. Align synchronizer gear holes of the 2nd
gear and synchronizer cone claws (4
portion). 4. Collar, 3rd gear and needle roller bearing.
(Figure 87 - 89)
2. Align outer ring claw and inner ring groove
(6 portion). 1. Apply grease to needle roller bearing.
3. Fit the outer ring to correct position by 2. Apply grease to 3rd gear thrust surface.
turning the 2nd gear. 3. Install needle roller bearing and 3rd gear to
the main shaft. The synchronizer gear side
4. Reassemble the synchronizer of 3rd gear
of the 3rd gear must be facing downward.
side in a same procedure.

Outer
Ring Synchronizer Cone

. Inner
Ring

Figure 87. Collar (1)

Figure 85. Synchronizer Assembly (1)
4. install the collar to the main shaft by tapping
5. Install insert, spring and plunger to the
with a brass bar.
clutch hub.
§. Check that the 2nd and 3rd gear turn
6. Align cut — cut portion of sleeve spline and
smoothly.
clutch hub groove (except plunger installing
position).
7. Install the sieeve to the clutch hub with
pressing plunger.
8. Note the direction as figure.
 MANUAL TRANSMISSION 7B2-37

4. Install the synchronizer assembly to the

main shaft by tapping with a brass bar.
5. The clutch hub oi! grooves must be facing
4th gear side.

Synchronizer
“ Assembly

Figure 88. Collar (2)

5. Snap ring.
6. 4th gear and needle roller bearing. (Figure 89)
1. Apply grease to needle roller bearing.
2. Apply grease to 4th gear thrust surface. Figure 91. Synchronizer Assembly (2)
3. Install needle rolier bearing and 4th gear to
8. Snap ring.
the main shaft. The synchronizer gear side
9. Reverse gear and needle rolier bearing. (Figure
of the 4th gear must be facing upward.
92)
1. Remove the main shaft assembly from a
vise.
2. Apply grease to needle roller bearing.
3. Apply grease to reverse gear thrust surface.
4. Install needle roller bearing and reverse
gear to the main shaft. The synchronizer
gear side of the reverse gear must be facing
upward.

Figure 89. 4th Gear and Needle Roller Bearing

7. 4th - 5th synchronizer assembly. (Figure 90 and

91)
1. Align cut — cut portion of sleeve spline and
clutch hub groove (except plunger installing
position).
2. Install the sleeve to the clutch hub with
pressing plunger.
3. Fit the blocking ring to the correct position Figure 92. Reverse Gear and Needle Roller Bearing
by turning the 4th gear.
10. 1st - reverse sleeve and clutch hub. (Figure 93)
1. Install the clutch hub to the main shaft
Insert
assembly.
‘ Cut-out 2. Install the sleeve to the main shaft
/ “@ ey Portion assembly.
3. Note the direction of the sleeve as figure.

Figure 90. Synchronizer Assembly (1)

7B2-38 MANUAL TRANSMISSION

Clutch Hub 1st Gear Side

1st Gear Side faa ,

Figure 93. 1st-Reverse Sleeve and Clutch Hub Figure 95. Thrust Washer
11. ist gear, needie roller bearing and collar.
(Figure 94)
1. Install the coilar to the main shaft assembly.
2. Apply grease to needle roller bearing.
3. Install needle roller bearing to the collar.
4. Apply grease to 1st gear thrust surface.
5. Install the 1st gear to the main shaft.
The synchronizer gear side of the 1st gear
must be facing downward.

Figure 94. 1st Gear

12. Thrust washer. (Figure 95)

1. Apply grease to the thrust washer, and
install to the main shaft assembly.
2. Thrust washer flat surface must be facing
1st gear side.

Install the holding fixture to the main shaft, then

semi tighten the used flange nut.
 MANUAL TRANSMISSION 7B2-39

COUNTER SHAFT ASSEMBLY

1. Snap ring 4. Key

2. Counter drive gear 5. Counter shaft
3. 4th gear

Figure 96. Counter Gear Shaft Assembly

| Remove or Disconnect

Refer to “MAJOR PARTS ASSEMBLIES’ earlier

in this section.

[6] Disassemble (Figure 97)

1. Snap ring.
2. Counter drive gear.
3. 4th gear. (Figure 97)
- Use a bench press to remove the counter
drive gear, 4th gear and key from counter Figure 97. 4th Gear
shaft assembly.
4. Key.
NOTE: 5. Counter shaft.
Be careful not to damage to the counter shaft
Inspect

Make necessary correction or parts replacement if

wear, damage or any other abnormal conditions are
found through inspection.

1. Visual check.
« Inspect all disassembled parts for wear,
damage or other abnormal conditions.
* Gears
« Counter shaft
7B2-40 MANUAL TRANSMISSION

| Install or Connect

CAUTION:
The counter shaft assembly is very heavy.
Always support the counter shaft
assembly with a hoist and wire.
Assemble (Figure 98)

1. Counter shaft.
2. Key.
3. 4th gear.
4. Counter drive gear.
1. Lubricate the counter shaft spindle with
engine oil.
2. Use a bench press to set each gear and key
to install the counter shaft.
3. Note the direction of each gears installation
as figure. (Figure 98)

ZL 4th Gear
a

a3 Counter Drive Gear

Figure 98. Counter Drive Gear

5. Snap ring.
Install the snap ring to the snap ring groove of
the counter shaft firmly.
 MANUAL TRANSMISSION 7B2-41

UPPER QUADRANT BOX

1. Air breather 6. Snap ring

2. Upper quadrant box 7. Internal shift lever
3. Key bolt, washer and nut 8. Shift shaft
4, External select lever, washer and 9. Boot
oil seal 10. Gap
5. Internal select lever 11. Oil seal and bushing

Figure 99. Upper Quadrant Box Assembly

 7B2-42 MANUAL TRANSMISSION

[+s] Remove and Disconnect

Assemble (Figure 101 - 103)
Refer to “MAJOR PARTS ASSEMBLIES’ earlier
in this section. [¥] Important

[$] Disassemble (Figure 99 and 100) Clean each part thoroughly.

. Air breather. 1. Oil seal and bushing. (Figure 101)

A

. Upper quadrant box. » Use a suitable bar to drive the bushing and
hy

. Key boit, washer and nut.

Oa

install it specified depth as shown in the

Bw

. External select lever, washer and oil seal. illustration.

. Internal select lever.
. Snap ring. NOTE:
. Internal shift lever. Take care not to damage the bushing.
CON

. Shift shaft. (Figure 100)

« Remove the snap ring (1) from the shift shaft
(2) snap ring groove to remove the shift shaft
from the upper quadrant box.

(mm)
Oil seal Bushing Oil seal

Figure 101. Bushing

1. Snap ring
2. Shift shaft * Apply gear oil to the seal outer circumference.
* Apply multi-purpose type grease to the oil seal
Figure 100. Shift Shaft lip.

NOTE: NOTE:
Take care not to damage the shift shaft. Be sure to use a new oil seal.

9. Boot. 2. Cap.
10. Cap. 3. Boot. (Figure 102)
11. Oil seal and bushing. + Install the boot to the upper quadrant box. The
“UP” mark of the boot must be facing upward.
Inspect

: All disassembied parts for wear, damage or other

abnormal condition.
« Check detent shoulders for rounding.
Rounding can cause gear slip out.
- Replace parts that are found worn.

1. Air breather.
2. Shift shaft.
3. Upper quadrant box.

Figure 102. Boot

 MANUAL TRANSMISSION 7B2-43

4. Shift shaft.
5. Internal shift lever.
6. Snap ring.
+ Apply gear oil to the shift shaft sliding portion.
+ Install the shift shaft to the upper quadrant
box.
« Align the shift shaft spline and internal shift
lever spline, install the internal shift tever to
the shift shaft. (Figure 103)
- Install the snap ring to the shift shaft snap ring
groove.

NOTE:
Take care not to damage the oil seal.

Figure 103. Internal Shift Lever

7. Internal select lever.

8. External select lever, washer and oil seal.
9. Key bolt, washer and nut.
* Apply a liquid gasket Loctite FMD-127 or
equivalent to the internal select lever sliding
portion.
- Install the internal select lever to the upper
quadrant box.
- Install the washer to the internal select lever.
- Install the key bolt to the external select lever.

Tighten

Key boit to 16 Nem (12 Ibeft)

10. Upper quadrant box.

11. Air breather.
- Apply a liquid gasket Loctite 242 or equivalent
to the air breather threaded portion.
+ Install the air brather to the upper quadrant
box.
7B2-44 MANUAL TRANSMISSION

LOWER QUADRANT BOX

1. Set bolt 6. 2nd - 3rd shift rod and shift arm

2. Back up light switch 7. 1st-reverse shift rod and shift arm
3. Neutral switch, pin and interlock 8. 4th - Sth shift rod and shift arm
bail 9. 6th shift rod and shift block
4. Lock bolt 10. 1st-reverse shift lever and spindle
5. ist-reverse shift rod and shift block 11. Lower quadrant box

Figure 104. Lower Quadrant Box Assembly

 MANUAL TRANSMISSION 7B2-45

[-s] Remove and Disconnect

Refer to “MAJOR PARTS ASSEMBLIES?’ earlier

a
in this section.
ie
[é] Disassemble (Figure 104 - 107)
Rp
1. Set bolt.
2. Back up light switch. ®
3. Neutral switch, pin and interlock ball.

NOTE:
Be careful not to lose the interlock ball and pin.
Figure 106. Shift Block
. Lock bolt. 10. 1st-reverse shift lever and spindle.
. tst-reverse shift rod and interlock bail. 11. Lower quadrant box.
Oa

. 2nd - 3rd shift rod and shift arm.

. 1st-reverse shift rod and shift arm. Inspect
OOnN

. 4th - 5th shift rod and shift arm.

. 6th shift rod and shift block. (Figure 105) « All disassembled parts for wear, damage or other
- Temporarily tighten the shift block to the abnormal condition.
regular pasition. + Check detent shoulders for rounding.
+ Drive out the rod together with cap. Rounding can cause gear slip out.
When removing parts, exercise care so as not + Replace parts that are found worn.
to permit detent ball to snap out of position.
« The interlock pin is loosely fitted in the shift 1. Visual check.
rod which is installed in position between the « Inspect all disassembled parts for wear,
interlock balls. Do not lose the pin after damage or other abnormal conditions.
removal of the rod. « Inspect the following parts paying particular
attention to the points shown in the
NOTE: illustrations.
Be careful not to damage the shift rod and 2. Shift rod and interlock pin. (Figure 107)
quadrant box inner surface. * Check the shift rods for excessively worn
detent grooves.
If the detent groove wear is excessive, the
shift rod should be replace.

Shift rocl
“a

Interlock pin
Figure 105. 6th shift Rod

+ Disassemble the shift block assembly. (Figure

106) Figure 107. Interlock Pin
Remove the cap from the shift block and draw out
the return spring and sleeve. A locking ball and
locking spring will jump out when the sleeve is
pulled out, so be careful not to lose them.
7B2-46 MANUAL TRANSMISSION

3. Shift block.
Measure (Figures 108 - 110)
Measure sleeve return spring and lock ball
1. Shift arm. (Figure 108) spring.
* Measure each shift arm thickness.
Sleeve Return Spring Free Length (Figure 110)
Shift Arm Thickness mm (in.) (Reference) mm (in.)
Standard Limit ist-Reverse 6th
11.0 (0.433) 10.0 (0.394) 61.5 (2.421) 61.5 (2.421)

if the measured value exceeds the specified limit, Lock Ball Spring (Reference) mm (in.)
the shift arm should be replaced. 1st-Reverse 6th
35 (1.378) 33 (1.299)

dle

Figure 108. Shift Arm

2. Detent spring. (Figure 109) Figure 110. Spring

* Measure the detent spring.
Assemble (Figures 111 - 122)
Detent Spring Free Length (Reference) mmiin.)
Standard Limit fy] important
28.0 (1.102) 26.0 (1.024)
« Clean each part thoroughly.
« When assembling parts, apply clean engine
If the measured value exceeds the specified limit, oil to their sliding and mating section.
detent spring should be replaced.
1. Lower quadrant box.
2. 1st-reverse spindle and shift lever. (Figure 111)
« Apply engine oil to the spindle.
* Install the spindle and shift lever to the lower
quadrant box.

fQ] Tighten

Spindle nut to 50 Nem (37 Ibeft)

Figure 109. Detent Spring

 MANUAL TRANSMISSION 7B2-47

_- Apply oil
~ Shift lever

Figure 111. Spindle and Shift Lever Figure 113. Shift Block

3. 6th shift rod and shift block. (Figure 112 and 4. 4th - 5th shift rod and shift arm. (Figure 114 -
113) 116)
+ Insert the lock ball spring and ball to the shift + Apply engine oil to rod, and insert the inter
block. lock pin.
» Apply engine oil and install the sleeve.
* Tighten cap to the specified torque, then caulk
1 portion.

Tighten

Cap to 88 Nem (65 Ibeft)

| 7 L Caulk

[ ae
NTN Figure 114. Interlock Pin

* The interlock pin is fitted in the shift rod which

is installed in position between the lock balls.
When installing rod, exercise care to prevent
the pin from being dislocated.

Figure 112. Cap

Detent ball
Apply engine oil to shift rod.
ball to the shift block. Shifter rod
Insert detent spring and
Install shift rod and arm in proper direction of
--

installation, then set the rod in neutral position.

Partially tighten the lock bolt to the shift block.
~-}-2

Do not lose inter

Interlock ball [ck pin

Figure 115. Interlock Pin

« Install shift rod and arm in proper direction of

installation, then set rod in neutral position.
7B2-48 MANUAL TRANSMISSION

7. 1st-reverse shift rod and shift block. (Figure 119

and 120)
+ Insert the lock ball spring and ball to the shift
block.
* Apply engine oil and install the sleeve.
* Apply liquid gasket (LOCTITE 242 or
Front Side
equivalent) to threaded portion of the cap.

[RQ] Tighten
Cap to 88 Nem (65 Ibeft)

Figure 116. Shift Rod and Arm

5. 1st-reverse shift rod and shift arm. (Figure 117)

+ Refer to reassembly procedure No. 4.
* Note the direction of shift arm installation as
figure.

A
= NW
ff

Front Side
Figure 119. Cap

» For reassembly of shift rod and shift block,

refer to step No. 4 reassembly procedure.
* Note the direction of shift block installation as
figure.

Figure 117. 1st-Reverse Shift Rod and Shit Arm

6. 2nd - 3rd shift rod and shift arm. (Figure 118)

- Refer to reassembly procedure No. 4.
* Note the direction of shift arm installation as
figure.
Goat
5
!

Figure 120. 1st-Reverse Shift Rod and Shift Arm

8. Lock bolt.
« Apply liquid gasket (LOCTITE 262 or
equivalent) to threaded portion of the bolt.
* Tighten lock bolts to the specified torque.

[A] Tighten
Figure 118. 2nd - 3rd Shift Rod and Shift Arm
Lock bolt to 20 Nem (14 lb-ft)
 MANUAL TRANSMISSION 7B2-49

9. Neutral switch, pin and interlock ball. (Figure

121)
« Insert interlock ball and pin to the switch hole,
and tighten neutral switch to the specified
torque.

Tighten

Neutral switch to 20 Nem (714 lb-ft)

Figure 121. Neural Switch

10. Back up light switch. (Figure 122)

Tighten
Back up light switch to 20 Nem (14 Ibeft)

&

Figure 122. Back-Up Light Switch

11. Set bolt.

+ Apply liquid gasket (LOCTITE 242 or
equivalent) to threaded portion of the set bolt.

Tighten

Set bolt to 18 Nem (13 Ibeft)

7B2-50 MANUAL TRANSMISSION

SPECIFICATIONS
TrANSMISSION TYPO... ee eee eseesceeteeeansessennsseeneessesesssseeearseaesnscateeessusensansasenarneuenees MBP-6P Direct Drive 6-Speed
Gear Mes Type on... ceeesccsesssseeccasssnensesceeneeaeneosseecaesesacesausesenesseeessasecacsaessepeacenseseassaneseces 2nd to 6th: Synchro-mesh
1st and Reverse: Constant-mesh
Gear Ration... ec cceceesceceseseesesssessssesseeceseeneeussaeunessesenoeseceaessceseessesesuseuessanseeneeceucoessssusaurssseasaseeetaasasenseaseners ist 6.378
2nd 3.627
3rd 2.239
4th 1.452
5th 1.000
6th 0.787
Reverse 6.595
LUDFICATING OF) oo eee ceeessecensecenessenescaneseusaeasecsaeescesseessstsnessesesesceueseesaunssneusaeseessacanensenenenens Engine Oil SAE 5W-30
Oil CAD ACIY ooo... ee eeeeeeeeeeeeceesseeeessanneratesetcenensssenesaeassescseaavecsusaeansatasesessenseasuessesenesses Approx. 5.3 Liters (11.20 pints)
Weight without Lubricating Oil 0... eee eeseeseceseesoecnesssersseessessessneseussuessensassseeseeseunpessearscsantssanaacssnte 130 kg (286 Ib)
Distance between Center of Shift Lever Play and Center Cluster............ccsscssscsecesssss 283 + 15 mm (11.1 + 0.6 in)
Clearance between Insert and Clutch HUD .0...... cc scesessesesssrecesssssensenenssonseetsnessectentssnees 0.1-0.4 mm (0.004-0.016 in)
Free Length Spring (2nd-3rd and 4th-Stt) ...... ss esssccescssecnsseccesssensssesensrssesesenssanenecseresesesecenaceouees 19.9 mm (0.784 in)
Free Length Spring (6th) 2.0.0.0... ee eeccseesecenssescseeseesensesneseasseasneseeueeneesnonsuesuesseesansesasensereatesceensenneeas 18.7 mm (0.736 in)
Clearance between Blocking Ring and SynchroniZet...............:ccssccssnecsscnsesessecsesseecenenanesessessssscoenes 2.0 mm (0.079 in)
Clearance between Synchronizer cone and Synchronizer gear (Dual Cone Type) ...........:.c.:ccce 1.1 mm (0.043 in)
Spline Play between Clutch Hub and Mainshaft ............:c.csesscsesesecsnesecesseseceseseeeseesserenes Less than 0.5 mm (0.020 in)
Shift Arm Thickn@Ss «0.0.0... cc eseeetescesoseeneeeseneenseeneerenetonteees poseantonsaennseseneeneatentsreoensess More than 10.0 mm (0.394 in)
Free Length of Detert Spring 0.0... ce ceessecceesseeeseecesaenoesesaeaseeesecusacesesgetenenauaesssaseness More than 26.0 mm (1.024 in)
Free Length of Return Spring (1St-reverse) 0... eeeeceeeseeceeeesenseneeesnaesesnsaneaesaeeeuess More than 61.5 mm (2.421 in)
Free Length of Return Spring (Gt) ........ ec eesscesseeeccceseeeseneeseesennesassesaeseenstuaseesnaesneens More than 61.5 mm (2.421 in)
Free Length of Lock Ball Spring (1St-reverse). 2.02... esecessscesneeeseeseeeceateseeeseneeaeeeennesses More than 35 mm (1.378 in)
Free Length of Lock Ball Spring (6th)... cc esscsscnessersseessseceeeressencsneceesesseseseeesouseensenans More than 33 mm (1.299 in)

FASTENER TORQUES

Clutch Housing to Flywheel HOUSING Bolt ....... cece ecesssesenenveceesseonaeeesussnsaceeenasenseeasecaueesssersssseedeeess 46 N-m (34 lb-ft)
Clutch Housing to Transmission Case Bollt.................ccscesscessecceesesccesseeesnseseesensseeeesecntenneseaueenasesueeess 118 N-m (87 lb-ft)
Rear Cover Bolt ........eeccceecsccsnesensereeeseeseesesaceneeesoeaeneesscusescemeneeeenessroneaoeteaeesseneneessinesseeteeeetaneseeneuaeueses 48 N-m (35 lb-ft)
Quadrant Bolt ..0....cecccseceeeeeeneesseecsesessenseeeeeaesecessnonseaneasonsaeesssnseeeusansnscessredeasenerersnonsensseseeeetsenssesanecsees 53 N-m (39 lb-ft)
Filler PlUG).......::cccsseeseessccsseseseeeeeceesscceserencnseneaesasecsnsesaaenacescassesaeensuesecaensedenuseneasencenueeseateeestieetteceneenens 69 N-m (51 Ib-ft)
Drain PIUG .........ccccssceccesecneesecersuesesuesounneencceneaesanreneonsones daneecereenseeanersonserse snesaedenseesaaesereeausoesensaeeceneesesses 69 N-m (51 Ib-ft)
Drive Coupling LOCK Nut... eee cceessesrescuseenssseseuesceaeonmessaesconsenssessensesneneesnadeeustectaceanaeessenenees 588 N-m (433 Ib-ft)
Backup Light SWitCh........ ccc seccesessesessesesectesenneescnenseseucoesaesaneasensenssnaneuconseusaesatentausestsnassteosenssenstenesaas 20 N-m (14 lb-ft)
Neutral SWHCH ..........:ccccsscecesssecerconseressseseeesnuessoeaeneneseneanssossetesuaeasseeedeseanensensscaneesecasessecanecseatesieeenneananes 20 N-m (14 lb-ft)
Transmission Rear Mount Nut and Bolt ............:cccsssccsssrscscssesssensaesonsessenenetensusenacseoeeseaseseuscnesseeenssusoues 97 N-m (72 lb-ft)
LOCK Bolt .......c:cccccscssesesceseeecesesesesneseesssnecenseeasseneesneasensnersecensssaenseesesaseessenenssaesenssanseeteoaseasneneesenseencecee® 20 N-m (14 lb-ft)
Set Bolt... csccessessesesssececeseceesesencessuseasaesensvaceeatsoasseseonsananeeseonsensenstes soncdenesersensosenaenecsenseseeenerentanens 18 N-m (13 Ib-in)
Clutch Slave Cylinder Mounting Bolt... ceessesceeaeseeeesanesccessneuccueveeusanesssusdseerseteneonssaseraeereaees 16 N-m (12 lb-ft)
Vehicle Speed Sensor Driven Gear Mounting Bolt... cs ccsecsssseseseneneneaneessensevseusnensssensesensseseasans 15 N-m (11 Ib-ft)
Vehicle Speed SONSOM oo... sea cesessecssscnesersesssnseeessesusceveceaesneseaususaseessassuaieceaueesseuseuseusnessssesausuavessenens 25 N-m (18 lb-ft)
 MANUAL TRANSMISSION 7B2-51

SPECIAL TOOLS
TOOL NO.
ILLUSTRATION TOOL NAME

J-35833
Remover;
Speedometer gear bushing

J-34827
Remover;
Main/Counter shaft rear
bearing

J-34539
Remover;
Reverse idle gear shaft

J-35858
Remover;
Counter shaft front bearing

J-35853
Tool;
Bearing setting
MEMO
 CLUTCH 7C1-1

SECTION 7C1

CLUTCH (FOR MXA TRANSMISSION)

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE

Description ........-.::sccccesscscsscsssoesusnesenrsssssnsonsesorstsestasnaenseneanssrenseanesnedstasnessesouecsesnensseanrersunearssecouuestannaeneusensuneseaes 7C1- 1

Clutch SySteim.........escsccsessccsessscsssssesensensunentausontnecsnsseneeeceateaeeeesenneensnsensesaeonersenessnenecenennscensesanananeneeneecnias 7C1- 1
Diagnosis Of ClUtCh ........cccsesssecsesssesensseecnsscnnnensenenseseenssneneseentsarsaneniasnenssensinsnaasennensisntnenuasaneusncerevaceusanssenezas 7Ci- 2
On-Vehicle Service .........:ccscccecececssessennenensesseseusueuessoasacersecaseessaceseiereceusanssesseasentane asneneneteedesenantaetnssennesaveseesues 7C1- 5
Clutch System Inspection.........ccsecescssscserstsentenrensanannennneensenesneansatesesiessercesentunsenaniaceneamaneecsnssenanenceranas 7C1- 5
Clutch Pedal Free Play, Height and Travel Adjustment ......... ponsndenuneevenensensaaseseeseeieesaaanausesoneesecrsauencauenes 7C1- 5
Bleeding the Clutch Hydraulic Circuits ...........:cesesesseeenesseneounernanenaes siedenncauvanseesaeauataueeuvansesneesurousenens 7C1- 7
Component Parts Replacement.........sccscseseceerseeenenssessennenseanvnninesansesenuseraeneasuvanesouoseeaaseneenererseanensonsseesesy 7C1- 8
Clutch Disc and Pressure Plate...........ccsscccscsersessseessscsusssecsesesesenusnesaneseusunseneesarsastorenensetenuoceensseeneneansensses 7C1- 8
Clutch HOUSIng ..........ccccsecsensecsssscnessnunseseeseusensrersencnsnsnnusneancncenensnersenseneneecaeasenacseaeaneneanasaseneeanenasienanaasanaes 7C1-10
Clutch Controls ......ccccsecstccsssssscescsnsesssesscescesannen tnenseaesontusnaceoons
wens tnuntoaeuysorsanseseucaesntanteneneassucanensae nsanonsunenencaine 761-14
Unit Repair.........ecececsssseecessserssssssenansonsnssaesesesessenssesensenencensansenesnascneneesieseodsaseaenuonsansrassaneasauausineiaueusuaueenesacasseates 701-13
Master Cylinder ..........:scscscsesssssesnusssserenenssssersenncnneeneceresseneaseasecesnnenssraneuesunneeconsenedneasananseesanecanscouanesseacontss 701-13
Slave Cylinder ........sccscessssrenesesenssseesareerecnesnenenersenneesenannrsanes sasaedenensureauevacdenusaedsesavaceueaeuausasuvaunesanennensas wn lC1-14
Specifications.......c..esssecesssesesercssssssssesseetesaceneeenssnnarerenecneucesaceneoosseesiancatecanesnansantaseeansseneusceeseeseansnnanssnenonses 761-16
Fastener TOrques..........sssccscseressssscensssssssnessstascenseesnresenseanenniecerarscetensnecnereannnneavensrsueuatausegnenssanvaenessunsungeanaas 761-16
Special TOOIS.......cscccsssscccsssessssnersnenscenenseessseseenseeeenanescecasieneeantaeaesreesnnerseneereess suvsuseueeusoevansaansesseeatensenaneneeanenens 701-16

DESCRIPTION

CLUTCH SYSTEM shaft through these same splines. Suitable frictional

facings are attached to each side of the clutch disc
Driving Members by means of rivets. These facings must be heat
The driving members of a clutch usually consist of resistant since friction produces heat.
two flat surfaces machined to a smooth finish.
One of these surfaces is usually the rear face of the Operating Members
engine flywheel, and the other is a comparatively The driving and driven members are held in
heavy flat ring with one side machined. This part is contact by spring pressure.
known as the pressure plate. It is fitted into a steel The throwout (clutch release) bearing is a
cover, which also contains some of the operating ballthrust bearing contained in the ciutch housing,
members, and is bolted to the flywheel. mounted on a sleeve attached to the front of the
transmission case. The throwout bearing is moved
Driven Member by the clutch release yoke to contact the release
levers and move the pressure plate to the rear, thus
The driven member is a clutch disc with a splined separating the clutch driving members from the
hub which is free to slide lengthwise along the driven member when the clutch pedal is depressed
splines of the clutch shaft, but which drives the
by the driver.
701-2 CLUTCH

Clutch Controls cylinder, interconnected with hydraulic lines. The

This system utilizes hydraulic pressure as a clutch pedal is connected to the master cylinder
means of transmitting clutch pedal movement to the pushrod, and the slave cylinder pushrod is
clutch release mechanism. The system consists of connected to the clutch release fork.
a pedal-operated master cylinder and a slave

DIAGNOSIS OF CLUTCH

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Slips 1. Binding of release levers in the 1. Replace the clutch cover assembly.
pressure plate and cover
assembly.
2. Clutch release levers improperly 2. If levers are in place, adjust free pedal.
adjusted.
3. Facings loose on the clutch disc. 3. Replace the driven disc assembly.
4. Improper clutch release bearing 4. Adjust for proper clearance (free pedal).
adjustment.
5. Binding or sticking clutch pedal 5. Repair or replace faulty parts.
assembly. Check linkage for proper adjustment.
6. Weak or broken clutch pressure 6. Replace the clutch cover assembly.
springs.
7. Burned clutch facings. 7. Replace cluich driven disc assembly
and check flywheel and pressure plate
friction surfaces for damage replace
parts as necessary.
8. Binding or sticking of the clutch 8. Lubricate splines with high temperature
disc hub on the transmission drive grease (if dry). Replace driven discs if
gear. splined hubs are worn.
9. Release bearing binding on 9. Replace release bearing or lubricate.
bearing retainer.
10. Warped pressure plate or engine 10. Replace defective parts. Check
flywheel. transmission, clutch, and engine
alignment.
11. No free pedal. 11. Adjust for free pedal, check clutch driven
disc wear and replace parts as required.

Clutch Chatters 1. Loose engine mounts. {. Tighten engine mount bolts to

During Engagement specifications.
2. Grease or oil on facings. 2. Replace driven disc assembly and repair
oil leak.
3. Slight binding in linkage during 3. Check linkage for wear or damage.
engagement. Replace parts as required.
4. Weak pressure springs. 4. Replace clutch cover assembly.
5. Clutch release levers binding 5. Repair or replace cluich cover
during engagement. assembly.
6. Worn or broken pilot bearing. 6. Replace and lubricate pilot bearing.
7. Rough engine idle. 7, Tune engine to manufacturer's
specifications.
 CLUTCH 7C1-3

DIAGNOSIS OF CLUTCH (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Chatters . Bent or out of plane pressure . Replace clutch cover assembly if
During Engagement plate fingers. release fingers are more than 2 mm
(Cont.) (0.079 in) out of plane.
. Driven disc warped, cracked, or . Replace driven disc assembly.
loose friction material.
10. Pressure plate warped or hot 10. Replace pressure plate or clutch cover
spots. assembly.
11. Flywheel warpage or 11. Replace flywheel.
discoloration.
12. Flywheel housing bore and face 12. Correct per alignment procedure.
not aligned.

Clutch Drags When 1. Pedal cannot disengage clutch 1. Check pedal and linkage for wear,
Disengaged because of excessive free pedal replace parts as required.
travel. Adjust clutch and linkage for proper free
travel.
2, Clutch release levers need 2. Replace clutch cover assembly.
adjustment.
3. High spots on clutch facings. 3. Replace driven disc assembly.
4. Loose rivet in facings. 4, Replace driven disc assembly.
Check for damaged flywheel and
pressure plate, replace as necessary.
5. Clutch disc wobbles because of 5. Replace driven disc assembly.
broken springs in hub.
6. Flange of clutch cover not in 6. Torque bolts to specifications or replace
alignment with flywheel because cover assembly.
of loose bolts or bent flange.
7. Deteriorated or broken engine 7. Replace engine mountings.
mounts.
8. Worn clutch release bearing. 8. Replace release bearing and adjust
clutch free pedal.
9. Worn linkage components. 9. Check pedal and linkage for wear;
replace parts as required.
10. Clutch disc warped. 10. Replace driven disc assembly, also
check flywheel for deep heat checks.
Replace flywheel as necessary.
11. Broken or loose facings. 11. Replace driven disc assembly.
12. Misalignment of transmission. 12. Check engine mounts, wear on flywheel
housing, and bolt torque.
13. Main drive gear misaligned 13. Repair transmission if required and
because of worn bearings. check flywheel pilot bearing; replace
pilot bearing as required.
14. Clutch pressure plate warped. 14. Replace clutch cover assembiy; also
check flywheel surface for dished out
wear pattern. Replace flywheel as
required.
15. Loase flywheel housing bolts. 15. Torque bolis to specifications.
701-4 CLUTCH

DIAGNOSIS OF CLUTCH (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Grabs . Grease or oil on clutch facings. . Replace driven disc assembly and
repair oil leak.
. Exposed rivet heads due to . Replace driven disc assembly and
excessively worn facings or check for flywheel and pressure plate
loose rivets. damage. Replace damaged parts.
. Loose engine mounts. . Tighten engine mount bolts to
specifications.
. Clutch pressure springs too stiff. . Replace clutch cover assembly.
. Momentary binding in linkage . Check pedal and linkage for wear or
while clutch is being engaged. damage. Replace parts as required.
. Warped pressure plate, or . Replace damaged parts. Check
flywheel. alignment.

Clutch Noisy When . mproper clutch release bearing . Adjust clutch linkage for pedal free
Engaged adjustment. play.
. Glutch disc damper springs . Replace driven disc assembly.
weak or broken.
. Linkage binds. . Check pedal and linkage. Replace or
repair as required.
. Clutch release bearing binding. . Check for alignment and release
bearing lubricant. Replace bearing as
required.
. Loose flywheel or clutch cover . Torque bolts to specifications.
bolts.
. Misalignment of transmission. . Gheck engine mountings, wear on
flywheel housing, and fastener torque.
. Worn splines on clutch disc or . Replace parts as required.
transmission main drive gear. Lubricate with high temperature
grease.
. Weak or missing clutch return . Replace clutch cover assembly.
springs.
. Clutch pedal assembly binding. . Check pedal and linkage for wear or
damage. Repair or replace parts as
required.

Clutch Pedal . Misalignment of transmission. . Check engine mountings, wear on

Pulsates During flywheel housing, and fastener torque.
Engagement . Loose or improperly installed . Refer to ENGINE (SEC. 6A) for proper
engine mounts. engine mount installation.
. Clutch release levers not . Replace clutch cover assembly.
adjusted to uniform height.

Clutch Rattles When . Wear or looseness in linkage. . Check linkage for wear or damage.
Disengaged with Replace parts as required.
Engine Idling . Retractor springs on release . Replace clutch cover assembly.
lever weak, broken, or
disconnected.
. Loose flywheel or clutch cover . Torque bolts to specifications.
bolts.
. Rough engine idle. . Tune engine to manufacturer’s
a

specifications.
 CLUTCH 7C1-5

DIAGNOSIS OF CLUTCH (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Noisy When 1. Pilot bearing or bushing in 1. Replace parts as required.

Disengaged crankshaft worn, damaged, Lubricate with high temperature
broken, or inadequately grease.
lubricated.
2. Release bearing worn, dirty, 2. Replace release bearing.
damaged, broken, or Lubricate with high temperature
inadequately jubricated. grease.
3. Transmission main drive gear 3. Repair transmission. Check for rear
bearing worn, dirty or lacks bearing cap oil hole for restriction
lubricant. clearance.

ON-VEHICLE SERVICE

CLUTCH SYSTEM INSPECTION

The system should be checked and serviced

periodically as stated below.
« Maintain the proper level of hydraulic fluid in the
master cylinder reservoir. Refer to
MAINTENANCE AND LUBRICATION (SEC. OB)
for recommended fluid and checking intervals.
+ Inspect the entire clutch system regularly for fluid
leakage. Leakage must be corrected immediately.
* Adjust the clutch linkage if necessary.
« If the clutch pedal action is springy or spongy, it is
an indication that air needs to be bled from the
hydraulic system.
A specified clearance in the hydraulic control
linkage must exist between the end of the push rod Figure 1. Master Cylinder Reservoir
and master cylinder piston. This clearance is
measured as pedal free travel.
Before making the adjustment, make sure that the
CLUTCH PEDAL. FREE PLAY, HEIGHT
level of fluid in the master cylinder reservoir is 13
AND TRAVEL ADJUSTMENT
mm (1/2 in) below the top of the reservoir. The fluid
system must be free of air.
Adjust (Figures 2, 3 and 4)
The dual brake/clutch master cylinder reservoir is 1. Loosen the jam nut (5) on the clutch switch (6)
in the left-upper portion of the dash panel. it can be (figure 4).
accessed by opening the driver door (figure 1). 3. Remove the master cylinder from the clutch
pedal assembly.
2. Loosen the jam nut on the master cylinder push
rod (figures 2 and 3).
3. Turn the push rod until the distance from the
centre of clevis pin hole to mounting surface of
clutch.pedal bracket should be set at
157.0-157.5 mm (6.18-6.20 in).
When fixed under this condition, there is no
need to adjust the clutch pedal height and free
play.
4. Tighten the master cylinder push rod jam nut.
701-6 CLUTCH

Tighten

+ Jam nut to 13 N-m (113 tb-in}. 157.0-157.5mm (6.18-6.20in) "|

5. Install the master cylinder to the clutch pedal

assembly.

Measurement (Figure 2)

* Clutch pedal normal play is between 15-25 mm

(0.6—1.0 in) (reference).
ay ate a
* Clutch pedal height “A” is between 160-170 mm
(6.3-6.7 in) (reference).
* Clutch pedal travel “B” is between 159-169 mm
(6.2-6.7 in) (reference).

6. Check clearance at the clutch switch. Turn the

switch in its bracket until the clearance between Figure 3. Master Cylinder Push Rod Adjustments
the fully depressed plunger and the clutch pedal
is 0.5~14.0 mm (0.02-0.04 in) (figure 4). CAUTION: Clutch switch must be adjusted so
that when the clutch pedal is released, it
closes the switch but does not completely
depress the switch plunger (max stroke see
figure 4). If the plunger is completely
depressed by the pedal, switch damage may
result.

7. Tighten the jam nut (5) at the clutch switch.

Tighten

* Jam nut to 13 N-m (113 Ib-in).

8. Recheck the clutch swich clearance..

A. Pedal Height....... 160-170 mm (6.3-6.7 in)

(reference)
B. Pedal Travel........ 159-169 mm (6.2—6.7 in)
(reference)

Figure 2. Clutch Pedal Height and

Travel Adjustment
 CLUTCH 7C1-7

BLEEDING THE CLUTCH HYDRAULIC

CIRCUITS
lf air enters the clutch circuit, it will cause the
Clutch to drag. It will be necessary to bieed the
clutch fluid circuit if the reservoir has been emptied
-—- OFF or the hydraulic circuit has been disassembled. To
~«— Max. Stroke Pieces re clutch circuit properly, an assistant will be
needed.

oe Bleeding Procedure
a” 5 (Figure 5)
1. Check the level of the clutch fluid in the clutch
reservoir and add clutch fluid if necessary.
2. Remove the rubber cap from the bleeder screw
and wipe the bleeder screw clean. Connect a
vinyl tube to the bleeder screw and insert the
other end of the vinyl tube into a transparent
container. Pump the clutch pedal repeatedly
and hoid the pedal in the depressed position.
3. Loosen the bleeder screw on the clutch slave
cylinder to discharge clutch fluid and air bubbles
into a container then tighten the bleeder screw
immediately.
4. Release the ciutch pedal slowly. Repeat step 3
5. Jam Nut
until all air bubbles disappear from the clutch
6. Clutch Switch
fluid being discharged into the container. During
. the bleeding operation, keep the clutch fluid
Figure 4. Clutch Switch Clearance reservoir filled to 13 mm (1/2 in) below the top
of the reservoir.
5. Install the rubber cap onto the bleeder screw.

Optional Bleeding Method

Tool Required:
J-35854 Power Bleeder Adapter or
Equivalent
¢ Connect a power bleeding machine to the master
cylinder with the use of adapter J-35854 or
equivalent. Bleed until all air bubbles are out of
the system and a solid pedal is obtained.

Figure 5. Loosening Clutch Slave Cylinder

Bieeder Screw
701-8 CLUTCH

COMPONENT PARTS REPLACEMENT

CLUTCH DISC AND PRESSURE PLATE

[+s] Remove or Disconnect (Figures 6 and 7)

1. Transmission. See MANUAL TRANSMISSION

(SEC. 7B1).
2. Bolts (1).
3. Pressure Piate Assembly (2).
4. Driven Pilate Assembly (3).

[3] Important

* Do not remove pilot bearing unless absolutely

necessary. Use J-2619-01 sliding hammer to 17, J-2619-01
remove the pilot bearing (figure 7).
Figure 7. Removing Crankshaft Pilot Bearing
Inspect

* Pressure plate cover for cracks or distortion. Measure (Figures 8, 9, 10, 11 and 12)
* Diaphragm spring for heat distortion.
* For loase or bent rivets. » The depression of the rivet head on the driven
« Wire ring for wear. plate. Replace the driven plate assembly if the
* Release bearing for roughness or noise by thickness of the friction material is less than 0.2
rotating the bearing race under light pressure. mm (0.008 in) (figure 8).
« Shift fork for wear or damage. * Driven plate warpage (figure 9).
* Pilot bearing on the crankshaft for roughness by Limit : 0.7 mm (0.028 in).
rotating the bearing race under light pressure. Clutch Size : 300 mm (11.81 in).
» Replace all parts that would effect proper « Pressure plate wear (figure 10).
operation of the clutch release assembly. If the wear exceeds the limit 1.0 mm (0.04 in), the
+ Replace the flywheel, pressure plate assembly, or pressure plate assembly must be replaced.
driven plate if found to be scored, burned, * Pressure plate clamping force. Invert the pressure
warped, or worn. Do not machine the flywheel or plate and position an 8.5 mm (0.39 in) thick plate
the pressure plate to eliminate these conditions. over the pressure plate with hydraulic press. Then
observe the load gage reading when the top of
the plate is flush with the pressure plate as
indicated by the arrows in figure 11. Replace the
pressure plate assembly if the clamping force is
less than 890 kg (1,962 \b.).
Height of the diaphragm spring fingers (figure 12).
2

Position an 8.5 mm (0.33 in) thick plate under the

pressure plate. Compress the diaphragm spring
untit the spring touches the table. Measure the
height of the diaphragm spring fingers. They must
be 49-51 mm (1.95-2.01 in) high.

1. Clutch Pressure Plate Mounting Bolts

2. Pressure Plate Assembly
3. Driven Plate Assembly

Figure 6. Clutch Disc and Pressure Plate

Disassembly
 CLUTCH 7C1-9

22. Rivet

WAAALIALEMLSDEDETLELIL
AO OMPEEEED REIS AION
J

52. 8.5 mm (0.33 in) Thick Plate

55. Load Gage

Figure 11. Measuring Pressure Plate Clamping

Force

49-51 mm
(1.93 — 2.01 in)

52
52. 8.6 mm (0.33in) Thick Plate
Figure 9. Measuring Driven Plate Warpage 90. Pressure Plate Cover
91. Diaphragm Spring Finger

Figure 12. Measuring Height of Diaphragm Spring

Fingers

Figure 10. Pressure Plate Wear

4. Spring
5. Shift Block with Bearing
6. Shift Fork

Figure 13. Clutch Housing Assembly

701-10 CLUTCH

CLUTCH HOUSING installation

Before installing the clutch, it is advisable to
Disassemble (Figure 13) check the following:
1. Spring (4). Inspect the friction face of the flywheel for
2. Shift block with bearing (5). smoothness, heat checks, scoring, excessive
« Use a bench press to separate the block and wear or runout on the contact surface. The
bearing. inspection for heat checks and scoring must be
3. Shift fork (6). visual and based on experience; however,
measure friction surface wear with straight edge
Assemble (Figure 13) feeler gage.
Replace the flywheel if wear is excessive.
1. Shift fork (6). If the clutch is new, remove the protective coating
+ Grease contact points on shift fork with MoSz from the pressure plate and intermediate plate.
grease. A new release bearing should be used with a new
2. Shift block with bearing (5). or rebuilt clutch.
* Apply multi-purpose grease and use a bench lf the flywheel has been replaced, always indicate
press to assemble the block and bearing prior the face and pilot diameters to make sure total
to installation. indicator run-outs are within engine
3. Spring (4). manufacturer’s specifications.
Check the fit of the splined hub of the friction disc
by sliding it on the main drive gear spline of the
transmission. The hub must slide free if the clutch
is to release cleanly and properly.

ENGINE ENGINE
HOUSING HOUSING

INDICATOR INDICATOR
RUNOUT ARUNOUT
0.008 in 0.008 in
(0.203mm) (0.203mm)
MAX, MAX.

ENGINE ENGINE
FLYWHEEL FLYWHEEL

FOR S.A.E. BELL NOS. 1 &2 FOR S.A.€. BELL NOS. 1 & 2

Checking Fiywheel Housing Checking Flywheel Housing

Runout Face Runout

ENGINE ENGINE
HOUSING HOUSING

INDICATOR
RUNOUT ‘
0.001 in Per Inch
(0.025mm Per 25mm)-. CLUTCH
DISC
INDICATOR ENGINE DIA.
RUNOUT a -—————— FLYWHEEL |
0.005 in
(0.127mm)
MAX.
Checking Flywheel Face Runout

Figure 14. Flywheel Housing Runout Check

 CLUTCH 7C1-11

¢ Check flywheel alignment with the engine

housing.
+ When installing a new driven disc, make sure it is
installed as marked. Instail a disc marked
“FLYWHEEL SIDE” toward the engine flywheel
and a disc marked “PRESSURE PLATE SIDE”
toward the clutch pressure plate.

| Install or Connect (Figures 15 and 16)

Tool Required:
J-39022, Clutch Pilot Aligner
* Apply MoS contained type grease to the hub
splines.
1. Pilot bearing if removed. Figure 16, Pressure Plate Boit Sequence
Use a suitable brass bar and hammer.
2. Driven plate assembly (3).
3. Clutch pilot aligner J-39022 into the center of CLUTCH CONTROLS
the driven plate assembly.
4. Pressure plate assembly (2). [+>] Remove or Disconnect (Figure 6)

NOTICE: See “NOTICE” on page 7C1-1 of this * line

Brain the clutch fluid from the clutch hydraulic
section.

NOTICE: Do not let clutch fluid remain on a

. 1).
6. *Pressure plate bolts
Finger tighten bolts (1)and check to be sure ail painted surface. Wash it off immediately.
rts are aligned correctly.
Paris a q y 1. Meter cluster and meter assembly.
Tighten « Pull out the meter cluster and disconnect
narness connectors.
« Pressure plate bolts to 40 N-m (30 lb-ft} in the Refer to INSTRUMENTAL PANEL (SEC.10D).
sequence shown in figure 16. 2. Electric vacuum pump
* Remove the electric vacuum pump.
. Remove the clutch pilot aligner (113). Refer to "ELECTRIC VACUUM PUMP"
~~ oO

. Install the transmission. Refer to MANUAL (SEC. 8}.

TRANSMISSION (SEC. 7B1). 2. Hose and pipe (1).
3. Glutch pedal and bracket assembly (2).
4, Clutch switch (3}.
5. Clevis pin (4).
6. Master cylinder (5).
7. Return spring (6).
8. Fulcrum pin (7).
9. Clutch pedal (8).
10. Flexible hose (9).
11. Slave cylinder (10).

Inspect

; * All parts for damage or wear.

Ng * The clearance between the pedai shaft and
bushings.
1. Pressure Plate Bolt * Replace the clutch pedal assembly if the
2. Pressure Plate Assembly clearance is excessive.
3. Driven Plate Assembly
113. J-39022 install or Connect (Figure 6)

Figure 15. Clutch Disc and Pressure Plate NOTICE: For steps 1,6 and 8 see “NOTICE”
installation on page 7C1-1 of this section.
701-12 CLUTCH

. Hose and Pipe

—

. Clutch Pedal and bracket Assembly

WN

. Clutch Switch
. Glevis Pin
OAR

. Master Cylinder
. Return Spring
- Fulcrum Pin
TOON

. Clutch Pedal
. Flexible Hose
. Slave Cylinder
os

Figure 17. Cluich Control Assembly

 CLUTCH 7C1-13

1. Slave cylinder. 7. Clutch switch.

8. Clutch pedal and bracket assembly.
Tighten
Tighten
* Slave cylinder bolt to 19 N-m (14 Ib-ft).
* Clutch pedal and bracket bolt to
. Flexible hose. 37 N-m (27 lb-ft).
NY

. Clutch pedal.
& ©
On

. Fulcrum pin 9. Hose and pipe

. Return spring. 10. Electric vacuum pump.
. Master cylinder. » Refer to ELECTRIC VACUUM PUMP
(SEC. 8).
Adjust 11. Meter cluster and meter assembly.
« Refer to INSTRUMENTAL PANEL (SEC.10D).
* Loosen the jam nut on the master cylinder
12. Bleed the clutch hydraulic circuit. Refer to
push rod. "Bleeding Clutch Hydraulic Circuits" previously
» Adjust push rod length t0157.0mm - 157.5mm
in this section.
(6.18 — 6.20 in.), and tighten the jam nut.

Tighten
» Master cylinder jam nut to 13 N-m (113 Ib-in).

UNIT REPAIR

MASTER CYLINDER 7. Push rod (7).

8. Piston assembly (8).
Disassemble (Figure 7) 9. Cylinder body (9).

1. Hose joint (1). tq Clean

2. Clevis york (2).
3. Nut (3). « All disassembled parts in brake fluid. Be sure to
4, Dust cover (4). check the ports for restrictions. Use a metal wire
5. Snap ring (5). to loosen the dirt.
6. Stopper (6).

Hose Joint
wON =

Clevis York
Nut
Dust Cover
OOS

Snap Ring
Stopper
Push Rod
BON

Piston Assembly

of
Clyinder Body

mee
ef Figure 18. Master Cylinder Assembly
701-14 CLUTCH

Inspect C. Piston Cup

* Cylinder bore and piston for wear and rust

formation.
* Spring for weakening.
« Replace any parts if wear, damage, or any other
abnormal conditions are found during inspection.

Measure (Figure 19)

* The bore inside the master cylinder body with a
dial indicator. Use a micrometer to check the
thickness of the piston. Replace the master
cylinder body or piston if the clearance is less
than 0.12 mm (0.0047 in) (figure 19). Figure 20. Installing Piston Assembly

\ SLAVE CYLINDER
[] Disassemble (Figure 21)

1. Push rod (7).

2. Boot (8).
3. Piston assembly (9).
4. Return spring (10).
5. Bleeder screw and cap (11,13).

2
6. Slave cylinder body (12).

Clean

» All disassembled parts in brake fluid. Be sure to

Figure 19. Measuring Clearance at Master
wipe excess brake fluid from the components.
Cylinder and Piston
inspect
Assemble (Figures 18 and 20) « Cylinder bore and piston for wear and rust
1. Cylinder body (9). formation.
2. Return spring (7). * Spring for weakening.
« Piston cups for wear, deterioration and scratches.
fy] important + Replace any parts if wear, damage, or any other
abnormal conditions are found during inspection.
- Before installing the parts, apply a thin coat of
brake fluid. Measure (Figure 22)

3. Piston assembly (8). Install new cup in groove * The clearance inside the slave cylinder body with
in piston with the lip turned toward the front of a dial indicator. Use a micrometer to check the
the cylinder body. Use care so as not to scratch thickness of the piston. Replace the slave cylinder
the lipped portion of the cup (figure 20). body or piston if the clearance is less than 0.11
4. Push rod assembly (7) with dust cover (4), snap mm (0.0043 in) (figure 22).
ring (5) and stopper (6).
5. Stopper (6).
6. Snap ring (5) to the cylinder body groove.
7. Dust cover (4).
8. Hose joint (1).
 CLUTCH 7C1-15

13

7. Pushrod
8. Boot
9. Piston Assembly
10. Return Spring
11. Bleeder Screw
12. Slave Cylinder Body
13. Cap

Figure 21. Slave Cylinder Assembly

2 . Bleeder screw and cap (11,13).

Tighten
+ Bleeder screw to 8 N-m (69 Ib-in).

. Return spring (10).

[¥] Important
¢ Before installing the parts, apply a thin coat of
brake fluid.
» Be sure to install the piston cup in the piston
groove with the lip turned toward the front of
the cylinder body. Use care so as not to
Figure 22. Measuring Clearance at Slave scratch the lip partion of the piston cup.
Cylinder and Piston
, Piston assembly (9}.
. Boot (8).
Assemble (Figure 21)
. Push rod (7).
om

1. Slave cylinder body (12).

NOTICE: See “NOTICE” on page 7C-1 of this

section.
701-16 CLUTCH

SPECIFICATIONS
Pressure Plate TyP@S............cesseessscsessreessseesssnecessseceeseeeettersesuesueeeenaes Dry Single Plate w/Cushioning Spring
Clearance Between Master Cylinder Body and Piston...........cc.cccccssscsscsecresseccsseccensessseees 0.12 mm (0.0047 in)
Clearance Between Slave Cylinder Body and Poiston............0..ccccccccsccssescesseceesecseesneecens 0.11 mm (0.0043 in)
Driven Plate Warpage Maximum Limit ............c.ccccceccsssccssssscsceusvssesscssescusaussesssensceecenseceenacens 0.7 mm (0.028 in)
ClUtCh SiZO oo... cece este ceenseeesseeeseeenseeesnereasersauessaeussscasesensesseeessaesvscsnessesseseaseaeaaenancensecenanenes 300 mm (11.81 in)
Depression of Rivet Head Maximum Limit: .0...........0cccccscseceseeusesscssesseecseseseresecesneccetesesenneees 0.2 mm (0.008 in)
Pressure Plate Clamping Force Maximum Limit ..............:ccccccssssecssccssssssesseceecsneeeseeeccenceneeuecs 890 kg (1,962 ib)
Pressure Plate Finger Height .............cesecssessesssssecsessncseceseecsonsseuessnsesauaceusnacsesensaas 49-51 mm (1.93-2.01 in)
Master Cylinder Push Rod Length
(From Centre of Crevis Pin Hole to Mounting Surface)..............0..08 veeeeteees 157.0-157.5 mm (6.18-6.20in)
Pedal Height (Reference) .0...... ce ee eeccececessnseesnseceeceeteueccenssereesesesestccserssecesnascaseneeeeees 160-170 mm (6.3—6.7in)
Pedal Travel (Reference) occ. ec cccccssnsceneeessssenessuseeeccesnuccaeaueassssscessusesseseusseesesaeas 159-169 mm (6.2-6.7in)
Free Play (Reference) .................c::cesssesssesenens ceeveuueceesaneaoesusesseumeesuiaueaasanesessaceesqaneetenuenee 15-25 mm (0.6—1.0 in)
Clutch Switch Clearance 200.0... ceccseececceecssnseessssuseecsentecesseneesesenseeveenscuaeeseauceseeees 0.5-1.0 mm (0.020-—0.039 in)

FASTENER TORQUES

Master Cylinder Push Rod Jam Nut........0.....ccccccccsssesescssececsessenevecsusucecescesseneesenseeceseneceeesenes 13 N-m (113 Ib-in)

Clutch Switch Jam Nut oo... eccccccccecceceseeccseeeceeeceurecseseavenusenseneeeseue beteentesenseerentatertesaestsseesneeens 20 N-m (14 lb-ft)
Pressure Plate Bolts ...........ecccescsneseeceecescsssonseeseeeessnscessssescesessessunsesuseessusssessuaaaeseeeensensareneess 40 N-m (30 Ib-ft)
Master Cylinder Bolts ...............:::::csssssessssseenssessssncnsnsucuenencesguseescesesacasanavenseaecaeaseaeasaeasaaauenanes 13 N-m (113 Ib-in)
Slave Cylinder Bolts ou... ccc ssccssneeeesescceessccssatecssaneaesssnaecscceaecccnsessseesenseeneseentaueussesneeseenses 19 N-m (14 lb-ft)
Flexible Hose Tube Nut...............cccccccccusssscssersecoenesatenavsnsseseaneecsesuncesusegeeauensacvessecteeenscavanerecars 20 N-m (14 Ib-ft)
Slave Cylinder Bleeder Screw «0.0... eccccessecnceeceesssonsenteceenesensnscasuescaesesucussuacansausessertenaaaeeress 8 N-m (69 Ib-in)
Clutch Pedal and Bracket Assembly Mounting Bolt ...............ccccccsccccssseesesscsseesecnensevsectereasesenee 37 N-m (27 Ib-ft)

SPECIAL TOOLS
TOOL NO.
ILLUSTRATION TOOL NAME

J-35854
Power Bleeder Adapter

EY} szets-01
wm Sliding Hammer
a

———— J-39022
Clutch Pilot Aligner
 CLUTCH 7C2-1

SECTION 7C2

CLUTCH (FOR MBP TRANSMISSION)

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
DeSCription .........cccsssesssensesrsnesssesennscceeesseneneneanenssausereurnauatentenneats
Clutch System ........cccsseusssssscerssnerscneesessenstenseerenennes FMae eno moe EES
Diagnosis of ClUtCH .........ccsssereee canenaaeeentersuansenseavonnuane seangeencaweoyane
On-Vehicle Service .......cccscsecsensenes snenseneansuaensaenaeaemensesous NHANES OAT KON AUT NHL T HNO RAT REDON EE CER NRA DASE T ALOK TSN OPERR HERS OKSHOTHWEDEH
Clutch System Inspection. ......ccssssecisnenensersenreses PARR U OO HONE EAH EHNA NOREEN TA CANON NAN ERS MET

Clutch Pedal Free Play, Height and Travel Adjustment SCAU UTES ATMA THON NOOR EEO E RKO M DAE Tee OWE RRR CEE ReU ET

Bleeding the Clutch Hydraulic Circuits ............ laneensaae ORAS SAU RASA APO HSHTPEUN TT HME ATU TARR O EROS EAE TESA NTRS HOHE SKKKEAO KURA TORE AKG

Component Parts Replacement...........nssesssseeneenvennes PUSS HM ETAT AEE NOT TUM RAT UN RERUN MOC AAA M SH TAH PLOK SRPMS SENT REDE SMRGEAAH

Cluich Assembly
Clutch Controls
Unit R@pair.........ccccssnenseessetecenesessnaenereensseeneeseeseareneeuuesen DMERTONMER PON TATAAT MERA TKI AERA HMAC TASTE AMM TOLC EMH RERSRTSSH ANAM KRONE RRA

Master Cylinder
Slave Cylinder ........csescsrcressorenensenseniectennacontearensseseniass OPPO N MAT TOONS ROOT NENA OTE RANK OT PATEL ATOM TORT KURT RROD ANNE ONES

Specifications. ..........eccesscsenaneecssnaerensereemeessuecsneansente RWEDSUAUACK NERA T EH NH OCT AM ARO RNR EMER MRE ORSON ACEC KERR OE MOAT E KEANE

Fastener Torques........ccc000 petaaustausanuuetnnoneustcaneenganeese ACU OCRACTOFON

SARE RA RN CTA CPE EARNER SOT SHOT AMAR HOSEA OR AAO TRO ORROA TAN AOA EO

Special TOOIS.......cccsscserscerensecnrscersesseanseesansensessunnneentens AOCCSMETTUA SCHUM TT AAT MRO NT OT MOPS ON TUT KAT EA AEROSTAR E OORT UTE OMEN HARRAM NCE RY ED

DESCRIPTION

CLUTCH SYSTEM shaft through these same splines. Suitable frictional

facings are attached to each side of the clutch disc
Driving Members by means of rivets. These facings must be heat
resistant since friction produces heat.
The driving members of a clutch usually consist of
two flat surfaces machined to a smooth finish. Operating Members
One of these surfaces is usually the rear face of the
engine flywheel, and the other is a comparatively The driving and driven members are held in
heavy flat ring with one side machined. This part is contact by spring pressure.
The throwout (clutch release) bearing is a
known as the pressure plate. It is fitted into a steel
ballthrust bearing contained in the clutch housing,
cover, which also contains some of the operating
members, and is bolted to the flywheel. mounted on a sleeve attached to the front of the
transmission case. The throwout bearing is moved
Driven Member by the clutch release yoke to contact the release
levers and move the pressure plate to the rear, thus
The driven member is a clutch disc with a splined separating the clutch driving members from the
hub which is free to slide lengthwise along the driven member when the clutch pedal is depressed
splines of the clutch shaft, but which drives the by the driver.
7C2-2 CLUTCH

Clutch Controls cylinder, interconnected with hydraulic lines. The

This system utilizes hydraulic pressure as a clutch pedal is connected to the master cylinder
means of transmitting clutch pedal movement to the pushrod, and the slave cylinder pushrod is
clutch release mechanism. The system consists of connected to the clutch release fork.
a pedal-operated master cylinder and a slave

DIAGNOSIS OF CLUTCH

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Slips 1. Binding of release levers in the 1. Replace the clutch cover assembly.
pressure plate and cover
assembly.
. Cluich release levers improperly . If levers are in place, adjust free pedal.
adjusted.
. Facings loose on the clutch disc. . Replace the driven disc assembly.
. Improper clutch release bearing . Adjust for proper clearance (free pedal).
adjustment.
. Binding or sticking clutch pedal . Repair or replace faulty parts.
assembly. Check linkage for proper adjustment.
. Weak or broken clutch pressure . Replace the clutch cover assembly.
springs.
. Burned clutch facings. . Repiace clutch driven disc assembly
and check flywheel and pressure plate
friction surfaces for damage replace
parts as necessary.
. Binding or sticking of the clutch . Lubricate splines with high temperature
disc hub on the transmission drive grease (if dry). Replace driven discs if
gear. splined hubs are worn.
. Release bearing binding on . Replace release bearing or lubricate.
bearing retainer.
10. Warped pressure plate or engine 10. Replace defective parts. Check
flywheel. transmission, clutch, and engine
alignment.
11. No free pedal. 11. Adjust for free pedal, check clutch driven
disc wear and replace parts as required.

Clutch Chatters 1. Loose engine mounts. 1. Tighten engine mount bolts to

During Engagement specifications.
2. Grease or oil on facings. 2. Repiace driven disc assembly and repair
oil leak.
3. Slight binding in linkage during 3. Gheck linkage for wear or damage.
engagement. Replace parts as required.
4. Weak pressure springs. 4, Replace clutch cover assembly.
5. Clutch release levers binding 5. Repair or replace clutch cover
during engagement. assembly.
6. Worn or broken pilot bearing. 6. Replace and lubricate pilot bearing.
7. Rough engine idle. 7. Tune engine to manufacturer's
specifications.
 CLUTCH 7C2-3

DIAGNOSIS OF CLUTCH (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Chatters 8. Bent or out of plane pressure 8. Replace clutch cover assembly if
During Engagement plate fingers. release fingers are more than 2 mm
(Cont.) (0.079 in) cut of plane.
9. Driven disc warped, cracked, or 9. Replace driven disc assembly.
loose friction material.
10. Pressure plate warped or hot 10. Replace pressure plate or clutch cover
spots. assembly.
11. Flywheel warpage or 11. Replace flywheel.
discoloration.
12. Flywheel housing bore and face 12. Correct per alignment procedure.
not aligned.

Clutch Drags When 1. Pedal carinot disengage clutch 1. Check pedal and linkage for wear,
Disengaged because of excessive free pedal repiace parts as required.
travel. Adjust clutch and linkage for proper free
travel.
2, Clutch release levers need 2. Replace clutch cover assembly.
adjustment.
3. High spots on clutch facings. 3. Replace driven disc assembly.
4, Loose rivet in facings. 4, Replace driven disc assembly.
Check for damaged flywheel and
pressure plate, replace as necessary.
5. Clutch disc wobbles because of 5. Replace driven disc assembly.
broken springs in hub.
6. Flange of clutch cover not in 6. Torque bolts to specifications or replace
alignment with flywheel because cover assembly.
of loose bolts or bent flange.
7. Deteriorated or broken engine 7. Replace engine mountings.
mounts.
8. Worn clutch release bearing. 8. Replace release bearing and adjust
clutch free pedal.
9. Worn linkage components. 9. Check pedal and linkage for wear;
replace parts as required.
10. Clutch disc warped. 10. Replace driven disc assembly, also
check flywheel for deep heat checks.
Replace flywheel as necessary.
11. Broken or loose facings. 11. Replace driven disc assembly.
12. Misalignment of transmission. 12, Check engine mounts, wear on flywheel
housing, and bolt torque.
13. Main drive gear misaligned 13. Repair transmission if required and
because of warn bearings. check flywheel pilot bearing; replace
pilot bearing as required.
14. Clutch pressure plate warped. 14. Replace clutch cover assembly; also
check flywheel surface for dished out
wear pattern. Replace flywheel as
required,
15. Loose flywheel housing bolts. 15. Torque bolts to specifications.
7C2-4 CLUTCH

DIAGNOSIS OF CLUTCH (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Grabs . Grease or oil on clutch facings. . Replace driven disc assembly and
repair oil leak.
. Exposed rivet heads due to . Replace driven disc assembly and
excessively worn facings or check for flywheel and pressure plate
loose rivets. damage. Replace damaged parts.
. Loose engine mounts. . Tighten engine mount bolts to
specifications.
. Clutch pressure springs too stiff. . Replace clutch cover assembly.
. Momentary binding in linkage . Check pedal and linkage for wear or
while clutch is being engaged. damage. Repiace parts as required.
. Warped pressure plate, or . Replace damaged paris. Check
flywheel. alignment.

Clutch Noisy When . Improper clutch release bearing . Adjust clutch linkage for pedal free
Engaged adjustment. play.
. Clutch disc damper springs . Replace driven disc assembly.
weak or broken.
. Linkage binds. . Check pedal and linkage. Replace or
repair as required.
. Clutch release bearing binding. . Check for alignment and release
bearing lubricant. Replace bearing as
required.
. Loose flywheel or clutch cover . Torque bolts to specifications.
bolts.
. Misalignment of transmission. . Check engine mountings, wear on
flywheel housing, and fastener torque.
. Worn splines on clutch disc or . Replace parts as required.
transmission main drive gear. Lubricate with high temperature
grease.
. Weak or missing clutch return . Replace clutch cover assembly.
springs.
. Clutch pedal assembly binding. . Check pedal and linkage for wear or
damage. Repair or replace parts as
required.

Clutch Pedal . Misalignment of transmission. 1. Check engine mountings, wear on

Pulsates During flywheel housing, and fastener torque.
Engagement . Loose or improperly installed . Refer to ENGINE (SEC. 6A) for proper
engine mounts. engine mount installation.
. Clutch release levers not . Replace clutch cover assembly.
adjusted to uniform height.

Clutch Rattles When . Wear or looseness in linkage. . Check linkage for wear or damage.
Disengaged with Replace parts as required.
Engine Idling . Retractor springs on release . Replace clutch cover assembly.
lever weak, broken, or
disconnected.
. Loose flywheel or clutch cover . Torque bolts to specifications.
bolts.
. Rough engine idle. . Tune engine to manufacturer's
specifications.
 CLUTCH 7C2-5

DIAGNOSIS OF CLUTCH (CONT.)

PROBLEM POSSIBLE CAUSE CORRECTION

Clutch Noisy When 1. Pilot bearing or bushing in 1. Replace parts as required.

Disengaged crankshaft worn, damaged, Lubricate with high temperature
broken, or inadequately grease.
lubricated.
2. Release bearing worn, dirty, 2. Replace release bearing.
damaged, broken, or Lubricate with high temperature
inadequately lubricated. grease.
3. Transmission main drive gear 3. Repair transmission. Gheck for rear
bearing worn, dirty or lacks bearing cap oil hole for restriction
lubricant. clearance.

ON-VEHICLE SERVICE

CLUTCH SYSTEM INSPECTION

The system should be checked and serviced
periodically as stated below.
« Maintain the proper level of hydraulic fluid in the
master cylinder reservoir. Refer to
MAINTENANCE AND LUBRICATION (SEC. 0B)
for recommended fluid and checking intervals.
- Inspect the entire clutch system regularly for fluid
leakage. Leakage must be corrected immediately.
« Adjust the clutch linkage if necessary.
- If the clutch pedal action is springy or spongy, it is
an indication that air needs to be bled from the
hydraulic system.
A specified clearance in the hydraulic control
linkage must exist between the end of the push rod Figure 1. Master Cylinder Reservoir
and master cylinder piston. This clearance is
as i fre
measured as pedal iros Wave
travel.
Before making the adjustment, make sure that the
CLUTCH PEDAL FREE PLAY, HEIGHT
level of fluid in the master cylinder reservoir is 13 AND TRAVEL ADJUSTMENT
mm (1/2 in) below the top of the reservoir. The fluid "x . .
system must be free of air. Adjust (Figures 2, 3 and 4)
The dual brake/clutch master cylinder reservoir is 1. Loosen the jam nut (5) on the clutch switch (6)
in the left-upper portion of the dash panel. It can be (figure 4).
accessed by opening the driver door (figure 1). 3. Remove the master cylinder from the clutch
pedal assembly.
2. Loosen the jam nut on the master cylinder push
rod (figures 2 and 3).
3. Turn the push rod until the distance from the
centre of clevis pin hole to mounting surface of
clutch peda! bracket shouid be set at
157.0-157.5 mm (6.18-6.20 in}.
When fixed under this condition, there is no
need to adjust the clutch pedal height and free
play.
4. Tighten the master cylinder push rod jam nut .
7C2-6 CLUTCH

[Ql] Tighten

* Jam nut to 13 N-m (113 lb-in). 156.5-157.5mm (6.16-6.20in) "

5. install the master cylinder to the clutch pedal
assembly.

Et —F
Measurement (Figure 2)

« Clutch pedal normal play is between 15-25 mm

(0.6~1.0 in} (reference).
« Clutch pedal height “A” is between 160-170 mm
(6.3-6.7 in) (reference).
+ Clutch pedal travel “B” is between 159-169 mm
{6.2-6.7 in) (reference).

6. Check clearance at the clutch switch. Turn the

switch in its bracket until the clearance between Figure 3. Master Cylinder Push Rod Adjustments
the fully depressed plunger and the clutch pedal
is 0.5—1.0 mm (0.02-0.04 in) (figure 4). CAUTION: Clutch switch must be adjusted so
that when the clutch pedal is released, it
closes the switch but does not completely
depress the switch plunger (max stroke see
figure 4). If the plunger is completely
iwoe depressed by the pedal, switch damage may
a
result.
¥ ail

7. Tighten the jam nut (5) at the clutch switch.

Gas
\
» © f=
j Tighten
« Jam nut to 13 N-m (113 Ib-ft).
| 1/44
NN XN G
/ 8. Recheck the clutch switch clearance.
/
h
4
é/
f a

/
~

oo

A. Pedal Height ....... 160-170 mm (6.3-6.7 in)

(reference)
B. Pedal Travel........ 159-169 mm (6.2-6.7 in)
(reference)

Figure 2. Clutch Pedal Height and

Travel Adjustment
 CLUTCH 7C2-7

I
BLEEDING THE CLUTCH HYDRAULIC
CIRCUITS
If air enters the clutch circuit, it will cause the
clutch to drag. It will be necessary to bleed the
-— OFF clutch fluid circuit if the reservoir has been emptied
or the hydraulic circuit has been disassembled. To
-«— Max. Stroke
bleed the clutch circuit properly, an assistant will be
needed.

Bleeding Procedure
(Figure 5)
1. Check the level of the clutch fluid in the clutch
reservoir and add clutch fluid if necessary.
2. Remove the rubber cap from the bleeder screw
and wipe the bleeder screw clean. Connect a
vinyl tube to the bleeder screw and insert the
other end of the vinyl tube into a transparent
container. Pump the clutch pedal repeatedly
and hold the pedal in the depressed position.
oo
. Loosen the bleeder screw on the clutch slave
cylinder to discharge clutch fluid and air bubbles
into a container then tighten the bleeder screw
immediately.
4, Release the clutch pedal slowly. Repeat step 3
5. Jam Nut until all air bubbles disappear from the clutch
6. Clutch Switch fluid being discharged into the container. During
the bleeding operation, keep the clutch fluid
Figure 4. Clutch Switch Clearance reservoir filled to 13 mm (1/2 in) below the top
of the reservoir.
5, Install the rubber cap onto the bleeder screw.

Optional Bleeding Method

Tool Required:
J-35854 Power Bleeder Adapter or
Equivalent
« Connect a power bleeding machine to the master
cylinder with the use of adapter J-35854 or
equivalent. Bleed until all air bubbles are out of
the system and a solid pedal is obtained.

Figure 5. Loosening Clutch Slave Cylinder

Bleeder Screw
7C2-8 CLUTCH

COMPONENT PARTS REPLACEMENT

1. Transmission Assembly 6. Set Bolt

2. Pressure Plate Assembly 7. Glutch Shaft
3. Driven Plate Assembly 8. Shift Fork
4. Return spring 3. Dust Cover
5. Shift Block and Release Bearing 10. Needle Bearing

Figure 6. Clutch Assembly

CLUTCH ASSEMBLY 5. Shift block and release bearing.
+ Use suitable puller to remove the release
| Remove or Disconnect (Figure 7, 8 and 9) bearing.

1. Transmission assembly.
Refer to “MANUAL TRANSMISSION”. (Section
7B2)
2. Pressure plate assembly.
3. Driven plate assembly. (Figure 7)

Figure 8. Release Bearing

6. Set bolt.
7. Clutch shaft.
« Remove the clutch shaft. Clutch shaft with a
brass ber to remove it.
Figure 7. Driven Plate

4, Return spring.
 CLUTCH 7C2-9

Pressure plate clamping force. Invert the pressure

plate and position an 9.2 mm (0.36 in ) thick plate
@ over the pressure plate with hydraulic press.
Then observe the load gage reading when the
dimention ® becomes 19 mm (0.75 in) as
indicated in figure 11. Replace the pressure plate
assembly if the clamping force is less than 970 kg
(2,139 Ib).

Clutch shaft
Shift fork

Figure 9. Clutch Shaft

8. Shift fork.
9. Dust cover.
10. Needle bearing.

Inspect
* Pressure plate cover for cracks or distortion. Figure 11. Pressure plate clamping force.
* Diaphragm spring for heat distortion.
« For loose or bent rivets. « The depression of the rivet head on the driven
« Release bearing for roughness or noise by plate. Replace the driven plate assembly if the
rotating the bearing race under light pressure. thickness of the friction material is less than 0.2
Shift fork for wear or damage. mm (0.008 in) (figure 12).
+ Pilot bearing on the crankshaft for roughness by
rotating the bearing race under light pressure.
Replace all parts that would effect proper
operation of the clutch release assembly.
* Replace the flywheel, pressure plate assembly, or
driven plate if found to be scored, burned,
warped, or worn. Do not machine the flywheel or
the pressure plate to eliminate these conditions.

Measure (Figure 10, 11, 12, 13, 14, 15 and 16)

« Pressure plate wear (figure 10).
If the wear exceeds the limit 0.3 mm (0.012 in),
the pressure plate assembly must be replaced. Figure 12. Depression of Rivet head.

« Driven plate warpage (figure 13).

Limit : 0.6 mm (0.024 in).
Clutch Size : 325 mm (12.80 in).

Figure 10. Pressure plate wear.

7C2-10 CLUTCH

Figure 13. Driven plate.

Figure 16. Clutch shaft wear
* Height of the diaphragm spring fingers (figure 14). [><] Install or connect (Figure 17, 18, 19, 20, and 27)
Position an 9.2 mm (0.36 in) thick plate under the
pressure plate. Compress the diaphragm spring {. Needle bearing
until the spring touches the table. Measure the » Use a 32 mm (1.26 in) diameter bar to drive
height of the diaphragm spring fingers. They must the Needie bearing from the marked side of
be 61.8-63.8 mm (2.43-2.51 in) high. bearing and install it specified depth as shows
in illustration.

ed

61.8 - 63.8 mm
(2.43 - 2.51in)
a
9.2 mm (0.36 in)
10.0 mm 10.0 mm
(0.39 in) (0.39 in}
Figure 14. Height of diaphragm spring.

* Check the surface of the shift block for wear or Figure 17. Needle bearing
damage (figure 15).
* Check the surface of the shift fork for wear or 2. Dust seal.
damage (figure 5). * Before installing the new bearing, apply MoS?
contained type grease to the bearing surfaces
and the clearance area between the bearing
and the dust seal.
Check for wear

\
Shift fork

Shift block ()

wale
2.0mm
Figure 15. Shift block and Shift fork wear
(0.079 in)
« Clutch shaft diameters as shown in figure 16. If
the diameter is less than 24.5 mm (0.96 in),
replace the clutch shaft and needle bearing. Figure 18. Dust seal
 CLUTCH 7C2-11

3. Shift fork.
4. Clutch shaft and key.
5. Set bolt.
+ Install the clutch shaft to the clutch housing.
* Key and shift fork onto the clutch shaft
assembly.
+ Tighten the set boit

fA] Tighten

Set boit to 13 Nem (113 Ibein)

Figure 21. Driven Plate assembly

9. Pressure plate assembly.

« Install the pressure plate assembly to the
flywheel.
if the pressure plate was replaced to new
parts, be sure to remove the ring which is
installed to the diaphragm spring.

Tighten
Clutch shaft
é ~ aoe
Pressure plate bolt to 40 Nem (30 Ibeft) in the
sequence shown in figure 22.
Figure 19, Set boit « Remove the pilot aligner.

6. Shift block and releace bearing

7. Return spring.
+ Apply the MoS? contained type grease to shift
fork and shift block surfaces.
* Install the return spring.

Return spring \\

)
\

Figure 22. Pressure plate assembly

10. Transmission assembly.

« Refer to “SECTION 7B2 ON-VEHICLE
SERVICE: TRANSMISSION ASSEMBLY
REPLACEMENT” in this manual.
Figure 20. Return spring
CLUTCH CONTROLS
8. Driven plate assembly.
» Clutch pilot aligner J~35253 into the center of [o9] Remove or Disconnect
the driven plate assembly.
« Brain the clutch fluid from the clutch hydraulic
line.

NOTICE: Do not let clutch fluid remain on a

painted surface. Wash it off immediately.
702-12 CLUTCH

. Meter cluster and meter assembly. 9. Clutch pedal (8).

* Pull out the meter cluster and disconnect 10. Flexible hose (9).
harness connectors. 11. Slave cylinder (10).
Refer to INSTRUMENTAL PANEL (SEC.10D).
. Electric vacuum pump Inspect
BS

* Remove the electric vacuum pump.

Refer to "ELECTRIC VACUUM PUMP" * All parts for damage or wear.
(SEC. 8). + The clearance between the pedal shaft and
bushings.
. Hose and pipe (1).
. Clutch pedai and bracket assembly (2). * Replace the clutch pedal assembly if the
Ww

clearance is excessive.
. Clutch switch (3).
B&B

. Clevis pin (4).

[><] Install or Connect (Figure 6)
Oo

. Master cylinder (5).

. Return spring (6). NOTICE: For steps 1, 6 and 8 see “NOTICE” on
ON

. Fulcrum pin (7). page 7C2-1 of this section.

. Hose and Pipe

wh —

. Clutch Pedal and bracket Assembly

COOaOnnarhkR

. Clutch Switch
. Clevis Pin

a
. Master Cylinder
. Return Spring
. Fulcrum Pin
. Clutch Pedal
‘ ;
. Flexible Hose
A
. Slave Cylinder
oh

Figure 23. Clutch Control Assembly

 CLUTCH 7C2-13

1. Slave cylinder. 7. Clutch switch.

8. Clutch pedal and bracket assembly.
Tighten |
Tighten
« Slave cylinder bolt to 19 N-m (14 lb-ft).
* Glutch pedal and bracket bolt to
2. Flexible hose. 37 N-m (27 lb-ft).
3. Clutch pedal.
4, Fulcrum pin 9. Hose and pipe
5. Return spring. 10. Electric vacuum pump.
6. Master cylinder. * Refer to ELECTRIC VACUUM PUMP
(SEC. 8).
[A] Adjust 11. Meter cluster and meter assembly.
* Refer to INSTRUMENTAL PANEL (SEC.10D).
« Loosen the jam nut on the master cylinder 12. Bleed the clutch hydraulic circuit. Refer to
push rod. "Bleeding Clutch Hydraulic Circuits" previously
¢ Adjust push rod length to156.56mm — 157.5mm in this section.
(6.16 ~ 6.20 in.), and tighten the jam nut.

Tighten
* Master cylinder jam nut to 13 N-m (113 Ib-in).

UNIT REPAIR

MASTER CYLINDER 7. Push rod (7).

8. Piston assembly (8).
[6] Disassemble (Figure 24) 9. Cylinder body (9).
1. Hose joint (1). ‘iH Clean
2. Clevis york (2).
3. Nut (3). « All disassembled parts in brake fluid. Be sure to
4. Dust cover (4). check the ports for restrictions. Use a metal wire
5. Snap ring (5). to loosen the dirt.
6. Stopper (6).

Hose Joint
r>

Clevis York
wh

Nut
CAONan

Dust Cover
Snap Ring
Stopper
Push Rod
Piston Assembly
Cylinder Body

Figure 24, Master Cylinder Assembly

7C2-14 CLUTCH

Inspect C. Piston Cup

- Cylinder bore and piston for wear and rust
formation.
« Spring for weakening.
* Replace any parts if wear, damage, or any other
abnormal conditions are found during inspection.

Measure (Figure 25)

+ The bore inside the master cylinder body with a

dial indicator. Use a micrometer to check the
thickness of the piston. Replace the master
cylinder bedy or piston if the clearance is less
than 0.12 mm (0.0047 in) (figure 25). Figure 26. Installing Piston Assembly

SLAVE CYLINDER
[$5] Disassemble (Figure 27)

1. Push rod (7).

2. Boot (8).
3. Piston assembly (9).
4. Return spring (10).
5. Bleeder screw and cap (11,13).
6. Slave cylinder body (12).

# Clean

* All disassembled parts in brake fluid. Be sure to

Figure 25. Measuring Clearance at Master
wipe excess brake fluid from the components.
Cylinder and Piston
Inspect
Assemble (Figures 24 and 26) + Cylinder bore and piston for wear and rust
1. Cylinder body (8). formation.
2. Return spring (7). * Spring for weakening.
« Piston cups for wear, deterioration and scratches.
[3] Important * Replace any parts if wear, damage, or any other
abnormal conditions are found during inspection.
« Before installing the parts, apply a thin coat of
brake fluid. Measure (Figure 28)

3. Piston assembly (8). Install new cup in groove « The clearance inside the slave cylinder body with
in piston with the lip turned toward the front of a dial indicator. Use a micrometer to check the
the cylinder body. Use care so as not to scratch thickness of the piston. Replace the slave cylinder
the lipped portion of the cup (figure 26). body or piston if the clearance is less than 0.11
. Push rod assembly (7) with dust cover (4), snap mm (0.0043 in) (figure 28).
+

ring (5) and stopper (6).

. Stopper (6).
aM

. Snap ring (5) to the cylinder body groove.

. Dust cover (4).
On

. Hose joint (1).

 CLUTCH 7C2-15

7. Pushrod
8. Boot
9. Piston Assembly
10. Return Spring
11. Bleeder Screw
12. Slave Cylinder Body
13. Cap

Figure 27. Slave Cylinder Assembly

2. Bleeder screw and cap (11,13}.

Tighten
« Bleeder screw to 8 N-m (69 Ib-in).

. Return spring (10).

[y] Important

* Before installing the parts, apply a thin coat of

brake fluid.
+ Be sure to install the piston cup in the piston
groove with the lip turned toward the front of
the cylinder body. Use care so as not to
Figure 28. Measuring Clearance at Slave scratch the lip portion of the piston cup.
Cylinder and Piston
. Piston assembly (9).
. Boot (8).
Assemble (Figure 27) . Push rod (7).
1. Slave cylinder body (12).

NOTICE: See “NOTICE” on page 7C2-1 of this

section.
7C2-16 CLUTCH

SPECIFICATIONS
PreSSUre Plate TYPOS... cceccseeecerereeeccnmeesseseeesesaeensanaesetenenesenensuanes Dry Single Plate w/Cushioning Spring
Clearance Between Master Cylinder Body and PiSton...............cc:ccscescoceeseeeeeeeeeneeserteceusanss 0.12 mm (0.0047 in)
Clearance Between Slave Cylinder Body and Poiston. ...............:ccccsecssecccceeectesessesseseneenes 0.11 mm (0.0043 in)
Driven Plate Warpage Maximum Limit 0.0.0... ceecceeteeeeceteeteee ceeeeechonsaasrersesanedausencessensensaees 0.6 mm (0.024 in)
CIUCH SiZ0 ose eee cece ee cece cence nneenaanaaeaenmacaesaaaaauaeaaconsaeaeonaeeeseneceseoeaeeeaenessaeaeouaesqasaeaaneesaueses 325 mm (12.80 in)
Depression of Rivet Head Maximum LUMIT oe eeeceeesecccsamecnsesnecccceauusnsesseecenessenaseeseeeeeeteoes 0.2 mm (0.008 in)
Pressure Plate Clamping Force Maximum Limit ...........:ccccccccecescecesssseeseceereecuceeseseesessacesezaneees 970 kg (2,139 Ib)
Pressure Plate Finger Height ..............:.cccccecereccnsecesensereereusesseeueeeaueececseussensersenees 61.8-63.8 mm (2.43-2.51 in)
Master Cylinder Push Rod Length
(From Centre of Crevis Pin Hole to Mounting Surface) .............. cc ceeeceeeteeee 156.5-157.5 mm (6.16—6.20in)
Pedal Height (Reference) ........ cece eeneestensesnneeneaaeeaeanesarameasenaeaeeeneaeasonecanmasananegnonmana 160-170 mm (6.3-6.7in)
Pedal Travel (Reference) «2.0.0.0... cee ccssneseecessnenenaaeameaneoseasuasaecuoegesueeaeneneaeneaneeeaqaaaaaneas 159-169 mm (6.2-6.7in)
Free Play (REfErENCE) oo. cccceceeeeereeatereeeeeeeteeseecetereeneececenecstepneetneeteeneeteereoneeneetenes 15-25 mm (0.6-1.0 in)
Clutch Switch Clearance ......... ccc ecccceeeeneeeeeneseeereeeeeaenaneauoavaaeeversaenectsaaeneseeeaeanaaeaes 0.5-1.0 mm (0.020-0.039 in)

FASTENER TORQUES

Master Cylinder Push Rod Jam Nut... eeeeessscncnsneeeeeaueaneeseanemaeaeanenaaeussnenmeaanaeneneeoeee 13 N-m (113 Ib-in)
Clutch Switch Jam Nut oo... ccccssseccucceccsccseneeseesenenesuecseseescessessssesensceeeaneceeececteneneueuensesseeseneeses 20 N-m (14 Ib-ft)
Pressure Plate Bolts ........0....cccccccccccccucussssereceeeeecesaneceseeeeeceeneessaneaseceeceeseaaaeeseeeeeseuaueaeasacssterenes 40 N-m (30 lb-ft)
Master Cylinder Bolts ......... 0. cccececcceceeeve nro cence tesesanecerasseasasssnaaanaasseesgaaenegsesgenetessnestepneceaeees 13 N-m (113 Ib-in)
Slave Cylinder Bolts... ee ceseereeterseeeenees bedeceneeseennaneneneeseeesocaeuaseesnessasanusnseecntecssannenagenes 19 N-m (14 lb-ft)
Flexible Hose Tube Nut ................ cece eeceeeneecsestensesnneasaameaseauaeaseueetauoudeceuadeaenuseeuaeaeeeuensneneneaeanes 20 N-m (14 Ib-ft)
Slave Cylinder Bleeder Screw ........... cece seen er tee ere eete renner ninaeasenmeseeaueedsaeesnndseeseeeeeneaneseneeceneoed 8 N-m (69 Ib-in)
Clutch Pedal and Bracket Assembly Mounting Blt oo... cc eccccecneseenecoenneneeneeeesceneeersmaneessessseaestes 37 N-m (27 Ib-ft)

SPECIAL TOOLS

TOOL NO.
ILLUSTRATION TOOL NAME

J-35854
Power Bleeder Adapter

J-35253
Clutch Pilot Aligner
 CAB AND CHASSIS ELECTRICAL 8-1

SECTION 8

CAB AND CHASSIS ELECTRICAL

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. if the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound, will be called out. The
correct torque values must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT
General Information ........ccsccssssccssccsnsssevennneensersesssenssensesnanssonneeenorsensen punanuesncsesseceenesvatuetecsssunnppenounnaess auunceaveces
Notes for Working on Electrical Items
Symbols and Abbreviations ..........cccsecsserssssnesensssesesssssscesssansnecnsneuseisnnseniensvesasnnoserssensersesssces
SYMDBOIS ........cscsscensenecucsetsssaesessvensstssecsetassnsenmuseonssassneseusueneeseuesontonsensungessuuseestustevesatenasarsseusnaass
Abbreviations .........:cccssscsusreccesesessonseesnnauseccausnsseueessnunneneaqensennsueees wasenvenucoeaes pensunaneeeeneataunesensonadewasassunausesans o
Parts for Electrical Circuit .............osssccssssesssceessnesensesnscassednnanenatessiessassueaauuvudensuueetenseueusconanuansounenensacersenusesse 5
HONOR SRO R ROAR CCH CEPAR PADRE CURA R CSTE NACE TAD T NTR TAN EHO A THU CAOK UNCER ST TOKE ER OUTLET HUTT OR ARAN OR RTO KRAT ANUS EKTTHRHEM HIME THK OONHTKU MEHR

COMME CHOS on. ccecceeeceepeeceemevesnentessunouseaetne scauceauuseeneqenceneusonacaaaseneansaueanonsaensonnuevansarueaqeaausnsustennaenene

Reading the Circuit Diagrarn .
Connector SYMDOI........cscscnsissenssessensnsenecensessessresenssenseresenereesnaney seduanduauaneeannaenineaaunitensseaeunueraenmasescenseavensea
JOIN COMMECTON ...........cceccccccncrssessnncoenseseenneuensasentonsenenmeed
danssasheeosonansauenss easeuneneaseeneeudsusendentacnsuecusanusuuausauuanaeeaae a
Main Data and Specifications. ..........ccsseccnnserscussssnsessmmeseresnseensnereseennesssseneses aenecnenescerenseuetsneesenttutenusenenanees
Bulb Specifications ........sscecnsecenesseenesersnsenssusnnesensensianaversnaaesssenunnianiantennrersaniansanestuarsnennaniarasaneanarensen
Fuse and Fusible Link LOGAtION..........:ccccccrscsnrssonssnsssussectesuneunendesvenisouruasaovos punecenteussoseusnoatuecaseusnanesznnensacanns ~ 2a
Fuse BIOGCK CirGuit.........cccccccesesssssonseseueenvensnusevanunscnnmeussnesnsevseadeuernanetaeasneeseeseesnsnenssanenuseneeennesanegaenn
nani sedsanteneen
Reference Table of Fuse
Relay Location ; ~ 2
Relay LiSt.......ccnssscsecserseseenesnessnensmssansaenrenseanmersensscascaitonnierinentonennneansuatontnea seustvensonesnrussateausvenqtunsanseaeeenanen B- 27
Diode Locatiori........... janesosneetenmeseunseuaetaravannacecnensaerecsusaenteoueausaueneusmeauseaeusnedaneediausagsavensqususanustonsusesoemuessasesgeneans 8- 28
Reference Table of Grounding Point ode 29
Grounding Point Location ........ccsssscosesssereeserneeseneiaecinsensienneesinmesteriniiseneaaiestreniiceseciiessnuaanereniinoneentare 8- 30
Cable Harness ROUting ..........::ccsseesssssrecressscresssensvetsntssceresteerseenrsnsorenecnnaueaeenassaneunesanagevevenenenmunsaranrnaes 8 34
System Repair..........ccccscssssesssessersesnensoesnecenaceconsensnseacestensentsenteenssinucoravousesssusiunanusnceniuseecgarssenauauenssuaneses ~ 34
Start and Charging + 34
Engine Control Module ........sccussessereresoensecsusinenseersrenanseass cnunusecenousintonspenuaasaeses coeondsenteensoreseetunteiaeninensuanneranse 8- 40
Engine Stop Systeim.......scsesenesssesesssresessneersenenseesnenserieertenenenssnienesensensmaneasasienvaneserentacenses tenet 5S
Headlight, D.R.L and Cornering Light .........scsseimessorsesneneensosanianiessuoneaeserseunsonseusnevartesesnes tee 8S
Clearance Light, Taillight, License Plate Light, ID Light and illumination Light 8 77
Turn Signal Light, Hazard Warning Light and Stoplight............scsssssesneaeenserssssorsannnsceninsesenantnseani gees 8- 90
Horn and Backup Light........cccceuseseenersesseesersmasseenesesensenieensenecsennuoranesseransnensisneedivsntccvectveseanrstansannusarsu es 8-103
Dome Light and Cab Interior Light .........:scsssssssenssecsneersenssatsoneansnneasusneninersueeuuarneneseneanaossuiennsesaverasasognenes 8-115
Transmission Control Module (TCM) 8-122
Windshield Wiper and Washer .....0....csccsssesnaeennueneneseeresenes 8-127
Audio and Cigarette Lighter ...........cesscesserenseseen sensraesnersetnansusavnseasau rivensesenucusgeavevenvasoson aneavauaneravansnonneaseny 8-145
8-2 CAB AND CHASSIS ELECTRICAL

Meter and Warning/Indicator Light .....0..scsssssssssenesensnensenseevscrenscenseeedeussscceneesnentenscaeenenesgetsuaesedeausseeusnens 8-153

Heater, Air Conditioning, Condensor Fan and Ceramic Heater... scccsscsssssssscesserssneeseeseunseseeanenes 8-190
Service Termitial..........cc:ccccccscscsesscecsecssessenenenssenseseconseesesceeeseesaesauumuersubeceevessenuanesasauensesccsaunarsueesangnesduesevenauanss 8-195
ABS (Anti-lock Brake SyStem) ........:cccccccncaescensenneessoeeenasenseessusvonuscocueeeeasaeeneesersesensenerenssonssenneantecnanecnanenenns 8-199
Power WINdOW ........0:cccsccssessssncerseasonsenensescesenas ea veauuensannessodsausenuasssaeetansentasesaasseesassoasseneesssaeanesseenessensenersnes 8-205
Power Door LOGCK........cc:ccccsconssecucerecnsscenseoesnaneaaneanespaeunnaasaessauasiunaacesuogueusauaaseseduseduonagenteuseaeasuunsavvaseceuosueanaenes 8-219
Wiring Diagram ou... cccccecrsescctescreniussssorssoenessisnanenseasnenunsenseusserseus
or seqesanscnrosuseusesnconanssoneaeseteonteoesaeatasraneeaene 8-229

GENERAL INFORMATION
The chassis electrical system is of 12-volt Disconnecting the Battery Cable (Figure 1)
specifications with a negative ground polarity. 1. All switches should be in the “OFF” position.
Wire sizes are appropriate to respective circuits, 2. Disconnect the battery ground cable @.
and classified by color. (The classification of 3. Disconnect the battery positive cable @.
harnesses by color is shown on the circuit diagram 4. Disconnect the battery cable @).
for ease of harness identification.)
The wire size is determined by load capacity and CAUTION: It is important that the battery ground
the length of wire required. cable be disconnected first.
The vehicle harnesses are: body harness, floor Disconnecting the battery positive cable first can
harness, engine harness, frame front harness, result in a short circuit.
frame rear harness, rear body harness, dome light
harness, door harness and battery cable. Connecting the Battery Cable
The harnesses are protected either by tape or Follow the disconnecting procedure in the reverse
corrugated tube, depending on harness location. order.
The circuit for each system consists of the power
source, wire, fuse, relay switch, load parts and CAUTION: Clean the battery terminal and apply a
ground, all of which are shown on the circuit light coat of grease to prevent terminal corrosion.
diagram.
In this manual, each electrical device is classified Connector Handling
by system. For major parts shown on the circuit Disconnecting The Connectors (Figure 2 and 3)
based on the circuit diagram for each system, a
summary, diagnosis of troubles, inspection and
removal and installation procedures are detailed.

NOTES FOR WORKING ON

ELECTRICAL ITEMS
BATTERY CABLE ~t Y
8
Figure 2. Disconnecting the Connectors (1)

Some connectors have a tang lock to hold the

connectors together during vehicle operation.
Some tang locks are released by pulling them
towards you @).
Other tang locks are released by pressing them
forward (2.
Determine which type of tang lock is on the
connector being handled.
Firmly grasp both sides (male and female) of the
Figure 1. Disconnecting the Battery Cable
connector.
 CAB AND CHASSIS ELECTRICAL 8-3

Release the tang lock and carefully pull the two

halves of the connector apart.
Never pull on the wires to separate the
connectors. This will result in wire breakage.

Figure 5. Connector Inspection (1)

Never insert the circuit tester test probes into the

connector open end to test the continuity. Broken or
open connector terminals will result (figure 6).
Figure 3. Disconnecting the Connectors (2)

Connecting the Connector

Firmly grasp both sides (male and female) of the
connector. Be sure that the connector pins and pin
holes match. Be sure that both sides of the
connector are aligned with each other. Firmly but Test probe
carefully push the two sides of the connector f
é

together until a distinct click is heard (figure 4).

Figure 6. Connector Inspection (2)

Waterproof Connector Inspection

It is not possible to insert the test probes into the
connector wire side of a waterproof connector.
Use one side of a connector @) with its wires cut
to make the test. Connect the test connector @ to
the connector to be tested. Connect the test probes
to the cut wires to check the connector continuity
Figure 4. Connecting the Connectors (figure 7),

Connector Inspection
Use a circuit tester to check the connector for
continuity. Insert the test probes from the connector
wire side (figure 5).
8-4 CAB AND CHASSIS ELECTRICAL

Stender shaft
Tang lock
Wire

Tast probe a
Housing open pad Pin

Figure 7. Waterproof Connector Inspection Figure 9. Disconnecting Pin Tang Lock Type

Connector Pin Insertion (Figure 10)

Connector Pin Removal 1. Check that the tang lock is fully up.
Connector Housing Tang Lock Type (Figure 8) 2. Insert the pin from the connector wire side.
1. Insert a slender shaft into the connector Push the pin in until the tang lock closes firmly.
housing open end. 3. Gently pull on the wires to make sure that the
2. Push the tang lock up (in the direction of the connector pin is firmly set in place.
arrow in the illustration). Pull the wire with pin
free from the wire side of the connector.

Tang tock Wire

Slender shaft
Tang fock

Housing open pad Pin Wire

Figure 10. Connector Pin Installation

Parts Handling
Figure 8. Disconnecting Housing Tang Lock Type
Be careful when handling electrical parts. They
Pin Tang Lock Type (Figure 9) should not be dropped or thrown, because short
1. Insert a slender shaft into the connector circuit or other damage may result (figure 11).
housing open end.
2. Push the tang lock fiat (toward the wire side of
the connector). Pull the wire with pin free from
the wire side of the connector.
 CAB AND CHASSIS ELECTRICAL 8-5

clearance from the other parts and guard the wiring

harness with a vinyl tube and clips to avoid direct
contact (figure 14).

LIK
OK Vinyl tube

Figure 11. Parts Handling

Cable Harness
When installing the parts, be careful not to pinch
or wedge the wiring harness (figure 12). Figure 14. Cable Harness (3)
All electrical connections must be kept clean and
tight. The wiring harness between engine and chassis
should be long enough to prevent chafing or
damage cue to various vibrations (figure 15).

NO
wv
OK
Figure 12. Cable Harness (1)

Use a grommet or guard tube to protect the wiring Figure 15. Cable Harness (4)
harness from contacting a sharp edge or surface
(figure 13).
SPLICING WIRE
1. Open the Harness
NO If the harness is taped, remove the tape. To
avoid wire insulation damage, use a sewing
“seam ripper” (available from sewing supply
stores) to cut open the harness.
if the harness has a block plastic conduit,
simply pull out the desired wire.

2. Cut the wire

Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire
later if you decide to cut more wire off to change
the location of a splice. You may have to adjust
Figure 13. Cable Harness (2) splice locations to make certain that each splice
is at least 1-1/2" (40 mm) away from other
Position the wiring harness with a enough
8-6 CAB AND CHASSIS ELECTRICAL

splices, harness branches, or connectors.

Wings of clip
. Strip the insulation touching former
When replacing a wire, use a wire of the same
size as the original wire. Check the stripped
wire for nicks or cut stands. If the wire is
damaged, repeat the procedure on a new
section of wire. The two stripped wire ends
should be equal in length.

. Crimp the Wires Back of clip

centered on anvil
Select the proper clip to secure the splice. To
determine the proper clip size for the wire being
spliced, follow the directions included with your
clips. Select the correct anvil on the crimper. Figure 17. Crimp the Wires (2)
(On most crimpers your choice is limited to
Before crimping the ends of the clip, be sure
either a small or large anvil.) Overlap the two
that:
stripped wire ends and hold them between your
« The wires extend beyond the clip in each
thumb and forefinger.
direction.
Then, center the splice clip under the stripped
« No strands of wire are cut loose, and
wires and hold it in piace (figure 16).
« No insulation is caught under the clip.

Crimp the splice again, once on each end. Do

not let the crimping tool extend beyond the edge
of the clip or you may damage or nick the wires
Over lap bare wires
(figure 18).

Splice clip

Splice clip
Align tool with
edge of clip to
crimp ends of
splice

Figure 16. Crimp the Wires (1)

+ Open the crimping tool to its full width and

rest one handle on a firm flat surface.
* Center the back of the splice clip on the
proper anvil and close the crimping tool to the
point where the back of the splice clip touches Figure 18. Crimp the Wires (3)
the wings of the clip.
. Solder
» Make sure that the clip and wires are still in
Apply 60/40 rosin core solder to the opening in
the correct position. Then, apply steady
the back of the clip. Follow the manufacturer’s
pressure until the crimping tool closes (figure
instructions for the solder equipment you are
17).
using (figure 19).
 CAB AND CHASSIS ELECTRICAL 8-7

lf the wire does not belong in a conduit or other

harness covering, tape the wire again. Use a
winding mation to cover the first piece of tape
(figure 21).

Figure 19. Crimp the Wires (4)

6. Tape the Splice

Center and roll the splicing tape. Tne tape
should cover the entire splice. Roll on enough
tape to duplicate the thickness of the insulation Figure 21. Crimp the Wires (6)
on the existing wires. Do not flag the tape.
Flagged tape may not provide enough
insulation, and the flagged ends will tangle with
the other wires in the harness (figure 20).

Good (Rolled) Bad (Flagged)

Figure 20. Crimp the Wires (5)

8-8 CAB AND CHASSIS ELECTRICAL

SYMBOLS AND ABBREVIATIONS

SYMBOLS

Symbol Meaning of Symbol Symbol Meaning of Symbol

—o NO Fuse © Bulb

Or” O— Fusible link @ Double filament bulb

—o\. 9— Fusible link wire (My Motor

LOH . WW vv a Variable register

Switch Rheostat

Lo” oOo Switch ; _ Coil (inductor), solenoid,

magnetic valve

(Normal close type)

Cntact wiring Relay

$ ° Battery

— Diode + Connector

&) Electronic Parts —-— Light emitting diode

—/\Wh— Resistor 4H Reed switch

mig Speaker —{}-— Condenser

ae Buzzer —)\— Horn

156+ Circuit breaker Leet Vacuum switching valve

Figure 22. Symbols

 CAB AND CHASSIS ELECTRICAL 8-9

ABBREVIATIONS

Abbreviation Meaning of Abbreviation Abbreviation Meaning of Abbreviation

A Ampere (S) IG ignition

ABS Anti-lock brake system kw kilowatt

ASM Assembly LH Left hand

AC Alternating current LWB Long wheel base

A/C Air conditioner M/T Manual transmission

ACC Accessories oD Over drive

AIT Automatic transmission OPT Option

C/B Circuit breaker Qos Quick on start

CSD Cold start device RH Right hand

DIS Direct ignition system RR Rear

D.R.L Daytime running light RWAL Rear wheel anti-lock brake system

EBCM Electronic brake control module ST Start

ECGI Electronic control gasoline injection STD Standard

ECM Electronic control module SW Switch

ECU Electronic control unit SWB Short wheel base

EFE Early fuel evaporation TCM Transmission control module

4A/T 4-speed automatic transmission 3A/T 3-speed automatic transmission

4x4 Four-wheel drive V Volt

FL Fusible link VSV Vacuum switching valve

FRT Front Ww Watt (S)

HBB Hydoro brake booster WOT Wide open throttle

H/L Headlight Wi With

Ic Integrated circuit W/O Without

8-10 CAB AND CHASSIS ELECTRICAL

PARTS FOR ELECTRICAL CIRCUIT

WIRING All wires have color-coded insulation.

Wires belonging to a system’s main harness will
Wire Color have a single color. Wires belonging to a system's
sub-circuits will have a colored stripe. Striped wires
use the following code to show wire size and colors.

Example: Q. 1 /B—B
‘LH Red (Stripe color)
Green (Base color)
Single color Wire size (0.5 mm?)

Abbreviations are used to indicate wire color

within a circuit diagram.
Refer to the following table.
Colored stripe

Figure 23. Wire Color

Wire Color Coding

Color-Coding Meaning Color-coding Meaning

B Black BR Brown

Ww White LG Light green

R Red GR Grey

G Green P Pink

Y Yellow LB Light blue

L Blue Vv Violet

0 Orange

Distinction of Circuit by Wire Base Color

Base color Circuits Base color Circuits

B Starter circuit Y Instrument circuit

WwW Charging circuit

ging L, 0, BR,
R Lighting circuit LG, GR, Other circuit
P, LB, V
G Signal circuits
 CAB AND CHASSIS ELECTRICAL 8-11

Wire Size
The size of wire used in a circuit is determined by
Outside diameter the amount of current (amperage), the length of the
circuit, and the voltage drop allowed. The following
wire size and load capacity, shown below, are
specified by AWG (American Wire Gauge) (Nominal
size means approximate cross sectional area)
{figure 24}.

Cross sectional area

Figure 24. Wire Size

Wire Size Table

Nominal size Cross sectional Outside diameter Allowable AWG size

area (mm?) (mm) current (A) {cross reference)
0.3 0.372 1.8 9 22
0.5 0.563 2.0 12 20
0.85 0.885 2.2 16 18
1.25 1.287 2.5 21 16
2 2.091 2.9 28 14
3 3.296 3.6 37.5 12
5 5.227 4.4 53 10
8 7.952 5.5 67 8
15 13.36 7.0 75 6
20 20.61 8.2 97 4

FUSE, FUSIBLE LINK AND CIRCUIT

Normal BREAKER

FUSE
Fuses are the most common form of circuit
protection used in vehicle wiring. A fuse is a thin
piece of wire or strip of metal encases in a glass or
plastic housing. It is wired in series with the circuit it
protects. When there is an overload of current in a
circuit, such as a short of a ground, the wire or
metal strip is designed to burn out and interrupt the
flow of current. This prevents a surge of high
current from reaching and damaging other
components in the circuit.
Figure 25. Fuse
Determine the cause of the overloaded before
replacing the fuse.
The replacement fuse must have the same
amperage specifications as the original fuse.
Never replace a biown fuse with a fuse of a
different amperage specification.
Doing so can result in an electrical fire or other
serious circuit damage. A blown fuse is easily
identified (figure 25).
8-12 CAB AND CHASSIS ELECTRICAL

FUSIBLE LINK
The fusible link is primarily used to protect circuits
Blown
where high amounts of current flow and where it
would not be practical to use a fuse. For example,
the starter circuit. When a current overload occurs,
the fusible link melts open and interrupts the flow of
current so as to prevent the rest of the wiring
harness from burning.
Determine the cause of the overload before
replacing the fusible link. The replacement fusible
link must have the same amperage specification as
the original fusible link.
Never replace a blown fusible link with fusible link
of a different amperage specification. Doing so can
Figure 26. Fusible Link result in an electrical fire or other serious circuit
damage.
A blown fusible link is easily identified (figure 26).

Fusible Link Specifications

Type Rating Case Color Maximum Circuit Current (A)

Connector 30A Pink 15

Connector 40A Green 20

Bolted 50A Red 25

Bolted 60A Yellow 30

Bolted 80A Black 40

 CAB AND CHASSIS ELECTRICAL 8-13

RELAY
Battery and load location may require that a
switch be placed some distance from either
component. This means a longer wire and a higher
voltage drop @. The installation of a relay between
the battery and the load reduces the voltage drop
@.
Because the switch controls the relay, amperage
through the switch can be reduced (figure 27).

Figure 27. Relay

RELAY SPECIFICATION AND CONFIGURATION

Name/ Rated Name/ Rated

Color voltage/Coil Internal circuit Color voltage/Coil Internal circuit
resistance resistance

12V/
MR5C | Approx. 902
(1T)/ Minimum
operating
Black | voltage: 7V 12V/
at 25°C (77°F) MR82C/| APPFOX. 2302

12v/
write | Minimum
label voltage: 7V
MRSC | Approx. 902 at 20°C (68°F)
(1T} Minimum
operating
Brown voltage: 10.5V
at 25°C (77°F) ols te

@ LB
24V/
MRS5C Approx. 2662
(ty Minimum
operating
Green voltage: 16V Approx. 1000
at 25°C (77°F} M820 Minimum
label operating
24V/ abe voltage: 16V
MR5C | Approx. 2662 at 20°C (68°F)
(Ty Minimum
operating
Grey voltage: 20V
at 25°C (77°F)

Figure 28. Relay Specification and Configuration

8-14 CAB AND CHASSIS ELECTRICAL

DIODE
DIODE SPECIFICATIONS AND CONFIGURATIONS

THERE SHOULD ) BE CONTINUITY IN

MARK/ IRCUIT
SHAPE
coLoR| CONSTRUCTION | CHECKING) teste R is CONNECTED WITH
DIODE TERMINAL
TERMINALNO, -——7—
Z ey)? (| 24
=) |G Oo" 31 |/connection[ A| @ [6
BLACK PATTERN B OS ®

TERMINALNO. | —

iP e
3 2 j

CONNECTION ® 9
PATTERN B @ SO

BLACK oO 1s
o—k}+-o—_
>}
TERMINAL NO. 3 3 1

A © ®
CONNECTION @ 9
PATTERN @ OQ
B 9 ®

TERMINAL NO. tt, —4

3 4 3 2 1
ale
pO A oe | ®@
‘ CONNECTION 9 ®
PATTERN O @
B ® | ©
BLACK ® S

Figure 29. Diode Specifications and Configurations

MAXIMUM RATING (Temp. =25°C)

items Rating Remarks

Peak reverse voltage 400V

Transient peak reverse voltage 500V

Average output current 1.54 Temp. = 40°C

Working ambient temperature -30°C~80°C

Storage temperature -40°C~100°C

 CAB AND CHASSIS ELECTRICAL 8-15

CONNECTOR The applicable terminal number is shown for each

connector (figure 33).
The connector pin shape determines whether the
connector is male or female.
5 i
The connector housing configuration does not
W-38 W-38
determine whether a connector is male or female
(figure 30).

SHIFT LOCK
4a;
waa] 288—
0.5 RL

——4 6 0.85 W/L.

¢w-sal}- —————
7 |
[w-38]
as Terminal number

Figure 33. Connector (4)

Female Connector Male
connector pin shape connector Sonnector terminal numbers are clearly shown.
Male side connector terminal numbers are in
sequence from upper right to lower left.
Female side connector terminal numbers are in
Figure 30. Connector (1) sequence from upper left to lower right (figure 34).

The symbol illustrated in the figure is used as

connector, in the circuit of this section (figure 31).
Female side connector Male side connector

Female side connector

| ond
mie

Terminal number

Male side connector Figure 34. Connector (5)

NOTICE: For those connectors on which specific

terminal numbers or symbols are shown (such as
Figure 31. Connector (2) ECM), the terminal numbers or symbols are used
in the circuit diagram, irrespective of the above
Connector is identified with a number (figure 32). rule (figure 35).
elelsjelalo|| ,

:felal=isle|-| |
[afalaletel-||
sesisisl- ||
fealeiel=tl-||

aE

Male side
3 ? a

4 0.5 RAL connector

-—Lw-38|}
SHIFT LOCK
_] * oss Wh
3
Petar Female side
a0] a0 | connector
sala
ee Connector number ELS EVEN
arene:

Figure 32. Connector (3) Figure 35. Connector (6)

8-16 CAB AND CHASSIS ELECTRICAL

The connectors used for relays have their own

terminal number assignment, irrespective of the
above rule (figure 36).

Figure 36. Connector (7)

READING THE CIRCUIT DIAGRAM

In this manual, each system has its own parts
location illustration, circuit diagram and connector
configuration used in the circuit diagram.

PARTS LOCATION
The parts location shows the location of the parts @ and the connector @ used in each harness routing @
(figure 37).

B-43 CIGARETTE LIGHTER ILLUMINATION

B-45 CIGARETTE LIGHTER

B-22 TAIL RELAY p44
CIGARETTE LIGHTER STARTER SW
RELAY BOX ASM (No. 1}

H-2

D-1 SPEAKER (RH)

FUSE BOX ASM

F-4, F-7, F-9
B-28RADIO& CLOCK - RELAY. BOX ASM
8-29 JOINT CONNECTOR FL~-1, FL-2 FUSIBLE LINK
D-5 SPEAKER (LH)

Figure 37. Parts Location

 CAB AND CHASSIS ELECTRICAL 8-17

CIRCUIT DIAGRAM
The circuit diagram shows the power supply @ the load or loads G) and the grounding point(s) © (figure 38).

9 N
—
ee
AN
Nee
sw . ae
«
NM 5 ;
Ne crabs

(ea) a
RADIO GAR

osay
SPEAKER (LH) SPEAKER GH
iat

Figure 38. Circuit Diagram

CONNECTOR LIST
The connector list shows each connectors’ configuration () and the pin number @) (figure 39).

[ez] [ez] [e-20] [229]

“nN tL2ps ajbie

TKO) ne J cea 7107 oe Th ods 11) 12) 2

[es] [a4] {a-7]

[es] 7
7 ey a Fi i

a
4

2
fe

Figure 39. Connector List

8-18 CAB AND CHASSIS ELECTRICAL

CONNECTOR SYMBOL

Connector Harness name Connector Harness name

Symbol! Symbol

B Body harness L Dome Light harness

D Door harness N Floor harness (LH & RH)

E Engine harness P Battery harness

H For joint between harnesses R Rear body harness

J Frame front & frame rear harness

JOINT CONNECTOR 2. When one joint connector must be shown from

This connector has the structure of plural number different angles in the circuit diagram (figure
of terminals collectively connected inside the 42).
connector (figure 40).

3
‘ane ¥ 4| itat :peg] '|Prat
0.85. «13
feaH— | * Lez]|
Len ewe een ee es
{
Joint
Joint connector
connector 8
aoe

Terminal
Joint connector

Figure 42. Joint Connector in the Circuit

Figure 40. Joint Connector Diagram (2)

How to show joint connector in the circuit

diagram
1. When joint connector can be shown as actual
circuit diagram (figure 41).

Joint connector

Figure 41. Joint Connector in the Circuit

Diagram (1)
 CAB AND CHASSIS ELECTRICAL 8-19

MAIN DATA AND SPECIFICATIONS

BULB SPECIFICATIONS

Dome light Identification light

promi, Roof marker light
License plate light

Backun fight Stoplight/

N\ | ae
“Co Ss -Turn signal

Ny

i J 4

Headlight (B) | >s . Af oo™

Headlight (A) AS Sf — Turn signal light

se
Cornering light / Clearance light

Figure 43. Bulb Specifications

Light Name Rated Power No. of Bulb Lens Color

A 60W/40W 2
Headlight Rectangular type Clear
B 50W 2

Turn signal light /

Front side marker light 27 Wi8W 2 Amber
Front combination light
Cornering light /
Clearance light 27Wwiew 2 Clear

Stoplight/Taillight 27W/i8W 2 Red

Rear combination light | Turn signal light 27Ww 2 Amber

Backup light 27W 2 Clear

License plate light 7.5W 1 Clear

Roof marker light SW 2 Amber

identification light SW 3 Amber

8-20 CAB AND CHASSIS ELECTRICAL

Light Name Rated Power No. of Bulb Lens Color

Dome light 10W 1 White

Glow 1.4W 1 Amber

Engine oil pressure 1.4W 1 Red

BRAKE 1.4W 1 Red

Charge 1.4W 1 Red

Exhaust brake ow 1 Green

High beam 1.4W 1 Blue

Indicator/Warning light Turn signal /
(In the meter assembly) Hazard warning 1.4W 2 Green

Fuel level 2Ww 1 Amber

BRAKE BOOSTER 1.4W 1 Red

O/D OFF 1.4W 1 Amber

CHECK TRANS 1.4W 1 Red

A/T OIL TEMP 1.4W 1 Red

ABS 1.4W 1 Amber

D.R.L 1.4W 1 Green

umnauon anf saw

Hazard warning switch 60mA 1

Dome light switch 60mA 1

illumination & Gab interior switch 1.2W 1

Indicator light AIC switch 60mA {

engine warming up 60mA {

O/D OFF switch 1.8W 1

Cigarette lighter 1.4W 1

Heater bezel 1.4W 1

Ashtray 1.4W 1

MILES CHECK Switch 60mA 1

 CAB AND CHASSIS ELECTRICAL 8-21

FUSE AND FUSIBLE LINK

LOCATION
FUSE

Fuse puller

vom

Fuse label Relay box

(Installed on
J the cab left
Fuse ( [F-21] ) side rear)

FUSE LABEL
“Oy | HEATER “® | WIPER, WASHER as —
‘3 | AIRCON “p> | GENERATOR 202 | CONDENSOR FAN
"9 | EXHAUST BRAKE ‘> | TURNS/LIGHT oA | ABS-1
1 ort ‘® | ECU (GN) OA | ABS-2
'S | ecu war) 208") AUDIO,CIGAR LIGHTER | | #95 | GAUGE, BACK
'® | DOME LIGHT “@ | POWER SOURCE 26" | POWER WINDOW
eS TAIL LIGHT > ENGINE STOP roe | power WINDOW
'B | stor LiGHT “® | HAZARD, HORN NOTICE: The fuse numbers @ ~
aD LIGHT (RH) 25A | ABs (BAT) sea
expressedon as [F-1]
@are indicated ool
@® |e
|208 ae ~ [F-20]
20A
HEAD LIGHT (LH) @ | STARTER
10A in the circuit diagrams of this
manual.

Figure 44. Fuse

8-22 CAB AND CHASSIS ELECTRICAL

FUSIBLE LINK

Relay box (Installed on the cab left

side rear)

Aaa | No. Name Capacity

®@ MAIN 80A

@ | KEYSW 50A
® GLOW 60A

Ne © | C/HEATER 60A

Figure 45. Fusible Link

 CAB AND CHASSIS ELECTRICAL 8-23

FUSE BLOCK CIRCUIT

GENERATOR
B

a
ooo ra
MOA FL [Ea
mp) Ot

STARTER SW |
Oo oO —_—
ACC oe KEYa SW =}
on, °
oO \ 8 OE
oo a] GLOW 60A
st. © ORD
oo “pt

3 \ GLOW RELAY
—f~ { °

‘ HEATER & | ot
[ A/C RELAY GLOW PLUG INDICATION ON LABEL
__ ~~ ae
aa F-1 25A ———— seven inrntnnn
O-—-—-| HEATER |
[F-2| | 10a eee
EXHAUST FS] on — AIRCON i
Cy —F BRAKE = 9 \O—-—| EXHAUST BRAKE
o RELAY (ea | i 10A i
ee =e OD | D.R.L
6 [F-5 | _10A ===
<9 \o-——| ECU (BAT)
F-6} | 10 Co
_ O™O-—-4, DOME LIGHT
F-7] | 10a | ier
i X e LA bo Mar .

HEADLIGHT RELAY [es] [aa _ tstopugar

> } F9| 20A ee
CPO —F ire | Oo \0-—[ HEAD LIGHT (RH) |
o [E10] | 20A ee
s
- 7~0-—-{ HEAD LIGHT (LH) ]

[F-17] 204 _—
\o--_| WIPER, WASHER
F121 | 204 One ——
= Opn GENERATOR
F-13] | 104 eee
Ede
-F4) | 0A
TURN SmigHT
nnn
Fale Ew,
OD
F-16| 204

[Ev] | 108
ONO

Fa] | 200
OND

20] 108
F.2 .

[F-22| ONO
204

CY

Figure 46. Fuse Block Circuit

8-24 CAB AND CHASSIS ELECTRICAL

REFERENCE TABLE OF FUSE

Fuse No. Capacity Indication on label Main parts (Load)

F-4 25A HEATER Blower motor, Blower resistor, A/C thermo relay,
Electronic thermostat, Heater & A/C relay

F-2 10A AIR CON A/C switch, Pressure switch, Heater & A/C relay,
Condensor fan relay, A/C thermo relay

F-3 10A EXHAUST BRAKE Exhaust brake cut relay, Engine warming cut-1 relay,
Exhaust brake control relay

10A D.R.L D.R.L unit, Exhaust broke relay

F-5 10A ECU (BAT) ECM

F-6 DOME LIGHT Dome light, cab interior light switch, ID light relay,
10A ID light, Manufacturer's connection, marker light,
Radio & clock

F-7 10A TAIL LIGHT Tail relay, lilurnination controller iD light,

lilumination light(s), EBCM

F-8 10A STOP LIGHT Stoplight, Stoplight switch

HEADLIGHT (RH) Tail relay, illumination light(s), Clearance light(s),

20A Tail light(s), liiumination controller, ID light relay,
Headlight (RH,), Headlight relay

20A HEADLIGHT (LH) Headlight (LH), Headlight relay

F-11 20A WIPER, WASHER Wiper motor, Wiper & washer switch, intermittent relay

F-12 20A GENERATOR Charge relay, Generator

 CAB AND CHASSIS ELECTRICAL 8-25

Fuse No. Capacity Indication on label Main parts (Load)

F-13 | 10A TURN S/LIGHT Hazard warning switch, Flasher unit,

Turn signal light switch

10A ECU (IGN) ECM, Timing relay, Timing magnetic valve

20A AUDIO, Power source relay, Radio & Clock ,
CIGAR LIGHTER Cigarette lighter

| F-16 | 20A POWER SOURCE Power source relay, Service terminal

10A ENGINE STOP Engine stop motor

20A HAZARD, HORN Horn relay, Horn, Horn switch,
Hazard warning switch, Flasher unit

F-19 25A ABS (BAT) EBCM

10A STARTER ECM, Starter relay,

Inhibitor switch, Neutral switch

F-21 — _ _

[ F-22 | 15A CONDENSER FAN | Condensor fan, Condensor-fan relay

F-23 15A ABS-1 EBCM, Hydraulic unit

[ F-24 | 10A ABS-2 EBCM, Hydraulic unit

F-25 10A GAUGE, BACK Starter switch, Cornering light relay,
TCM, Meter, Inhibitor switch, Backup light switch,
EBCM, RR speed sensor,
Power window relay, Exhaust brake control relay,
Glow relay, Low switch,
VSV; VSS, VSV; Aneroid compensator, VSV; EGR

F-26 25A POWER WINDOW Power window relay, Power window moior,
Power window switch

F-27 15A POWER WINDOW Door lock relay, Door lock switch
8-26 CAB AND CHASSIS ELECTRICAL

RELAY LOCATION

Relay box
(Installed on the instrument panel)
j I

om B-35} |B-36} |B-37} |B-38

A218 B-20| |p-21| {8-22 |B-23 =

Relay box
{Installed on the left side rear of the
cab)

Figure 47. Relay Location

 CAB AND CHASSIS ELECTRICAL 8-27

RELAY LIST

Connector Na. B-9 B-19 B-20 B-21 B-22

Relay name intermittent Charge Headlight Heater & A/C Tail

Connector No. B-23 B-24 B-34 B-35 B-36

Relay name Buzzer cansel Horn Power source Cornering light | Exh. brake cut

Connector No. B-37 B-38 B-261 B-211 J-12

Relay name A/G thermo Exh. brake Timing Vacuum pump Starter

Connector No. J-13 J-14 J-15 J-17 J-18

Relay name Glow-1 C/HEATER | Eng. warm cut 1 | Condensor fan Exh, brake

Connector No. J-19 J-20 B-12 B-307

Relay name Eng. warm cut 2 ID light Door lock Wien

8-28 CAB AND CHASSIS ELECTRICAL

DIODE LOCATION

B-18 8B-17
B-25 B-26
Relay box (Installed on the
\ | instrument panel)

\ 3 cI [1

A f—— 4 fb fp Fe} ALS ALO

9 eo

Relay box (Installed on the cab left

side rear)
Relay box

B-25

Connector No. B-25 B-26 J-21 B-17 J-23

HBB ENGINE
Usage WARMING STARTER VACUUM FICD
AIC CUT

Figure 48. Diode Location

 CAB AND CHASSIS ELECTRICAL 8-29

REFERENCE TABLE OF
GROUNDING POINT
NOTICE:Abnormail phenomena of electrical components are considered resulted from defective grounding.
in repair, be sure to inspect grounding points and to tighten all fastening parts surrounding the grounding
points.

Connector No. Cable pamess Location Main Parts (Load)

Frame-Lh (FRT) Vehicle speed sensor, Turn signal

| B-1 indicator light, Meter, Exhaust brake
indicator light

Headlight ECM, D.R.L unit, Brake fluid level switch,

B-7 | bracket (LH) TCM, Cornering light, Wiper motor,
Washer motor, Intermittent relay, Heater
& AIG relay, Radio & clock, Cigarette
lighter, Fan switch, Cab interior switch,
Body harness Flasher unit, Clearance light, ID light,
Kick down switch, Electronic vacuum
pump, Power source relay,
Dome light switch, Combination switch,
OD switch, Data link connector, Marker
light, Front combination light, Exhaust
brake cut relay, EBCM,
Power window relay, Power window
switch (LH), Door lock relay, Door lock
switch, Timing relay, Pressure switch

Frame front Frame-LH (CTR) Fuel tank unit, Starter relay, Neutral
harness switch, Pressure switch, Exhaust brake
control relay, Exhaust brake magnetic
valve, Engine stop motor, Inhibitor
switch, Engine warming cut relay, ID
relay, Condensor fan relay, Condensor
fan,License plate light, Taillight, Rear
turn signal light, Stoplight, Backup light,
Manufacturer's connection, Hydraulic
unit, VSV; FICD, VSV; INTAKE
THROTTLE, HBB oil level sensor

Ceramic heater instrument panel Ceramic heater

B-136 harness reinforcement
8-30 CAB AND CHASSIS ELECTRICAL

GROUNDING POINT LOCATION

Figure 49. Grounding Point Location

 CAB AND CHASSIS ELECTRICAL 8-31

CABLE HARNESS ROUTING

8-32 CAB AND CHASSIS ELECTRICAL

DOOR HARNESS (LH)

DOME LIGHT HARNESS

BODY HARNESS
DOOR HARNESS (RH)

Figure 51. Cable Harness Routing (2)

 CAB AND CHASSIS ELECTRICAL 8-33

REAR FRAME HARNESS

REAR BODY HARNESS

FRONT FRAME HARNESS

Figure 52. Gable Harness Routing

8-34 CAB AND CHASSIS ELECTRICAL
SYSTEM REPAIR
START AND CHARGING
GENERAL DESCRIPTION
The system consists of the starter switch, starter, through the starter relay to start the starter.
AC generator, starter relay and charge relay. When
the starter SW is set to the “ST” position, the
battery voltage is applied to the starter solenoid coil
STARTING CIRCUIT

BATTERY (+)
A

vi y
_ OFF
y “ag | STARTER SW
et “ST* POSITION

STARTER | ~/ é
RELAY i

STARTER
q

Figure 53. Starting Circuit

CAB AND CHASSIS ELECTRICAL 8-35

YaLYVLS
L2-f
SV XOg Aw 13
AW dd YALYVLS ZL-f
SNET F1giSNd 2-14 ‘L-dd
AAS SOLIBIHNI

Figure 54. Parts Location

Yn
: \ YOLOSNNOD LNIOF 62-4
iy
\
\
02-4 ‘ZL-4
WsvV XOS 3Snd
PARTS LOCATION

/ / / \
69°F YOLVHANAD ¢-f Lf /
(L °ON) WSYV XOd AV 13"
AV 139 JDYVHO 6L-d
 STARTER SWITCH

FL-1] 80A [Fiz] 50a

MAIN KEY SW [F-12] 200
fe GENERATOR
Ly AY O.5WwiR RELAY; EXHAUST
BRAKE(2}
ost RELAY; CHARGE
CIRCUIT DIAGRAM

RELAY:

MAA
O.SW/R

ola]
ie

60BL
HEATER&A/C(2)

STARTER
10A
RELAY; STARTER
gay 1 3
£12
FRAME P-6 Tare 0.5B/W
STARTER | +26

O.BWA. CHARGE WARNING

O.3BAV
LIGHT [B-52] (3)
iMETER}

0.85W/L
8-36 CAB AND CHASSIS ELECTRICAL

ECM [B-233] (15)

Figure 55. Circuit Diagram

1.28WAL

NEUTRAL SWITCH (M/T)

GENERATOR
wz 8

0.5B
0.58
FRAME-LH
{CENTER}
 CAB AND CHASSIS ELECTRICAL 8-37

CONNECTOR LIST

a
ae
1] pre 3l12t 43} 190

aay

[ p-6 || v2} { J-9 | | J-12|

“) —I—KO) (0

[ei}(e2] [ps] [ea] [rs|

|
ele! |

ate|
elal|
Saad

eo
ae

>
eu

Bie
BHT

Figure 56. Connector List

8-38 CAB AND CHASSIS ELECTRICAL

STARTER SWITCH The starter switch positions are LOCK, ACC, ON

and START. Turning the starter key to these
positions a circuit for starting the engine, the
operation of accessories, or stop the engine (figure
58).

Figure 57. Starter Switch

Inspeci (Figure 58)

Check the continuity between the starter switch

connector terminals.
Repair or replace the switch when the result of
inspection is found abnormal.

Switch side

7 Connector
No. B-67 B-68
starter Terminal 1 2 3 4 1 2 4 5 6
SW No.
key position ACC B ON ST BI P1 P2 Ww Ww

Removed
LOCK O--O

Acc | O-—-O O-+—-O

| ted ~ O-+—-O
nserte ON | O-+-O-+-O O —O
START O--O---O | O- O

Figure 58. Starter Switch inspection

 CAB AND CHASSIS ELECTRICAL 8-39

[es] Remove or Disconnect (Figure 59)

Preparation:Disconnect the battery ground

cable.

1. Steering cow!
Remove four screws and take off the steering
cowl.
2. Starter switch
* Disconnect the connector.
* Remove the screw.

Figure 60. Starter Relay

CHARGE RELAY
Inspect (Figure 61)

Check to see if there is any continuity between

the relay terminals.
Replace the relay with a correct one when the
result of inspection is found abnormal.

OS ae No continuity
1. Steering Cowl (When battery voltage is applied between @ — ©)
2. Starter Switch OQ) — B) vvecccccccusees Continuity

Figure 59. Starter Switch Removal

foe] Instail or Gonnect

To install, follow the removal steps in the reverse

order.

STARTER RELAY

Inspect (Figure 60)

Check to see if there is any continuity between

the relay terminals.
Replace the relay when the resuit of inspection is
found abnormal.
Figure 61. Charge Relay
() ek) eee Continuity
GQ) — © rrsscccceeeee No continuity
(When battery voltage is applied between @) —- @)
@ -—@ veccscescceeeee No continuity
D ~ © vecsccccerevers Continuity
8-40 CAB AND CHASSIS ELECTRICAL

ENGINE CONTROL MODULE (ECM)

GENERAL DESCRIPTION OF ENGINE
CONTROL MODULE (ECM)
This ECM consists mainly of QOS System,
Exhaust Brake/Warmup System, and EGR/QWS
System.

1. QOS (QUICK ON START) SYSTEM brake system to increase exhaust pressure for the
DESCRIPTION generation of EGR function (feedback of exhaust
gas into the cylinders) so that a rise of compression
This circuit consists of starter switch, engine temperature promote warmup.
control unit, glow relay, thermosensor, glow plug, As this system varies with models, refer to the
glow indicator light, etc. Circuit Diagrams by Models for the detaiis.
When the starter switch is turned to the “ON”
position, the glow relay is closed to start preheating 3. EGR/QWS SYSTEM
the engine and the glow indicator light comes on. DESCRIPTION
The engine is started after the glow indicator light
goes out. This circuit consists of starter switch, engine
The glow relay remains closed, regardless of the control unit, rack sensor, electric vacuum regulating
state of the glow indicator light, even after the valve (EVRV}, engine speed sensor, warmup
engine startup till the specified after-glow time. switch, thermosensor, relay, etc.
After the lapse of the time, the engine control unit is The EGR system recirculates part of exhaust gas
actuated to open the glow relay and stop in the intake manifold to mix the intaken air with an
preheating. inert gas to lower combustion temperature, thereby
The engine control unit has a self-diagnostic controling the generation of NOx.
function, making the glow indicator light blink in The QWS system is a system by which the
case of glow relay trouble. amount of intake air and the amount of exhaust gas
are compressed to shorten the time for warming up
2. EXHAUST BRAKE/WARMUP SYSTEM the engine.
DESCRIPTION These systems are controled by the engine
control unit.
This circuit comprises starter switch, exhaust
brake switch (combination switch), accel switch,
clutch switch, warmup switch, thermosensor,
vacuum switching valve, neutral switch, relay, etc.
The exhaust brake system serves to take au
“engine brake” effect by compressing exhaust gas
to increase the engine exhaust pressure.
When the exhaust brake switch is put on, the
exhaust brake valve is actuated due to the action of
the magnetic valve to apply exhaust brake. The
exhaust brake indicator light comes on.
When the transmission is in the neutral position,
exhaust brake is released. When the QWS being in
its working range, however, the exhaust brake is
not released.
When either the accel pedal or clutch pedal is
stepped on, either is switched off to release
exhaust brake.
The warmup system is available in two types.
One type controls air intake by changing the
opening of throttle valve, thereby changing the ratio
of air/fuel to be supplied into the cylinders to
improve thermal capacity for the promotion of
warmup. The other type makes use of the exhaust
 (W3L3W) LHOM YOLVOIGNI SVE
CAB AND CHASSIS ELECTRICAL 8-41

HX3 ‘MOTD LS-4

HILIW 729-8
(L/W)
YOLOSNNOD LYOHS
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Figure 62. Parts Location

JAVA DILANOVW Bly OEL-F
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ONId MOD €-3
8-42 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM - M/T

SB/L

Osby

38/7

=
—_

[F-i4)
+ 104
ECU
O.BBIY’ (GN)

-%
:
&3

:
sam
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a

58
| aw

= yn i — _» RELAY:
FRAME 9 cee OBLGM
al 4 [EASA EXHAUST BRAKE(5}
= EXHAUST TOA
Ecu
8-36 Bai yg BRAKE
J @
a
(BAT)
33 & Bzke
Sib B51] 3
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B-36 | | B- Had
a g 8
é
SW:EXH BRAKE
{COMBINATION SW) 3 B51] 5

nn il
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go

ENGINE TYPE
wi > 2 [p-238} N-SPEC ONLY
<2 3 1-68 ol
pe ° 8)e| 832
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x3 4° 5
15 | 7 frie] eles
s {i {3 9
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29 3% [8-234] [6-233] [8-233] [B-234
33 = $afAe saa 63 AS
se 53 8 sT GLOW IGN
a 2 EXH
“T1871 &
I-15 5) 9 => = FICD BRAKE
3 A-30 B-19
[B:234) B-2331
® 30 288
S .
3 a5
4 3

0.5BRAY
Hse is z
AC
0.6BR/R cOmMP
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1189 zo =|
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B-39 4 3 1
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8-26
DIODE sw:
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DIODE

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6 o
BELG 45
i 1 1
3-40 [oar] Jat
MAGNETIC
VALVE:
EXHAUST
BRAKE

J40 | VSV:INTAKE
THROTTLE
0.58
C.5B

0.58
FRAME-LH | | HEPe 38
“ 0.858

Figure 63a. Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-43

SB/.

O.5B/¥

O.SB/Y
lo

RELAY:GLOW
O.5B/Y
O.5BY

Gay

fe]
ees
s

SB/Y
5
32
2ss
DATA LINK ge ce 4
CONNECTOR SB iz 3 | GLOW PLUG
ag is
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232
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stl =|
8) 8) B 8 [
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B-1i
Tale
ei
1
A16
16
ra82[2
VSV-VSS vsV: . CHECKER DIAG GLOW
ANECON RELAY
RACK MV
THERMOGND THERMOSIG RACK. SIG RACK+ ENG- ENG SIG TIMING EVAV- :
37 B-8 Alt AT A6 8-3 8-10 en Acta oe Ae
p-299 [5-234 9-234] jp-234) |B-294) [8-233] B-233 5-234 8-234] [8-234]
7 8 24 7 6 3 10 “14 13 22
=

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= LZ td 1 3 12 14 HB &

ad J"

%; 3! s eo; sf 3 S 3 =
° 1 [ies
fea E-76 || &-76 €-43 |/ €-43 | [E-43 E2 | = a =

Low bt Lop
: LP Lam WW bE = Zz
= le irae Ss
po

WATER TEMP SENSOR RACK SENSOR ENGINE SPEED SENSOR Z

> EVAV-EGR
=
Ww

5<
. =
8-272| JOINT CONNECTOR

HEAD LIGHT | by k 38? ° ? 38

BRACKET-LH
0.5B/L

Figure 63a. Circuit Diagram

8-44 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM - A/T

SBA.
FL-3 a
60A . ——___—_. 0.5 BY .
GLOW 2 aa :
— —— ON 3Bv
FLA oO HB
5 0A o-2_H [p67
a MAIN tl
STARTER SW 3
onl

+ OFF0 + F-20}10A fis 3

STARTER 10A ne 5
[PsPa | GAUGE. BACK O.SB/Y ECU
Gn) 8 we

(ej) & wen *

Le) lee
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se
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1 a 2t 3 19
P5 !
= Q O.SLGW RELAY: #8] O.5B/Y 5
FRAME a
Oo 3
~ [F13}10a
EXHAUST BRAKEIS) [Es]
=
g
EXHAUST 10A &
B-36) BRAKE ECU 3] 19 20
& (BAT) a

a,
a~z
fea ° =
re rem
#io ° [6-230] 12) [B-229} (23)
SW:EXH BRAKE $
(COMBINATION SW) 5 a
2 a z
_| ° Ss

e B-51
60
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vil ot [a BS
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Bo = 2S (B-234] [6-239] |p-233| |B-234!
eZ YylAes Bie 8s As
<= S| 8 st slow ten ECM
mB aE
zs x ca EXH
f15} [15] 5 ue aws FICD BRAKE
i B-12 A-30 8-19
éa =
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amike 52
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H09] 37
O.5BRW (as |
O.SBAYR COMP
9
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DIODE J-23 || J-23 |[ J-23
DIODE 7 DIODE
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B-26 “Ls r3]
1 2 H-14 [re
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SW:ACCEL a g
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1 i 1
3-40 Pia 331
MAGNETIC
VALVE:
EXHAUST
r BRAKE
J-40 | VSV:INTAKE J41] vsvFicD = | J-31
3 THROTTLE 7 3
OSB
12 o
[H-13] 3
7 3B 0.6B |
FRAME-LH If }—| J-9 i
oN 0,858

Figure 63c. Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-45

BBL

0.5e/v rren22
[Hs]

i
a3
[3]— J-13 4 1-13 =
od

:
Qo

3 ols :
>

a
i
2 a «
3 3-18 3-13
6 a

a =
2 a
OSB 1
3
aa18 |
J-146
&
} J-136 i
12
s
DATA LINK ce 1
CONNECTOR. = E-3 | GLOW PLUG
148] vsv:vss
=
[a-79|| 6-79
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233 B-234 5-234] _[p-233)
Bi Br ATG Re 62
CHECKER VSV:EGR O1AG gLow
RACK ECM MV
THEAMO GND THERMO SIG RACK. SIG RACK+ — ENG- ENG SIG GND TIMING EVRV- EVRV+ GND
87 88 Al AT AG a9 B10 AS A Aid A138 Acz2
B-233 [:233| 18-234] [8-234] |e-234) [8-233] 8-233] |p-234) 3-234) [B-234 6-234 B-234)
leas 8060 a Te = 3 70 8 _. E at ea ry
| [B-272
bE
ox oOiz rey

Ss} s| 3 * age ° 5|
>| 88 2 eI = 2
bel a z a
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ba
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tae A A eat re ronan a . [Hs [i
86
feta] [reval feta reas] [aa] [ita [ints fava
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;

fEnlinifes| [Ealfecifesl [eel fea |g

H-13 H-13

Law|
AN A Lawl
mike talalsa] &
&
Wa
6-108 pe
fi-toe|

WATER TEMP SENSOR RACK SENSOR ENGINE SPEED SENSOR =d EVAV:EGA

&
é
[e272 a = 7 |
JOINT CONNECTOR | 6 =
HEADLIGHT Wek 36 2 ? 38
BRACKET-LH OsBA

Figure 63c. Circuit Diagram

8-46 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

J-19

287 ias|[E2]

7(sfas py
uu

a
a
=
N

~
a

Sod
=+<KS

azlaj4 4{3{2]1

3 sons i wos

(TeTataTa1)
ris{s
12/13]14

Figure 64. Connector List

 CAB AND CHASSIS ELECTRICAL 8-47

CONNECTOR LIST

_ = (ea) [Pa]
I

( neon, (Os

Figure 65. Connector List

8-48 CAB AND CHASSIS ELECTRICAL

STARTER SWITCH GLOW RELAY

Refer to “START AND CHARGING? in this Inspect (Figure 67)

section.

GLOW INDICATOR LIGHT Check to see if there is any continuity between

the relay terminals.
Refer to “METER AND WARNING/INDICATOR Replace the relay when the result of inspection is
LIGHT” in this section. found abnormal.

ENGINE CONTROL MODULE (ECM) Q) ~— @) ceccecerecceces No continuity

(When battery voltage is applied between @) — ©)
A) = © cecececcccrens Continuity

tt i_—
Cae)

| ATIAZIASTASIAS | AGIA7 ABL AQ olan}

espe epopepetaoperelapatal)
Figure 67. Glow Relay
tt Py —.
[es 8283 B4 Bs 0667 aa salen

Figure 66. ECM

 CAB AND CHASSIS ELECTRICAL 8-49

STARTER RELAY
CHARGE RELAY Accel Cable — Accel Pedal
STARTER SWITCH / Bracket
1 ee Connector
Refer to “START AND CHARGING” in this
section.

ACCEL SWITCH Accel Pedal ~ Lead Wire

NN
Inspect (Figure 68)
1. Check the continuity between the switch 1. Accel switch
connector terminals. This illustration is based on the M/T model vehicle
2. Check to see if switch plunger operates
smoothly. Figure 69. Accel Switch Removal
Repair or replace the accel switch when result
of inspection is found abnormal.
[oe] Install or Connect

To install, follow the removal steps in the reverse

order, noting the following points.

Inspect

1. Check to see if the accel pedal has been

returned by the return spring to the specified

Sa iea=a position.

CLUTCH SWITCH (M/T)

Switch 1 | Switch 2
rlunger Terminal 1 2 3 4 Inspect (Figure 70)
1. Check the continuity between the switch
Free connector terminals.
2. Check ta see if switch push rod operate
Push OO | O--O smoothly.
Repair or replace the switch when result of
inspection is found abnormal.
Figure 68. Acce/l Switch

[eo] Remove or Disconnect (Figure 69)

Preparation: Disconnect the battery ground

cable.
|_| 80.5
1. Accel switch
+ Disconnect the connector.
« Remove the two screws.

SW position

Push rod in OH-OC

Push rod out

Figure 70. Clutch Switch

8-50 CAB AND CHASSIS ELECTRICAL

| Remove or Disconnect (Figure 71) [oe] Install or Connect

Preparation: Disconnect the battery ground To install, follow the removal steps in the reverse
cable. order, noting the following points.

1. Clutch switch
+ Disconnect the connector.
+ Loosen the lock nut of the switch. 1. Check to see if the clutch pedal has been
* Remove the switch by turning it. returned by the return spring to the specified
position.
2. Turn the clutch switch clockwise until the tip of
Connector the threaded portion of the switch contacts the
pedal arm.

iO
3. Tighten the lock nut to the specified torque.

Lock nut torque N-m (kg-cm/Ib-in)

13 (130/113)

1. Clutch Switch

Figure 77. Clutch Switch Removal

EXHAUST BRAKE SWITCH

Inspect (Figure 72)

Check the continuity between the terminals of the

exhaust brake switch.
Repair or replace the switch when result of
inspection is found abnormal.

_:
er,
18 2/3]4)
Exhaust brake switch a rel7lel Switch side
Terminal
Sw No. 2 5
position

ON O-+0
OFF

Combination switch

Figure 72. Exhaust Brake Switch

 CAB AND CHASSIS ELECTRICAL 8-51

[es] Remove or Disconnect

EXHAUST BRAKE RELAY
EXHAUST BRAKE CONTROL RELAY
ENGINE WARMING CUT RELAY 1
[oe] Install or Connect ENGINE WARMING CUT RELAY 2
Refer to “HEADLIGHT, FOG LIGHT AND inspect (Figure 74)
CORNERING LIGHT” in this section.
Check to see if there is any continuity between
EXHAUST BRAKE MAGNETIC VALVE the relay terminals.
Replace the relay when the result of inspection is
inspect (Figure 73) found abnormal.
Connect the magnetic valve connector terminal
— B) vccccccreeeane Continuity
No. 1 to the battery (+) terminal and terminal No. 2
GD) ~ &) veccseecsceees No continuity
to the (-) terminal and then check the continuity
among each port. (When battery voltage is applied between @ — @)
Repair or replace the magnetic valve when the (Ce) re No continuity
result of inspection is found abnormal. (Oke) ee Continuity

FO
= oS}

EA;
Mn ny
B I 1G

We 7
A— /
Figure 74. Exhaust Brake, Exhaust Brake Control
Port
and Engine Warming Cut Relay
Operation A B C

When battery
voltage applied O--O
When battery _
voltage not applied O-7-O

Figure 73. Exhaust Brake Magnetic Valve

8-52 CAB AND CHASSIS ELECTRICAL

MEMO
 CAB AND CHASSIS ELECTRICAL 8-53

ENGINE STOP SYSTEM

GENERAL DESCRIPTION
The circuit consists of starter switch and engine This engine system is forcible pull the injection
stop motor. pump control rack to the direction of fuel supply
The engine stop mechanism aims at shut-off of reduction by means of engine stop motor, thus
fuel supply. shutting it off.
 PARTS LOCATION

FUSE BOX ASM

F-17 \ STARTER SW
8-54 CAB AND CHASSIS ELECTRICAL

Figure 77. Parts Location

FL-1, FL-2, FUSIBLE LINK
J-34 ENGINE STOP MOTOR
 CAB AND CHASSIS ELECTRICAL 8-55

CIRCUIT DIAGRAM

STARTER SWITCH

80A FL-2| 504

aL MAIN KEY SW
3W/B

O.5LAV
FRAME
[F-77] 104
ENGINE STOP

M
ENGINE STOP MOTOR

FRAME-LH (CENTER) |

Figure 78. Circuit Diagram

8-56 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

Figure 79. Connector List

 CAB AND CHASSIS ELECTRICAL 8-57

FUNCTION OF ENGINE STOP MOTOR

Starter SW Starter SW
A
Turn the starter switch from “ACC” position to “ON”,
Pe \y P, and the engine stop motor will turn by 180 degress
Ln
{from 0° to 180°) so that the stop motor's electrode
will be in potential equal to that of the starter switch
for the stop.

Turn the starter switch from “ON” position to “ACC”

or “LOCK”, and then the stop motor will rotate by
180 degree (from 180° to 360°) and cease
operating.
Stop motor Stop motor

Connector
Sa No. B-68
Nerina A Pi P2 Stop motor Stop lever position
Starter No.
SW key position NN 1 2 4
LOC K
O-7-O
a on
0° (360°) Stop
ACC O---O
ACC -*+ ON 0° -> 180° Stop — Run
cn,
ON = © 180° Stop
START > O
ON — ACC ©» o ae
LOCK 0 360 Stop -> Run

Figure 80. Engine Stop Motor

8-58 CAB AND CHASSIS ELECTRICAL

HEADLIGHT, D.R.L AND

CORNERING LIGHT
GENERAL DESCRIPTION
The circuit consists of headlight, Cornering light, or down by operating the dimmer SW while
starter switch, Combination switch (Lighting switch, headlight SW on.
dimmer - passing switch, cornering light switch), The passing SW is independent of the lighting
high beam indicator light, relay and D.R.L unit. SW, and the optical axis of the passing light can be
With the engine running, and the parking brake turned up only while the switch lever is pulled up
released, the D.R.L function lights up the headlight and held in this state.
automaticaily. When the headlight is on, turn the turn-signal
When the lighting SW is turned on by setting it at switch left or right, and then the cornering switch
headlight position, the D.R.L function is cancelled. built in the combination switch turns on, followed by
The optical axis of the headlight can be turned up the cornering light turning on

LIGHTING CIRCUIT

CORNERING LIGHT HEADLIGHT

Battery(+) ~~

-——e- Starter sw.(ON}

io
3 aA | Lighting
Si
v
Lighting sw.
”* 1D
e

J
4
t
& | Cornering
Ler

4
+ aT

a
, ~~ | light relay

y
LE
Headlight
Cornering
ra

i light sw.
~
HE

Dimmer sw. tc
Cornering
light <= D.R.L
r_UNIT Parking

tL
<> | brake SW
<=

i}

NOTE: Arrow marks “ ——>” indicate the direction

of current

Figure 81. Lighting Circuit

CAB AND CHASSIS ELECTRICAL 8-59

(H1) LHOM ONISNUOD $2 (H1) (v) LHOMGW3H 9-8

H7) (9) LHOMQWSH SFl-d
(W3L3IN) LHOM YOLVOIGNI Tuo 26-8
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NIT 3JISISN 7-74 “b-Ts. a
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8-H ‘LH ‘SH
AdaLiva —
——— (Hy) (@) LHOMGW3H OSL-8
—

Figure 82. Parts Location

wd" a Hu) (v) LHDMOWSH €£-8
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AA oN _
| I\\W“ Old '6-4 LAP
Lo /
Ph \SANN
\ AA
WSsY XOg 3SN
MS 2a ONDWd A / ING
° \
/ MS YaLyvis AO Ne ON) WSV XO8 AV134u
/ \ A148 JNVUG HX 8e-8
PARTS LOCATION

/
/ \ \
AV134 MWWL 22-8 (1 -on) WS¥ xOg aN
AW1a¥ LHOMGW3H 02-8 AV148 LHOI ONINANHOD Sé-g
(MS LHOIM ONINANHOD ‘MS ONILHDIT) MS NOLLYNIGIWIOD
8-60 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM

[FZ] soa
KEY Sw awa ant awe
1 H-7

aw sw ow
e Hee
FL-1] 80A EARTH
0.3B
MAIN

‘ IE a a _f|eoh
fp st a=
= S

x TAIL LIGHT oi|

g
e
S
&
oO
4
RELAY EXH BRAKE
> Ww

a
z & 3 3
is [- o
rm
[ : 8 9 £ c;
om no ad
I & |§ [& & 5

RELAY HEAD : = q RELAY,CHARGE

é : "0A
= DRL
& & e RELAY,
2 % TAIL
+ mo
gE
os
2
F-25 }10A
GAUGE, BACK a a
.
g
SW,LIGHTING a 2 8
=] 0 B5LGIR
* Onan te CLEARANCE LIGHT
OfF 1 2

}-— H 8-70) 1
ose

T
| s-70% O383G/a

i -
oO SwiR \

3
&
[EI
é [Eva] 20a [FS] 208
x 3 HEAD HEAD
o3uA = LIGHT (LH) LIGHT(AK)
~~ 4, 7 0.3L/P “ - fT 296
alez)

;
Zz

9
i Hi
qe IB.
,
S

=
ray
eB wD

b
y
id

e
te£ Le
i
eval B70
2 p-- i 4
§G
&a § 2225 F é

ane L__| —
|S
J
&
g
z
« 8 g
o3Wi8
rmamraninnncrnimonipd
7] [8.298

|B-22E|
:=
Fe

6 4
é ey
10 «HIGH = PASS B 5 E af
= gl =
=a
SW.DIMMER 3
SW;CORNERING
o5Re 2
© BT 225
a p é a DAL
56 w UNIT
QO Ms
o 9° a &

‘
s
a&] S|
1 2
cd

&
emp 5 1.25RV¥
.

5
1 08sRG 0.B5RYG
éa [e287}
O.5SRYY
6 La» = METER
=
i.
Z
sé coe [Bajo
[8288| an METERID.R.L)
° 0 3RIL [esa]

oie
fez} 3B
+4
co 8 36

8-272 | JOINT CONNECTOR

Figure 82. Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-61

CONNECTOR LIST

Al IEE
Ti

el] |
wet
fT om
il

Ln
ala
win
ae

ele

J
e
=

[12]
| |

a ( o[«liozealfa
a

=
ein
ey

oe

aha aay hes

n

—_
ii
=
wt
oe
2

Oooo

[P+ | [es] [ea] [Pe] [e-z26]

CO} | =
Figure 83. Connector List
8-62 CAB AND CHASSIS ELECTRICAL

DIAGNOSIS
QUICK CHART FOR CHECK POINT
1. HEADLIGHT

.
—~_Check point: F
|____TE°E ____{Headlight|Lighting i
eesing .
DRL | 209") cable
Trouble mode = >. (20A) | (20A) relay | SW SW unit 7 RH harness

1-1. Both Headlights O O O O

inoperative (1) (3) (4) (2)
1-2. Headlight on the left (or O O O
right) side inoperative (1) {(1)) (2)
1-3. Headlight in low-beam O O
inoperative (1) (2)
1-4. Headlight in high-beam © OQ
inoperative (1) (2)

NOTE: Figure in parenthesis “(__)” indicates the order of inspection.

2. D.R.L (Daytime running light)

o . F as ;
—__ Check point|_*S*2 —_Heaatight| U9PG | Parking | ot | "°PSE9™ | cable | Relay
Trouble mode ~~ |{20A)|(20A) relay |pimmer sw| Brake SW] unit 7a harness) rake
; ; O] oO O O O O};oO}] oO O O
2-1. D.R.L inoperative a} a} @) (4) 6 | @ {i} @l a | 6)
2-2. D.R.L remain on when -
the parking lever is Oy o 5
pulled

2-3. D.R.L remain on when

the lighing SW is 0 o o
turned on

NOTE: Figure in parenthesis “()” indicates the order of inspection.

3. CORNERING LIGHT

a Check point Fuse Cornering | Cornering | Cornering} G11,

ee F-10 F-25 light light light harness
Trouble mode “~~ | {20A) | (10A) SW bulb relay

2-1. Both cornering lights inoperative % © S o

2-2. Cornering light on the left (or right) © © Oo

side inoperative (2) (1) (3)
2-3. Cornering light remains on even O
when steering wheel is in the 4
straight ahead position. (1)
NOTE: Figure in parenthesis “( )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-63

1. HEAD LIGHT

1-1. BOTH HEADLIGHTS INOPERATIVE

@ iS THE HEADLIGHT RELAY NORMAL?

E
[+ Is GROUNDED SECURELY? | REPLACE THE HEADLIGHT RELAY

LL
_ « DISCONNECT THE LIGHTING SW CONNECTOR
—NO
| GROUND IT SECURELY
e IS THERE CONTINUITY BETWEEN THE HARNESS
SIDE CONNECTOR 4[B-70] AND

Lo
a
| ® IS THE LIGHTING SW NORMAL REPAIR AN OPEN CIRCUIT_
BETWEEN 4 [B-70] AND [B-7]

|
__« DISCONNECT THE D.R.L UNIT CONNECTOR
No |
Ae
REPAIR OR REPLACE THE
e IS THERE CONTINUITY BETWEEN THE HARNESS LIGHTING SW
SIDE CONNECTOR 8 AND GROUND WHEN
THE LIGHTING SW AT THE HEAD LIGHT POSITION?

oe® DISCONNECT THE D.R.L UNIT CONNECTOR REPAIR AN OPEN CIRCUIT

BETWEEN 8[B-225] AND 1 [B-70
e IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
HARNESS SIDE CONNECTOR 9 AND
GROUND?

e DISCONNECT THE D.R.L UNIT CONNECTOR REPAIR A POOR CONNECTION AT

© WHEN THE HARNESS SIDE CONNECTOR 9[B-225] IS THE CONNECTORS OR AN OPEN
CONNECTED TO GROUND IS THE BATTERY BATTERY [P-1] AND 9 [B-225|
VOLTAGE APPLIED BETWEEN THE HARNESS SIDE
CONNECTOR 1 (5 ) AND GROUND?

CONTINUED ON THE FOLLOWING PAGE

 8-64 CAB AND CHASSIS ELECTRICAL

CONTINUED FROM THE PREVIOUS PAGE

i] cs
e REPLACE THE D.R.L UNIT | REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT
BETWEEN THE MAIN FUSE (80A) AND
1 [B-226 |(5 {B-226 |)

1-2. HEADLIGHT ON THE LEFT (OR RIGHT) SIDE INOPERATIVE

| IS THE FUSE F-10 OR F-9 (20A) NORMAL? |

LL
7
« IS THE BULB NORMAL? | REPLACE THE FUSE

YES x

REPAIR A POOR CONNECTION AT THE CONNECTORS | REPLACE THE BULB

OR AN OPEN CIRCUIT BETWEEN FUSE F-10 (20A) AND
3 B-4] {OR 3 [B-148]) OR FUSE F-9 (20A) AND 3
(OR 3 [B-150))

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT

BETWEEN 2 (OR 2[B-73]) AND 1 [B-226 ]OR BETWEEN 1 (OR 2 [B-148] OR
1 OR 2 [B-150])AND 5 (B-226]

1-3. HEADLIGHTS IN LOW-BEAM INOPERATIVE

e DISCONNECT THE D.R.L UNIT CONNECTOR

e WHEN THE HARNESS SIDE CONNECTOR 9 [B-225 | 1S CONNECTED TO GROUND IS
THE BATTERY VOLTAGE APPLIED BETWEEN THE HARNESS SIDE CONNECTOR
1 (B-226 |JAND GROUND?

Ps] ae
« REPLACE THE D.R.L UNIT | REPAIR A POOR CONNECTION AT THE
CONNECTOR OR AN OPEN CIRCUIT
BETWEEN 2 (OR 2 [B-73] AND
1
 CAB AND CHASSIS ELECTRICAL 8-65

1-4. HEADLIGHT IN HIGH-BEAM INOPERATIVE

| e IS THE DIMMER SW NORMAL? |

ca 8[_
e DISCONNECT THE DIMMER SW AND D.R.L UNIT | REPAIR OR REPLACE THE SW
CONNECTOR
e IS THERE CONTINUITY BETWEEN 10 [B-70] AND
3 [B-226]?

YES NO
e DISCONNECT THE D.R.L UNIT AND HEAD LIGHT (RH) REPAIR A POOR CONNECTION AT THE
CONNECTOR CONNECTOR OR AN OPEN CIRCUIT BETWEEN
e IS THERE CONTINUITY BETWEEN 5 [B-226 |AND 10 AND 3 [B-226
1 ?

YES [No |
| ¢ REPLACE THE D.R.L UNIT | REPAIR A POOR CONNECTION AT THE
CONNECTOR OR AN OPEN CIRCUIT BETWEEN
5 [B-226] AND 1 [B-73](OR 2 [B-150]OR 2
OR 1 [B-4])
8-66 CAB AND CHASSIS ELECTRICAL

2. D.R.L (DAY TIME RUNNING LIGHT)

2-1. D.R.L INOPERATIVE

e IS THE FUSE F-10 OR F9 (20A) NORMAL?

_L..
YES
No |

a
e 1S THE BULB NORMAL? | REPLACE THE FUSE

YES
ai
e IS THE HEADLIGHT RELAY NORMAL?

YES
[
[ « IS THE RELAY ; EXH BRAKE NORMAL? | | REPLACE THE HEADLIGHT RELAY

- |
YES [No |
i
e DISCONNECT THE D.R.L UNIT CONNECTOR | REPLACE THE RELAY ; EXH BRAKE
e IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
HARNESS SIDE CONNECTOR 9 [B-225 |AND
GROUND?

ao]
YES [e
e DISCONNECT THE D.R.L UNIT CONNECTOR REPAIR A POOR CONNECTION AT THE
¢ IS THE BATTERY VOLTAGE APPLIED BETWEEN THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN
HARNESS SIDE CONNECTOR 1 [8-226 |AND BATTERY [P-7] AND 9 [B-225
GROUND?

YES

e IS GROUNDED SECURELY? REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
[FL-7] (804) AND 1[B-226

YES

e DISCONNECT THE D.R.L UNIT CONNECTOR GROUNDED IT SECURELY

e« IS THERE CONTINUITY BETWEEN 2 [B-226 |AND
GROUND

YES [No|
CONTINUED ON THE FOLLOWING PAGE CONTINUED ON THE FOLLOWING PAGE
 CAB AND CHASSIS ELECTRICAL 8-67

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE
|
@ DISCONNECT THE D.R.L UNIT CONNECTOR _ REPAIR A POOR CONNECTION AT THE
e IS THE HARNESS SIDE CONNECTOR 2[B-225]OPEN CONNECTORS OR AN OPEN CIRCUIT BETWEEN
CIRCUIT WHEN THE PARKING BRAKE LEVER IS 2 [B-226 JAND
RELEASED?

YES

© DISCONNECT THE D.R.L UNIT CONNECTOR e DISCONNECT THE PARKING BRAKE SW

e 1S THE BATTERY VOLTAGE APPLIED BETWEEN THE CONNECTOR
HARNESS SIDE CONNECTOR 1[B-225] AND GROUND, ® IS THERE CONTINUITY BETWEEN THE SW SIDE
WHEN RELAY ; EXH BRAKE IS ON? (ENGINE IS START CONNECTOR 1 AND GROUND, WHEN THE
TO RUN) PARKING LEVER IS RELEASED?

to aL
[ Yes [no|
| ft
REPAIR OR REPLACE REPAIR THE CIRCUIT
THE SWITCH BETWEEN 2
AND 1

|
aNO |

| e REPLACE THE D.R.L UNIT REPAIR AN OPEN CIRCUIT BETWEEN 1[B-225

AND[FL-1](80A)
8-68 CAB AND CHASSIS ELECTRICAL

2-2. D.R.L REMAIN ON WHEN THE PARKING LEVER IS PULLED

e IS THE WARNING LIGHT BRAKE GO ON WHEN

PARKING BRAKE LEVER IS PULLED?

YES
Ln
| 6 REPLACE THE D.R.L UNIT * DISCONNECT THE D.R.L AND THE PARKING
BRAKE SW CONNECTOR

-
e IS THERE CONTINUITY BETWEEN 2
AND GROUND?

| REPAIR OR REPLACE THE SWITCH

2-3. D.R.L REMAIN ON WHEN THE LIGHTING SWITCH IS TURNED ON

| e IS THE LIGHTING SWITCH NORMAL |

YES NO

e WHEN THE LIGHTING SW IS AT THE HEADLIGHT REPAIR OR REPLACE THE SWITCH

POSITION AND THE DIMMER SW IS AT LOW BEAM
POSITION ARE THE HEADLIGHTS BECOME MORE
BRIGHTLY?

No|

e DISCONNECT THE D.R.L CONNECTOR

* IS THERE CONTINUITY BETWEEN 8[B-225|
AND GROUND WHEN THE LIGHTING SW IS AT
THE HEADLIGHT POSITION

YES [ne
[ « REPLACE THE D.R.L UNIT REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT BETWEEN
8 [B-225
]AND 1[B-70 |
 CAB AND CHASSIS ELECTRICAL 8-69

3. CORNERING LIGHT

3-1. BOTH CORNERING LIGHTS INOPERATIVE

| ® DO THE HEADLIGHTS COME ON?

__
| » IS FUSE F-25 (10A) NORMAL? | TURN THE HEADLIGHT ON. (REFER TO
DIAGNOSIS CHART FOR HEADLIGHT.)

2
1
Le
| ¢ 1S[B-7] GROUNDED SECURELY? | | REPLACE THE FUSE

YES

| e IS THE CORNERING RELAY NORMAL? | | GROUND IT SECURELY

to
i] —
REMOVE THE CORNERING LIGHT RELAY | REPAIR OR REPLACE THE RELAY
TURN THE STARTER SWITCH ON
IS THERE A BATTERY VOLTAGE APPLIED BETWEEN
THE RELAY HARNESS SIDE CONNECTOR 2[B-35] AND
GROUND?

__ TURN THE STARTER SWITCH ON

DISCONNECT THE COMBINATION SWITCH
REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT BETWEEN
CONNECTOR FUSE F-25 (10A) AND 2
IS THERE A BATTERY VOLTAGE APPLIED BETWEEN
SWITCH HARNESS SIDE CONNECTOR 1[B-70] AND
THE GROUND?

[ves|
CONTINUED ON THE FOLLOWING PAGE CONTINUED ON THE FOLLOWING PAGE
 8-70 CAB AND CHASSIS ELECTRICAL

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE

|
e IS THERE ANY CONTINUITY BETWEEN THE SWITCH REPAIR A POOR CONNECTION OR A OPEN
CONNECTORS 2[B-70] AND 11 [B-70] (WHEN CIRCUIT AT THE CONNECTOR BETWEEN 4
TURNING LEFT) OR 2 [B-70] AND 9 [B-70] (WHEN AND 3(B-225]OR BETWEEN 8 [B-225 JAND 1 [B-70
TURNING RIGHT) RESPECTIVELY?
NO |

| REPLACE THE D.R.L UNIT

Lo
[ YES Le
REPAIR A POOR CONNECTION OR AN OPEN CIRCUIT | REPAIR OR REPLACE THE SWITCH
BETWEEN THE HARNESS SIDE CONNECTORS
5 [B-35]
AND 2 [B-70]

3-2. CORNERING LIGHT ON THE LEFT (OR RIGHT) SIDE INOPERATIVE

e IS THE CORNERING LIGHT BULB ON THE LEFT (OR

RIGHT) NORMAL?

YES

« DISCONNECT THE COMBINATION SWITCH | REPLACE THE BULB

CONNECTOR
e 1S THERE ANY CONTINUITY BETWEEN THE SWITCH
CONNECTOR TERMINALS 2|B-70] AND 11 (IN
TURNING LEFT) (2 [B-70]- 9[B-70]: IN TURNING
RIGHT)

YES NO|
« IS THERE ANY CONTINUITY BETWEEN THE REPAIR OR REPLACE THE CORNERING
CORNERING LIGHT SWITCH HARNESS SIDE LIGHT SWITCH
CONNECTOR TERMINALS 11[B-70] AND 3
(9 AND 3 )?

YES NO|

REPAIR A POOR CONNECTION AT THE CONNECTORS OR REPAIR A POOR CONNECTION AT THE

AN OPEN CIRCUIT BETWEEN 1 [B-5]AND [B-7]OR CONNECTORS OR AN OPEN CIRCUIT
1 [B-74] AND BETWEEN 11[B-70] AND 3[B-5] (9 [B-701
AND 3 [B-74]

NOTE: FIGURES IN PARENTHESIS “(__)” INDICATE PLACE OF INSPECTION FOR THE CORNERING
LIGHT ON THE RIGHT.
 CAB AND CHASSIS ELECTRICAL 8-71

3-3. CORNERING LIGHT REMAINS ON EVEN WHEN STEERING WHEEL IS IN STRAIGHT

AHEAD POSITION

* DOES THE CORNERING LIGHT SWITCH OPERATE

SMOOTHLY

NO|

REPAIR OR REPLACE THE CORNERING LIGHT

SWITCH (COMBINATION SWITCH)
 8-72 CAB AND CHASSIS ELECTRICAL

STARTER SWITCH HEADLIGHT ASSEMBLY

Refer to “START AND CHARGING” in this [+>] Remove or Disconnect (Figure 85)
section.
Preparation:Disconnect the battery ground
cable.
HIGH BEAM INDICATOR LIGHT
1. Dummy lens
Refer to “METER AND WARNING/INDICATOR
* Remove two screws.
LIGHT” in this section.
2. Lower cover
* Pull the lower cover to disconnect the clips.
HEADLIGHT LENS UNIT
3. Headlight assembly
[es] Remove or Disconnect (Figure 84) * Remove the fixing screws.
* Disconnect the connectors.
Preparation:Disconnect the battery ground
cable.

1. Dummy lens
« Remove two screws.
2. Lower cover
* Pull the lower cover to disconnect the clips.
3.
» Remove four screws.
4. Headlight lens unit
+ Remove the headlight lens unit together with
headlight rim.

1. Dummy Lens
2. Lower Cover
3. Headlight Assembly

Figure 85. Headlight Assembly Removal

| Install or Connect

To install, follow the removal steps in the reverse

~~ Headlight trim order, noting the following point:
1. Dummy Lens 3.
1. After installing the headlight assembly, be sure
2. Lower Cover 4. Headlight Lens Unit
to adjust the headlight aim.
Figure 84. Headlight Lens Unit Removal

[oe] Install or Connect

To install, follow the removal steps in the reverse

order.
 CAB AND CHASSIS ELECTRICAL 8-73

[A] Aiming of Headlight (Figure 86)

Preparation:Place the unioaded vehicle on a
level surface and check to see if the inflation
pressure of the tires is correct, the lenses are
clean, and the battery is sufficiently charged.
Adjust the aim with the headlight tester.
When adjusting, follow the procedure of the
tester manufacturer's.

Figure 88. Horizontal Adjustment

CORNERING LIGHT/BULB
| Remove or Disconnect (Figure 89)

Preparation:Disconnect the battery ground

cabie.

1. Front combination light lens

Figure 86. Headlight Aiming
« Remove the two screws.
« Disconnect the connector.
[A] Vertical Adjustment (Figure 87) 2. Bulb

Use a screwdriver for vertical adjustment.

1. Front Combination Light Lens

2. Bulb
Figure 87. Vertical Adjustment
Figure 89. Cornering Light/Bulb

[P| Horizontal Adjustment (Figure 88)

| instail or Connect
Use a screwdriver for horizontal adjustment.
To install, follow the removal steps in the reverse
order.
8-74 CAB AND CHASSIS ELECTRICAL

COMBINATION SWITCH (LIGHTING

SWITCH, DIMMER-PASSING SWITCH AND
CORNERING LIGHT SWITCH)
Inspect (Figure 90)

Check the continuity between the connector

terminals while operating the switch.
Replace the switch when the result of inspection
is found abnormal.

Switch side

Terminal No.
SW position

2D
Lighting SW =DIE
OFF
. High beam
Dimmer-
passing SW Passing

Turning left

Cornering Neutral
light SW eulre
Turning
right

Figure 90. Combination Switch

 CAB AND CHASSIS ELECTRICAL 8-75

[es] Remove or Disconnect (Figure 91) HEADLIGHT RELAY

TAIL RELAY
Preparation:Disconnect the battery ground EXHAUST BRAKE RELAY
cable. CORNERING LIGHT RELAY
1. Horn pad Inspect (Figure 92)
: Hold the horn pad and pull it upward.
2. Steering wheel
* Remove the steering shaft nut.
* Remove the steering wheel by using steering
wheel remover.
(Refer to Section 3B4 “STEERING COLUMN”
for steering wheel removal steps.)
3. Steering cowl
Remove four screws
4. Combination switch
* Remove four screws.
* Disconnect the connector.

Figure 92. Relay inspection

Check to see if there is any continuity between

the relay terminals.
Replace the relay when the result of inspection is
found abnormal.

]) — @ visseeescccvnes Continuity
‘OL ee No continuity
(When battery voltage is applied between @) — @)
) — GB) vevserscceevens No continuity
. Horn Pad
OL) ee Continuity
OM =

. Steering Wheel
. Steering Cowl
. Combination Switch

Figure 91. Combination Switch Removal

| Install or Connect

To install, follow the removal steps in the reverse

order, noting the following point.
1. Tighten the steering shaft nut to the specified
torque.

Shaft nut torque N-m (lb-ft)

49 (36)
 8-76 CAB AND CHASSIS ELECTRICAL

D.R.L UNIT

| Remove or Disconnect (Figure 93)

Preparation:Disconnect the battery ground

cable.

1. Glove box
* Open the lid and remove four screws.
2. D.R.L UNIT
+ Press up ward the unit with your hand.

1. D.R.L Unit

Figure 93. D.R.L Unit Removal

fe] install or Connect

To install, follow the removal steps in the reverse

order.
 CAB AND CHASSIS ELECTRICAL 8-77

CLEARANCE LIGHT, TAILLIGHT,

LICENSE PLATE LIGHT, ID LIGHT
AND ILLUMINATION LIGHT
GENERAL DESCRIPTION
The circuit consists of the lighting switch, All these lights come on when the lighting switch
clearance light, taillight, license plate light and the are turned on with the switch to either clearance or
illumination light for each of switch, meter and headlight position.
ashtray.

LIGHTING CIRCUIT

Battery (+)

OFF 12D0<¢; 2D
* Lighting
ru pT opt | SW ke
-
i 4
(a
___t

i
I
»
| a8 Tail relay

<<) | k&>

Ashtray 3 Hf light
Clearance light
Tag tein
ili M
MS © — ©switches . ;
roy
Itumination ID
f light
controller

Figure 94. Lighting Circuit

 AV13¥ LHOM Ol 02-F
INIT 3148ISNa b-13 YSLAW 25-8
\
MS GO L-N
WSvV X08 AV1348
| YATIOULNOD
NOILLVNIANNTH
L-a 9-H
: /
YOLOANNOO LNIOF ¢Ze-d

Figure 95, Parts Location

8-78 CAB AND CHASSIS ELECTRICAL

LHOM SLWid SSN39N €- “2-4

/ MS ONILHON
PARTS LOCATION

i
AVYL HSV 99-8 / 01-7 i-d'9-4
(HY) LHOIMTIVWL 9-u /
gL
AVW134Y TIVL 22@-a WSvV xoa 3SNd
/ HSLHOM ALLAYVOID €r-d
MS LHDI1 SWOd 98-4 (L °ON) INSV XO8 AV13¥
MS ONINYVM GYeVZVH 0&-8
MS 13ZZ39 Y3SLV3H Cf-8
 CAB AND CHASSIS ELECTRICAL 8-79

CIRCUIT DIAGRAM

CLEARANCE LIGHT (RH

7 “es 5 ar 0.858
a a

CLEARANCE LIGHT (LHI

OB GR sTal ey 9868 _4
a

TAIL LIGHT RH (REAR COMBINATION LIGHT)

eee Hise ——__
0 LGR 7 YS} 1 268
TAIL LIGHT LH
Pa B {REAR COMBINATION LIGHT)
3 ¢ O5LGR al Ed = =f]
oo l=] OBLGA ~? Yel s2s8 | 1268 [||
LICENSE PLATE LIGHT
E asia nfs] vile
&8 jr |7 eaeleR Je wll~ vee 88
~ fc — o
g § g
g . é° 2. The 0 85AG
0.85R -ffe {8h MANUFACTURER'S
es Sho a CONNECTION
085A we)
AS Lay [>] ]<. 056
P oReA |S Sy
RELAY, 10 LIGHT

« °
:g :£
°

MARKER LIGHT (1)

“fey oS “lho gt [2 _9.8e
a oP

a oo
oo HO LIGHT (1)
SWS Tile lo (9-58

. 1D LIGHT (2)
71

tc TOE
wi 2 OSG bs Q rT 0.58

Te Te
& . iO
0.5 -
5 ta ru IE
£ © a —
S g 3

| a tetrey
B 8 6 MARKER LIGHT (2)
o o oO “
Oo SRG. 2 4| OSB
og -
B ILLUMINATION LIGHT (METER}
3
3a Si) | osion fist1a py Ts"Tale 2.51618
z RELAY: TAIL .
z 2 &«
ie RADIO = g
to O.85LGR «! 4
O8L.GIR S 958 Z
a lf os &
ae 5
s & afl] é8
z # ILLUMINATION “\e se , 38. e5
° CONTROLLER asicm |= x oacR

alle 9.5L.6/8, “
i
z2 — faut
* Le DOME LIGHT SWITCH
a 9 BBLG/R 3 3 0 51.5/8 3
|| 3 fen
O46

ASH THAY 9
25LGrA g $l] 05.68
,1 “pr ae sie 7
=z 2 =e aig Sg
3 e cs es, 3 3] 3 1258 HEATER BEZEL
| OBLG/R Hs

fF FE2 E2 2 e (5 j| a
2 ob o CIGAR LIGHTER
3°35 ~=5
a a + O.BLG/R 7 OBL.
z zc ec « anal
a Ga
é nl fe
5
& ag3 " ae
g
é ak = oF
& toe ded bela HAZARD NG SWITCH = oe
$ OSLG/A 8 3 osiae ge
“ie abe ag &
(nel? 3B
a2
es
5a
a
COMBINATION SWITCH
z&

Figure 96. Circuit Diagram

8-80 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

[228 |
[T -
va fal cop |
Tee)
7] e@] ey wid ss) 52) 13
=| we
SIS
3)4 eetsheand)
ii

os|
meh
a

| L-7 | {| v9 | [u-11] [0-13] [1-15 |

OF , iB| ft-10| [2-12] [2-14] [1-16|

[|

Figure 97. Connector List (1)

 CAB AND CHASSIS ELECTRICAL 8-81

CONNECTOR LIST

Sere
aie jy

|e| *
0101 |

Figure 98. Connector List (2)

8-82 CAB AND CHASSIS ELECTRICAL

DIAGNOSIS
QUICK CHART FOR CHECK POINT

Check point Fuse iahti tiaht (Clearance} License ID ID

— P F7 | Fe | lighting) Taillight "ight [Plate light] light | light ngable|
Trouble mode (10A) | (410A) bulb bulb bulb relay
1. Both clearance lights O Oo O O
inoperative (1) (3) (2) (4)
2. Clearance light on the
left (or right) side i o)
inoperative
3. Both taillights O © O
inoperative (1) (2) (3)

4. Taillight on the left (or O O

right) side inoperative (1) (2)

5. License plate light O O

inoperative (1) (2)

6. ID lights inoperative O O O Oo
(1) (2) (3) (4)
NOTE: Figure in parenthesis “(_ )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-83

1. BOTH CLEARANCE LIGHTS INOPERATIVE

e ARE BOTH TAILLIGHTS OPERATIVE?

LL
YES Lae
|» 1s [B-7]SECURELY GROUNDED? TURN TAILLIGHTS ON (REFER TO TAILLIGHT
DIAGNOSIS IN THIS SECTION)

~
L
[Ne |
e TURN THE LIGHTING SWITCH TO =IXE OR 2 POSITION | GROUND IT SECURELY
e 1S THERE BATTERY VOLTAGE APPLIED TO CLEARANCE
LIGHT CONNECTOR 4 (4 } AND GROUND.

|
YES =
REPAIR A POOR CONNECTION AT THE CONNECTORS OR REPAIR A POOR CONNECTION AT THE
AN OPEN CIRCUIT BETWEEN CLEARANCE LIGHT CONNECTORS OR AN OPEN CIRCUIT BETWEEN
CONNECTOR TERMINAL 1 [B-5](1 ) AND FUSE [F-7] (104) AND 4 [B-5]
(4 [B-74])

NOTE: FIGURE IN PARENTHESIS “( )” INDICATES PLACE OF INSPECTION FOR CLEARANCE LIGHT ON

THE RIGHT SIDE.

2. CLEARANCE LIGHT ON THE LEFT (OR RIGHT) SIDE INOPERATIVE

e IS THE CLEARANCE LIGHT BULB ON THE LEFT (OR

RIGHT) SIDE NORMAL?

#
L
ie
e IS THERE ANY CONTINUITY BETWEEN THE
HARNESS SIDE CONNECTOR 5 [B-22 AND 4
| | REPLACE THE BULB
(OR 4 [B-74 |?)

ee REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
+so
REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT IN THE
1 [B-5] (1 [B-74])
AND [B-7] CIRCUIT

NOTE: FIGURE IN PARENTHESIS “( )” INDICATES PLACE OF INSPECTION FOR CLEARANCE LIGHT ON

THE RIGHT SIDE.
8-84 CAB AND CHASSIS ELECTRICAL

3. BOTH TAILLIGHTS INOPERATIVE

| » 1S FUSE F-7 (10A) NORMAL?

YES
cs
| » 1S[J-9 SECURELY GROUNDED? | REPLACE THE FUSE

-
| e IS THE TAIL RELAY NORMAL? | GROUND IT SECURELY

=
| ¢ IS THE LIGHTING SWITCH NORMAL?
<-
| REPLACE THE RELAY

L
YES NO |

e IS THE BATTERY VOLTAGE APPLIED BETWEEN REPAIR OR REPLACE THE LIGHTING

LIGHTING SWITCH HARNESS SIDE CONNECTOR SWITCH
8 AND THE GROUND?

|
YES Ene
CONTINUED ON THE FOLLOWING PAGE CONTINUED ON THE FOLLOWING PAGE
 CAB AND CHASSIS ELECTRICAL 8-85

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE

e TURN THE LIGHTING SWITCH TO [CE OR 2D POSITION REPAIR A POOR CONNECTION AT THE
» 1S THERE BATTERY VOLTAGE APPLIED TO 3 CONNECTORS OR AN OPEN CIRCUIT BETWEEN
AND GROUND FUSE F-7 (10A) AND
8 [B-70]

|_
[vs [me
® REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT THE
OR AN OPEN CIRCUIT BETWEEN LIGHTING SWITCH CONNECTORS OR AN OPEN CIRCUIT BETWEEN
HARNESS SIDE CONNECTORS 8[H-16] AND Sitio RELAY CONNECTORS 5 AND
3 [H-16]

4. TAILLIGHT ON THE LEFT (OR RIGHT) SIDE INOPERATIVE

© IS TAILLIGHT BULB ON THE LEFT (OR RIGHT) SIDE

NORMAL?

YES a

e REPAIR A POOR CONNECTION AT THE CONNECTORS REPLACE THE BULB |

OR AN OPEN CIRCUIT BETWEEN CONNECTOR
TERMINAL 3 AND TAILLIGHT CONNECTOR
1 (1 [R-6])

NOTE: FIGURE IN PARENTHESIS “( )” INDICATES PLACE OF INSPECTION FOR TAILLIGHT ON THE

RIGHT SIDE.
8-86 CAB AND CHASSIS ELECTRICAL

5. LICENSE PLATE LIGHT INOPERATIVE

e ARE BOTH TAILLIGHTS OPERATIVE? |

to
YES
Le
« IS THE LICENSE PLATE LIGHT BULB NORMAL? | TURN THE TAILLIGHT ON (REFER TO
TAILLIGHT DIAGNOSIS IN THIS SECTION)

a
e IS THERE BATTERY VOLTAGE APPLIED BETWEEN
1[R-3]AND THE GROUND WHEN TURNING THE
%
REPLACE THE BULB |
LIGHTING SWITCH ON?

YES
|
e REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT THE
OR AN OPEN CIRCUIT BETWEEN 1[R-2]AND 8 CONNECTORS OR AN OPEN CIRCUIT IN THE
CIRCUITS
 CAB AND CHASSIS ELECTRICAL 8-87

6. ID LIGHT INOPERATIVE

e ARE BOTH TAILLIGHTS OPERATIVE?

YES NO |

« IS FUSE F-6 (10A} NORMAL? TURN THE TAILLIGHT ON (REFER TO

TAILLIGHT DIAGNOSIS IN THIS SECTION)

| « 1S [-9]SECURELY GROUNDED? | | REPLACE THE FUSE

1
Lvs [ne
[ » IS ID LIGHT RELAY NORMAL? | | GROUND IT SECURELY

YES [No|

© TURN THE LIGHTING SWITCH TO [D0 OR D POSITION | REPLACE THE ID LIGHT RELAY
e IS THERE BATTERY VOLTAGE APPLIED TO 2 [H-10|AND
GROUND

LL
¥ Lae
* REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT THE
OR AN OPEN CIRCUIT BETWEEN 1 [H-10] AND CONNECTORS OR AN OPEN CIRCUIT BETWEEN
ID LIGHT RELAY CONNECTORS 5 [J-20
| AND
11 [H-69] OR 11 [H-69] AND 2[H-10]

7. ID LIGHT INOPERATIVE

[ » 1S 1D LIGHT BULB NORMAL? |

Le
YES fe
e REPAIR A POOR CONNECTION AT THE CONNECTORS | REPLACE THE BULB
OR AN OPEN CIRCUIT BETWEEN CONNECTOR
TERMINAL 11LH-69] AND ID LIGHT CONNECTOR
4 (L-8] (1 [C-70]OR 1[C-72] OR 1[L-74] OR 1[L-16})
8-88 CAB AND CHASSIS ELECTRICAL

LIGHTING SWITCH | install or Connect

Refer to “HEADLIGHT, FOG LIGHT AND To install, follow the removal steps in the reverse
CORNERING LIGHT” in this section. order.

CLEARANCE LIGHT/BULB LICENSE PLATE LIGHT BULB

[es] Remove or Disconnect (Figure 99) [eo] Remove or Disconnect (Figure 101)
1. Front combination light lens 1, Cover
* Remove four screws. 2. Lens
2. Bulb 3. Bulb

1. Cover
2. Lens
1. Front Combination Light Lens
3. Bulb
2. Bulb
Figure 101. License Plate Light Bulb
Figure 99. Clearance Light/bulb
[oe] Install or Connect
| Install or Connect
To install, follow the removal steps in the reverse
To install, follow the removal steps in the reverse
order.
order.
TAIL RELAY
TAILLIGHT BULB
ID LIGHT RELAY
| Remove or Disconnect (Figure 100)
| Install or Connect (Figure 102)
1. Lens
2. Bulb
the relay terminals.
Replace the relay when the result of inspection is
found abnormal.
8) ~ © eveaeeereeee GOntinuity
CD) = &) vecccecersenene No continuity
(When battery voltage is applied between @ — @)
CD) = BY ceccccccceeneee No continuity
CD) — ©) ecneseceeseeee Continuity

1. Lens
2. Bulb with Pacing

Figure 100. Taillight Bulb

 CAB AND CHASSIS ELECTRICAL 8-89

ILLUMINATION CONTROLLER
inspect (Figure 104)

1. Connect the illumination controller connector

terminal No.1 to the battery (+) terminal and
No.2 to the (—) terminal.
2. Connect a test bulb of 1.4 W or 3.4 W between
terminal No.1 and No.3.

Figure 102. Tail & ID Light Relay

Murmination
ROOF MARKER LIGHT 3,2 controller
IDENTIFICATION LIGHT
| Remove or Disconnect (Figure 103)

Preparation:Disconnect the battery ground

cable
Figure 104. tliumination Controller Check
1. Lens
« Remove two screws.
| Remove or Disconnect (Figure 105)
2. Bulb
* Pull out the bulb. Preparation:Disconnect the battery ground
3. Base cable
¢ Remove two nuts.
¢ Disconnect the connectors. 1. Bezel with illumination controller
¢ Pull the controller bezel to release the locks.
7 f 2. Controller knob
* Pull out the knob.

(ie 3. Humination controller

* Loosen the lock nut then remove the washer

lop °
and controller.

x= 3 3

Roof panel

1. Lens ,
2. Bulb \ i %
3. Base

Figure 103. Identification Light Removal

Washer Lock nut -
[oe] Install or Connect 1. Bezel with Illumination Controller @
2. Controller Knob
To install, follow the removal steps in the reverse 3. Illumination Controller
order.
Figure 105. INumination Controller Removal

foe] install or Connect

To install, follow the removal steps in the reverse

order.
8-90 CAB AND CHASSIS ELECTRICAL

TURN SIGNAL LIGHT, HAZARD

WARNING LIGHT, AND STOPLIGHT
GENERAL DESCRIPTION
The circuit consists of the starter switch, turn flows to the flasher unit through the hazard warning
signal light (front and rear), turn signal light switch, switch to cause the hazard warning light to flash,
hazard warning light, flasher unit, stoplight and independent of the position of the starter switch. At
stoplight switch. the same time, the indicator lights in the meter also
When turning on the respective switches with the start flashing.
starter switch on, the turn signal light will operate. The stoplight switch will turn on and the light
When the turn signal light is flashing, the indicator comes on once the brake pedal is depressed,
light in the meter also start flashing. When the independent of the position of the starter switch.
hazard warning switch is turned on, the current
CAB AND CHASSIS ELECTRICAL 8-91

(H1) LHOM NOLLWNIGWOD LNOUS $-8.

(WaLaW)
LH5!1 HOLVSIGNI TWNDIS NHNL SS-¢ . . ca
(W3L3WW)
LHI YOLVSIGNI TWNOIS NHNL 25-9
INI A1ISN4 2-14 bL
WSV X08 AV734

Figure 106. Parts Location

LHS dOLs
(H7) LHOM TIWNOIS NYNL b-u
~ YOLOANNOD LNIOL 222-8
> LINN YSHSV Td 9b-d
(HY) LHOMdOLS 9-4
(HY) LHOIT IWNOSIS NYNL
\ Si-d ‘EL-d "Bd
PARTS LOCATION

MS HELYVLS Wsv xO8 3SN4

MS LHI OSNIYSNYOO/IVNOIS NYNL
MS DNINYYM GYV2ZVH 08-8
8-92 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM

STOP LIGHT
F-8]10A

STOP LIGHT SWITCH STOP LIGHT (RH)

0.856, - = (3
wolfe 0.5G al @) fee 1.258
° a [Efoof | TG [| - 0.856

5 fF 4,258
HAZARD, HORN

STOP LIGHT (LH)

) [£18] 20a

0.856

3B/Y 0.5Y/R,
TURN, S/LAMP
[F-13] 108
3B/Y

O5LG/B ofS
g——0:SLG/B__.. 1, LUMINATION CONTROLLER (3)
STARTER SWITCH
5wW

TURN SIGNAL
0.5LG/8

INDICATOR LIGHT (RH) (METER)

oe
/

nn 0: 5G/W fal @ aE 0.858

TURN SIGNAL LIGHT (RH)

(FRONT COMBINATION LIGHT (RH))
0.5GAV fg a B-74
5 0.85B
6.56

somecenttows BELAY; TAIL (5)

TURN SIGNAL LIGHT (RH)
(REAR COMBINATION LIGHT (RH)}
oF fa © O.BGAV ofall oye | 0 ole
a i 05 2] 0.5 C7 [=] 1.258
" cw GW

B)e_0.5G/8 2
ef wal «ffS] mh] Lo
a Ea o5 afo5 |= oT 258
GB Ga

4.258
TURN SIGNAL LIGHT (LH)
TURN SIGNAL LIGHT SWITCH
{REAR COMBINATION LIGHT (LH)}
(COMBINATION SWITCH)
4___.0.56/8 {3} ©) ak
0.38

0.858
0.5G/B

H-16 8
3W/B

TURN SIGNAL LIGHT (LH)

5W

(FRONT COMBINATION LIGHT (LH))

bs S18_ 2] 9 () aie 0.8658
1.25B

TURN SIGNAL INDICATOR LIGHT (LH) (METER)

FL-2) 50A

| s 38
KEY SW

Lt
aw

JOINT CONNECTO

0.858

P
FL-1] 80A

3B
MAIN

B-7

J
ter}
8B

HEADLIGHT BRACKET (LH) iff

#]

FRAME-LH (CENTER) |}
FRAME-LH (FRONT)

Figure 107. Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-93

CONNECTOR LIST

bbe
my
1? on?
Ee

oe
ny
-

ola
6

a
a

pra poeay
1}2{3 al sie
7 sf 10] 11) 12
[14718 | 16] [18
rad [zi aa
ras [27 |
31 | 32/33 | 34 | 38 | 30 | 37
a39|

Figure 108. Connector List

8-94 CAB AND CHASSIS ELECTRICAL

DIAGNOSIS
QUICK CHART FOR CHECK POINT
1. TURN SIGNAL LIGHT, HAZARD WARNING LIGHT

Fuse Turn Hazard Turn

ae Check point F-18 F-13 signal warning Flasher | signal Cable
Troublemode —-—_ | oa) | (oa) | Ww | awe] oO [agp | Ramess
1-1. Turn signal lights O O O Oo
inoperative (1) (3) (2) {4)

1-2. Turn signal lights flashes O O

too quickly (1) (2)

1-3. Hazard warning lights O ©

inoperative (1) (2)

NOTE: Figure in parenthesis “( )” indicates the order of inspection.

2. STOPLIGHT

——— Check point ruse Stoplight Stoplight Cable

Trouble mode eee —. (10A)
SW bulb harness
See t : O © O
2-1. Both stoplights inoperative (1) (2) (3)

2-2. Stoplight on the left (or right) side O Oo

inoperative (1) (2)
NOTE: Figure in parenthesis “( )” indicates the order of inspection.
 CAB AND CHASSIS ELECTRICAL 8-95

1. TURN SIGNAL LIGHT, HAZARD WARNING LIGHT

1-1. TURN SIGNAL LIGHTS INOPERATIVE

| » IS FUSE F-13 (10A) NORMAL?

1
YES ae
e DISCONNECT THE CONNECTOR OF THE HAZARD | REPLACE THE FUSE |
WARNING SWITCH
e TURN THE STARTER SWITCH ON.
e IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
HAZARD WARNING SWITCH HARNESS SIDE
CONNECTOR 5 AND GROUND?

YES

e WITH THE HAZARD WARNING SWITCH TURNED OFF, REPAIR A POOR CONNECTION AT THE
IS THERE ANY CONTINUITY BETWEEN THE SWITCH CONNECTORS OR AN OPEN CIRCUIT BETWEEN
CONNECTORS 5 [B-30] AND 6 THE FUSE F-13 (10A) AND 5 .

YES

¢ DISCONNECT THE FLASHER UNIT CONNECTOR REPAIR OR REPLACE THE SWITCH

e IS THERE ANY CONTINUITY BETWEEN THE FLASHER
UNIT HARNESS SIDE CONNECTORS 1 [B-16] AND THE
GROUND?

=
L_
[ae 0
| e IS THE FLASHER UNIT NORMAL? REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE HARNESS SIDE CONNECTORS 1[8-16] AND
6 [B-30 |

YES ce
|e 1S [B-7] SECURELY GROUNDED? | REPLACE THE FLASHER UNIT

YES

CONTINUED ON THE FOLLOWING PAGE CONTINUED ON THE FOLLOWING PAGE

 8-96 CAB AND CHASSIS ELECTRICAL

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE

| |
e IS THERE ANY CONTINUITY BETWEEN THE HARNESS | GROUND IT SECURELY |
SIDE CONNECTORS 3[B-16] AND [B-7|?

-NO |
e DISCONNECT THE COMBINATION SWITCH REPAIR A POOR CONNECTION AT THE
CONNECTOR CONNECTORS OR AN OPEN CIRCUIT BETWEEN
e 1S THERE ANY CONTINUITY BETWEEN THE SWITCH THE CIRCUIT
CONNECTORS 5 AND 12 [B-70 (WHEN
TURNING LEFT), 13 [B-70 |AND 12 [B-70] (WHEN
TURNING RIGHT) RESPECTIVELY?

[ Yes

e REPAIR A POOR CONNECTION AT THE CONNECTORS | REPAIR OR REPLACE THE SWITCH

OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE
CONNECTORS 2 [B-16] AND 12 [B-70 |

1-2. TURN SIGNAL LIGHTS FLASHES TOO QUICKLY

e DOES ANY TURN SIGNAL LIGHT REMAIN

=
UNLIGHTED?

DISCONNECT AND REINSTALL THE BULB, OR

REPLACE IT, OR REPAIR AN OPEN CIRCUIT IN
THE CIRCUIT OF THE INOPERATIVE BULB, OR
CHECK THE GROUND
 CAB AND CHASSIS ELECTRICAL 8-97

1-3. HAZARD WARNING LIGHTS INOPERATIVE

| ¢ IS FUSE F-18 (20A) NORMAL? |

YES ce

@ DOES THE HAZARD WARNING LIGHT SWITCH | REPLACE THE FUSE |

FUNCTION NORMALLY? ee

|
YES a |
[No
e REPAIR A POOR CONNECTION AT THE CONNECTORS REPLACE THE HAZARD WARNING LIGHT
OR AN OPEN CIRCUIT BETWEEN FUSE F-18 (20A) AND SWITCH
1

2. STOPLIGHT
2-1. BOTH STOPLIGHTS INOPERATIVE

| » IS FUSE F-8 (104) NORMAL? |

Lvs [xo |
[
« 1S (J-9]GROUNDED SECURELY? | | REPLACE THE FUSE

lL
a = Do |
NO

e IS BATTERY VOLTAGE APPLIED TO THE 1 OF | GROUND IT SECURELY

THE STOPLIGHT SW? —

YES No |

e IS STOPLIGHT SWITCH IS NORMALLY? | REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE FUSE F-8 (10A) AND 1

YES [ No |

CONTINUED ON THE FOLLOWING PAGE CONTINUED ON THE FOLLOWING PAGE

8-98 CAB AND CHASSIS ELECTRICAL

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE

| |
e DOES THE PUSH ROD OF THE STOPLIGHT SW | REPLACE THE STOPLIGHT SW
OPERATE SMOOTHLY?

YES No |
=
REPAIR A POOR CONNECTION AT THE CONNECTORS | REPLACE THE STOPLIGHT SW
OR AN OPEN CIRCUIT BETWEEN 2 [B-66] AND [J-9]

2-2. STOPLIGHT ON THE LEFT (OR RIGHT)SIDE INOPERATIVE

e IS THE STOPLIGHT BULB ON THE LEFT (OR RIGHT)

SIDE NORMAL?

|
YES ;
[ NO_
e IS THERE CONTINUITY BETWEEN THE STOPLIGHT | REPLACE THE BULB |
CONNECTOR 2 AND 6 (2(R-6]AND | oss —
6 [H-16])

YES _No|
e REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT CONNECTORS
OR AN OPEN CIRCUIT BETWEEN THE STOPLIGHT OR AN OPEN CIRCUIT
CONNECTOR 6 [R-1] AND 6 (8 [R-6]AND
8 )

NOTE: FIGURE IN PARENTHESIS “( )” INDICATE THE PLACE OF INSPECTION FOR THE RIGHT SIDE
STOPLIGHT.
 CAB AND CHASSIS ELECTRICAL 8-99

STARTER SWITCH REAR TURN SIGNAL LIGHT/BULB

Refer to “START AND CHARGING? in this | Remove or Disconnect (Figure 110)

section.
Preparation:Disconnect the battery ground
cable.
FRONT TURN SIGNAL LIGHT/BULB
| Remove or Disconnect (Figure 109) 1. Lens
2. Bulb
Preparation:Disconnect the battery ground
cable.

1. Front combination light lens

Remove four screws.
2. Bulb

1. Lens
2. Bulb
Figure 110. Rear Turn Signal Light/bulb

[oe] install or Connect

1. Front Combination Light Lens.
To install, follow the removal steps in the reverse
2. Bulb
order.
Figure 109. Front Turn Signal Light/bulb

| Install or Connect

To install, follow the removal steps in the reverse

order.
8-100 CAB AND CHASSIS ELECTRICAL

TURN SIGNAL LIGHT SWITCH

(COMBINATION SWITCH)
Inspect (Figure 111)

Check the continuity between the terminals of the

turn signal light switch.
Repair or replace the switch when the result of
inspection is found abnermal.

8-70 |

ESE aisis
7] ©) Sfomataiat

Switch side

ee Terminal No.
11 | 12 | 13

d
SW position

on
night Neutral

right O+O
Figure 111. Turn Signal Light Switch

| Remove or Disconnect

Refer to “HEADLIGHT AND CORNERING LIGHT”

in this section.

[oe] Install or Connect

Refer to “HEADLIGHT AND CORNERING LIGHT”

in this section.

FLASHER UNIT

Inspect (Figure 112)

When a 55W bulb is connected to the unit side

terminals “L” and “E” while connecting the battery
(+) terminal to terminal “B”, and the battery (-)
terminal to terminal “E” does the bulb light on and
off?
Replace the unit when the result of inspection is
found abnormal.

Figure 112. Flasher Unit

 CAB AND CHASSIS ELECTRICAL 8-101

STOPLIGHT BULB
[es] Remove or Disconnect

Refer to “CLEARANCE LIGHT, TAILLIGHT,

LICENSE PLATE LIGHT, I|D LIGHT AND
ILLUMINATION LIGHT” for TAILLIGHT BULB
removal and installation steps in this section.

be] install or Connect

rock nut
Refer to “CLEARANCE LIGHT, TAILLIGHT,
Brake pedal arm /
LIGENSE PLATE LIGHT, ID LIGHT AND
ILLUMINATION LIGHT” for TAILLIGHT BULB
1. Stoplight Switch
removal and installation steps in this section.
Figure 114. Stoplight Switch Removal
STOPLIGHT SWITCH

Inspect (Figure 113) Install or Connect

* Check to see if the stoplight switch is installed To install, follow the removal steps in the reverse
correctly to the specified position. Adjust the order, noting the following points.
position when the result of the inspection is found
abnormal.
Check Stoplight Switch (Figure 115)
* Check to see if there is any continuity between « Check to see if the brake pedal has been returned
the terminals of the stoplight switch. by the return spring to the specified position.
Replace the switch when the result of inspection « Turn the stoplight switch clockwise until the tip of
is found abnormal. the threaded portion of the switch contacts the
pedal arm.
« Turn the switch counterclockwise until the space
between the tip of the threaded portion and the
pedal arm is 0.5 to 1.0mm (0.02 ~ 0.04in.)

Terminal No.
Lock nut
SW position ee
Depress brake pedal (Push ~ _
rod out) O--O
Release brake pedal (Push
red in)
Brake Recel°/
arr J
Figure 113. Stoplight Switch
i /
Stoplight switch
[es] Remove or Disconnect (Figure 114}

Preparation:Disconnect the battery ground

Figure 115. Check Stoplight Switch
cable.

1. Stoplight switch
« Disconnect the connector.
* Loosen the lock nut of the switch.
* Remove the switch by turning it.
8-102 CAB AND CHASSIS ELECTRICAL

HAZARD WARNING SWITCH 1. Meter Cluster

2. Hazard Warning Switch
Inspect (Figure 116)
Check the continuity between the terminals of the
hazard warning switch.
Repair or replace the switch when the result of
inspection is found abnormal.

Ss
esos |
| yoyo)
LJ

Terminal
sw™ No} 6; 5} 1] 2/3/417)8
position
ON [OFOTO[OFOTO OO
OFF OO
manent

Figure 116. Hazard Warning Switch

This illustration is based on the dome light switch
| Remove or Disconnect (Figure 117)
Figure 117. Hazard Warning Switch Removal
Preparation:Disconnect the battery ground
cable. [oe] Instali or Connect

1. Meter cluster To install, follow the removal steps in the reverse

Refer to the “METER AND order noting the following point.
WARNING/INDICATOR LIGHT?” in this section.
2. Hazard warning switch 1. Push the switch with your fingers until locks
Release the lock pushing the switch from the securely.
back side of the meter cluster.
 CAB AND CHASSIS ELECTRICAL 8-103

HORN AND BACKUP LIGHT

GENERAL DESCRIPTION

The circuit consists of the starter switch, horn, the position of the starter switch, the relay is
horn switch, backup light (Rear combination light), activated to sound the horn. When the backup light
backup light switch and the relay. switch turns on with the starter switch on, the
When the horn switch is turned on independent of backup light will operate.
8-104 CAB AND CHASSIS ELECTRICAL

PARTS LOCATION

fa
Mw
> z

F 2B
o Be x 3 l.

z fp ;, Ba
f >
B =_ ~3 6
O A gh 7
E i .
e 2
2 2
+

zi g
x
E~
oS | <
s —~ ‘
< /
x<So

a /\, H -
f

z= / Lyf
: zZ
S
2 |
5 L- Ys eS
Dy _
97
= a / ff

an .> S+
uw~” co =x “
— tr 2
iL Li uw
a

Figure 118. Parts Location

 CAB AND CHASSIS ELECTRICAL 8-105

CIRCUIT DIAGRAM
B-51|(8)
METER[B-51]

BACK UP LIGHT
BACK UP LIGHT SWITCH (MBP T/M)} (REAR COMBINATION LIGHT-RH)
5=| osByY
. fo__|
2 spy
. lle alla OR,O.5R/L
3 al Teg i +O
O.5R/L affe) O.SR/L te or io 1.258

Eat 8 ets

O.5BY foo >] O.SR/L.

v INHIBITOR SWITCH (A/T) BACK UP LIGHT
ad (REAR COMBINATION LIGHT-LH)
oa
ee 1 O.SR/L 7] €) (zk 1.258 .

=,
rq
oO

ffivie}*
STARTER SWITCH

ost |
ACCS

ON
oO

1.25B
7 FR HORN SWITCH
a a (COMBINATION SWITCH)
CONTACT

=
”
}o_ OF!
0.85G/R
, HORN

H ORN

a \~/
9] 20a
HAZARD
3we

ix) ep = ,
RELAY; HORN
HORN (LH)
[F-1

vt

ai]>-” @__Je]o_0.85GW ofl] o.esca ly mM i)

a |e : i = Hl
HORN (RH) 22

4& =i
“le
|= Q§
8 x
a w =

Figure 119. Circuit Diagram

8-106 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

an
itech
ride] Mel
hel aaa alse
| 70 that

pe
zalvi-f
xialaisie|

sini

sfisiale|

laseaef
duel
usisialelo

10
alsa

Fale
a
13

‘gog0
| iG |
fagactale
rere 5-5 factors
farorente

eT

EE) G) =
Figure 120. Connector List
 CAB AND CHASSIS ELECTRICAL 8-107

DIAGNOSIS
QUICK CHART FOR CHECK POINT
1. HORN

Check point} Frigg Hom Horn Horn Horn Cable

Trouble mode — F-18(20A) Sw relay | contact | harness
| O O O O O
1-1. Horn does not sound O
(1) (4) (6) (2) (5) (3)
J O O
1-2. Horn does not shut off O
(2) (1) (3)

NOTE: Figure in parenthesis “( )” indicates the order of inspection.

2. BACKUP LIGHT

‘ Backup
Check point | case | light SW eight Cable
Trouble mode F-25 (10A)| (Inhibitor bulb harness
SW)
; ; ; O OQ ©
2-1. Both backup lights inoperative
pene (1) 3) (2)
2-2. Backup light on the left (or right) side O O
inoperative (i) (2)

; ; ©
2-3. Backup light remains on (1)

NOTE: Figure in parenthesis “( )” indicates the order of inspection.

8-108 CAB AND CHASSIS ELECTRICAL

1. HORN

1-1. HORN DOES NOT SOUND

e IS FUSE F-18 (20A) NORMAL?

YES
i

e IS THE HORN RELAY NORMAL? | REPLACE THE FUSE

LL
YES oe
a

e IS THE HORN NORMALLY GROUNDED? REPLACE THE HORN RELAY

YES _NO-
2 IS THE HORN CONNECTOR 1[J-4]0R 1 [J-5] CLEAN UP THE FITTING SURFACE AND THE
SECURELY CONNECTED? GROUND FIRMLY

YES —|
No

® DISCONNECTED THE HORN SWITCH CONNECTOR CONNECT THE CONNECTOR SECURELY

e IS THERE BATTERY VOLTAGE APPLIED BETWEEN
3 AND THE GROUND?

L
YES i
» (S THERE ANY CONTINUITY BETWEEN THE HORN REPAIR A POOR CONNECTION AT THE
RELAY HARNESS SIDE CONNECTOR 5 AND CONNECTORS OR AN OPEN CIRCUIT OR REPAIR
1 [5-4] (OR 1 (9-5])? A POOR CONNECTION AT THE HORN
CONNECTOR

e
iL
re
CONTINUED ON THE FOLLOWING PAGE CONTINUED ON THE FOLLOWING PAGE
 CAB AND CHASSIS ELECTRICAL 8-109

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE

e DOES THE HORN SOUND WHEN CONNECTING THE REPAIR A POOR CONNECTION AT THE
BATTERY (+) TERMINAL TO THE HORN CONNECTOR CONNECTORS OR AN OPEN CIRCUIT IN THE
1 [J-4](1 [J-5]), AND (-) TERMINAL TO THE HORN CIRCUIT
BRACKET?
|
LL
Le
| PEPLACE THE HORN

1-2. HORN DOES NOT SHUT OFF

e IS THE HORN RELAY NORMAL?

YES

e REMOVE THE HORN SW REPLACE THE HORN RELAY

e IS THE MOVABLE PORTION OF THE HORN SW
ALWAYS OUT OF CONTACT WITH THE GROUND
BRACKET?

=
REPAIR A SHORT CIRCUIT BETWEEN HORN RELAY
HARNESS SIDE CONNECTOR 4[B-24] AND 3
NO—

REPAIR OR REPLACE THE HORN SW

 [St-H]
v ANV ([0t-3]z HO[6P-T]z YO)
[69-7] p YOLOSNNOD AGIS SSANHVH HOLIMS
MS SYOLISIHNI HO HOLIMS LHOM dn OWE JHL NAIMLIG LINDHIO NadO NV
LHD11 dNIOVE SHL JOV1dSy HO IWdsd HO HOLOINNOOD JHL LY NOILOSNNOOS YOOd V YlVdad
([Oi-3} 2
anv [Ot-3] 1 yO[6P-T] 2 GNV[6P-f] tb YO), 69-f) v
GNV [69-7] 2 YOLOANNOO JIS MS 3HL NaaMLa
[Ol-3]t ALINNILNOD ANY JYSH! SI HOLIMS LHOM
dNNOVE FHL JO YHOLOSNNOSD SH1 SAOWSY NAHM °
YyOL6H-T] L HO[69-f] Z GNV (VOL) Sz-4 3SN
NaaM 13d LINDHID NadO NV HO YHOLOANNOO NOILISOd JSHAAAY
JHL LW NOLLOINNOD HOOd V Hlvday OL H3AZ1 LAIHS NOISSIANSNVdL SHL YSLNA ¢
SAA
éGNNOYD FHL ONV([OL-3] L YO[6b-F] | HO)LE9-F] Z
YOLOINNOOD 3GIS SSSNYVH HOLIMS LHONM dnova
SHL NJSML3A Galdd¥ JOVLIOA AYALLVE FHL SI ¢
NO MS ¥3SLHYVLS FHLNYNL ¢
S3A |
iGSCNNOUD ATauNDAS[ETI]SI *
a
EIVWHON (VOL) S7-4 3SN4 SI * |
SAILVYAdONI SLHDIT dNHOVE ‘be
LHOIT dNNOvVd ‘c
WWOlWL0314 SISSVHD GNV GVO OFl-8
 CAB AND CHASSIS ELECTRICAL 8-111

2-2. BACKUP LIGHT ON THE LEFT (OR RIGHT)SIDE INOPERATIVE

e IS THE BACKUP LIGHT BULB ON THE LEFT (OR

RIGHT) SIDE NORMAL?

YES cei.
e IS THERE BATTERY VOLTAGE APPLIED BETWEEN | REPLACE THE BULB |
THE BACKUP LIGHT HARNESS SIDE CONNECTOR
5 [R-1], (5 [R-6])
AND 4 [H-16]?

YES

REPAIR A POOR CONNECTION AT THE CONNECTORS REPAIR A POOR CONNECTION AT THE

OR AN OPEN CIRCUIT BETWEEN BACKUP L GHT CONNECTORS OR AN OPEN CIRCUIT IN
HARNESS SIDE CONNECTOR 6 [R-1), (6 [R-6 ) AND [J-9] THE CIRCUIT

2-3. BACKUP LIGHT REMAINS ON

| REPAIR OR REPLACE THE BACKUP LIGHT SW OR INHIBITOR SW

 8-112 CAB AND CHASSIS ELECTRICAL

STARTER SWITCH HORN SWITCH

Refer to “START AND CHARGING? in this Inspect (Figure 123)

section.
With the contact point of the horn switch pressed
to the switch bracket, check the continuity between
HORN
the connector terminal and the bracket of the
Inspect (Figure 121} switch.
Check the contact condition between horn contact
Check to see if horn sound when a battery of the combination switch and contact plate of
voltage between horn terminal and the fixing steering wheel.
bracket. Repair or replace the horn when the result Repair or replace the switch when the result of
of inspection is found abnormal. inspection is found abnormal.

Oshyy <
OHYYZns
\
Figure 121. Horn Figure 123. Horn Switch Inspection

fo] Remove or Disconnect (Figure 122) | Remove or Disconnect (Figure 124)

Preparation:Disconnect the battery ground Preparation:Disconnect the battery ground

cable. cable.

1. Bumper 1. Horn pad

Refer to “BUMPER?” in section 2B. * Hold the horn pad and pull it upward.
2. Horn 2. Steering wheel
Disconnect the connector. « Remove the steering shaft nut.
« Remove the steering wheel by using steering
wheel remover.
(Refer to Section 3D “STEERING COLUMN”
for steering wheel removal steps.)
3. Horn switch

1. Bumper
2. Horn

Figure 122. Horn Removal

fre] Instali or Connect

To install, follow the removal steps in the reverse

order.
 CAB AND CHASSIS ELECTRICAL 8-113

BACKUP LIGHT BULB

[es] Remove or Disconnect (Figure 126)

Preparation:Disconnect the battery ground

cable.

1. Lens
2. Bulb

1. Horn Pad
2. Steering Wheel
3. Horn Switch

Figure 124. Horn Switch Removal

| Install or Connect

To install, follow the removal steps in the reverse

order, noting the following point.
* Tighten the steering shaft nut to the specified
torque
Figure 126. Backup Light Bulb
Shaft nut torque N-m (lb-ft)
49 (36) x Install or Connect

HORN RELAY To install, foilow the removal steps in the reverse

order.
Inspect (Figure 125)

Figure 125. Relay Inspection

Check to see if there is any continuity between

the relay terminals.
Replace the relay when the result of inspection is
found abnorrnal.

BD -© cecsecccesenee Continuity
D — © verre No continuity
(When battery voltage is applied between @ — @)
(Oa © ee No continuity
Oe ee Continuity
8-114 CAB AND CHASSIS ELECTRICAL

BACKUP LIGHT SWITCH [es] Remove or Disconnect

Inspect (Figure 127) Preparation: Disconnect the battery ground

cable.
1. Withe the switch installed to the transmission,
check the continuity between the terminals of
1. Backup light switch
the switch connectors.
* Disconnect the connectors.
When the continuity is found between the
« Remove the switch by turning it
terminals only with the switch shifted to the
counterclockwise.
reverse position, the switch is normal.
. When the result of the above inspection is found [oe] Install or Connect
abnormal, remove the switch from the
transmission and conduct a test on the switch 1. Backup light switch
alone. Apply liquid gasket to the screw portion of the
if the continuity appears between the connector switch to prevent oil leak.
terminals when the ball of the switch is pushed,
the switch is not normal. (When the ball is
released, the continuity appears.)
. If there is no continuity with the switch installed
to the transmission, even though the switch is
found to be normal, then adjust the stroke of the
switch by changing the thickness of the switch
gasket.

0.9 mm (0.35 in)

Figure 127. Backup Light Switch

 CAB AND CHASSIS ELECTRICAL 8-115

DOME LIGHT AND CAB INTERIOR

LIGHT
GENERAL DESCRIPTION

The circuit consists of the dome light, dome light The dome light can be lit by respective switch
switch, door switch and cab interior switch. independent of the position of the starter switch.
The dome light lights up when the left side door is By operating the dome light switch fitted on the
opened with the switch set at the door mode. It can instrument panel, the dome light can be lit
be lit by operating ON or OFF of the dome light indpendent of the switch position of dome light.
switch.

LIGHTING CIRCUIT

BATTERY (+) «

+) >
\ ®
av 1S
-—-—|, DOOR|DOME LIGHT —b a
OFF ono © 5
? a
| =

TO CAB
INTERIOR
LIGHT

DOME SY DOOR SW
LIGHT SW} gs ‘| (DRIVER SIDE)

<ix) :Lighting circuit by door SW | 1

<@gms :Lighting circuit by dome light SW

—_. te
mana

<<txs :Lighting circuit by cab interior SW

NOTE: Arrow marks" indicate the direction of current

Figure 128. Lighting Circuit

 RELAY BOX ASM (No. 1) L-2 DOME LIGHT
PARTS LOCATION

—
FUSE BOX ASM

nee
F-6 N-2 DOOR SW (LH)

nenae
ere
8-116 CAB AND CHASSIS ELECTRICAL

mm,

STARTER SW

Figure 129. Parts Location

BATTERY

RELAY BOX ASM

8-272 JOINT CONNECTOR
FL-1 FUSIBLE LINK
J-20 ID LIGHT RELAY

B-86 DOME LIGHT SW

B-158 CAB INTERIOR SW
H-12
 CAB AND CHASSIS ELECTRICAL 8-117

[fsr “qe% %allt 0.58

=] Q85LG/R 0.85LG/R SrQU-8
-W a .
BRo
4 |all? __0.85R/G “(all
{zh ossr/G _— fell| o.5R/G iD LIGHT
aa
g RELAY:
2 1D LIGHT
aoO oc
iB B ? .
@ 3 EAETH i
ing
0.85R/G * aS
‘coe

MARKER ice
a 0.85R «| POWER
3155
Sikm
3 SOURCE 13s
ez O.85RY CAB
—| CAB iiS
ed aoe
a
x 3B t “
EARTH i
0.85R/G ol maRKER ine
lee
ore
+156
“fs 0.85R 0.85R | POWER SiBE
i SOURCE ig
CAB INTERIOR LIGHT SWITCH ise
4
10
-[g al OBR fe O85R/Y -|CAB 2G
———]--«
a a [e} 0.85R/¥ LIGHT Ai
-Q Bio 0.58
a

Bl ge
a)o 8oO

DOME LIGHT DOOR SWITCH (DRIVER SIDE)

© cin 0.5GR/B O.5GR/B ~[a]] 1.25GAR -[o i
gore lz{f 2
q
ofs= ff Y
6 I
OSA FI o5R Neel i
> [[cle_oscr ffS]_oscr_ gis 0.58 1
cl zi a
3
oO

we
wo
° ir a
4 g
oo 2 ax 4 7,
oO
5
2
i 8 z
a
$s
x
Se
koa
6 5
8 = $8 Ble
o - Ser Q~"
5
Ke < 34Oo a
a
x Lae
go ot 2D
a5 2
ao
2 w }
oo
nia
1 o ~ m

a) {3

4= [s}¢ = =
=
BE ~ &
ge, 2 5
: Rd
oe?
a | Ws -
Pg
Sg
= ©

4
Las
bea

Figure 130. Circuit Diagram

8-118 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

wth.
aeiw

Ci] a
isle 7 eh litre
ODnED
[feersnenrps

.
,

Figure 131. Connecior List

 CAB AND CHASSIS ELECTRICAL 8-119

DOME LIGHT BULB

[es] Remove or Disconnect (Figure 132)

Preparation:Disconnect the battery ground (=) aa 3 | 8-86 |

cable. 2

1.Lens
Hold the lens and pull it downward. Terminal
2. Bulb sw > No.| 2 | 4/1 1 3
position ~
ON | OO

Figure 133. Dome Light Switch

[-9] Remove or Disconnect (Figure 134)

Preparation: Disconnect the battery ground

cable.

1. Meter cluster
Refer to the “METER AND
WARNING/INDICATOR LIGHT” in this section.
2. Dome light switch
Figure 132. Dome Light Bulb
Release the lock pushing the switch from the
back side of the meter cluster.
fo] Install or Connect

To install, follow the removal steps in the reverse 1. Meter Cluster

order. 2. Dome Light Switch

DOME LIGHT SWITCH

inspect (Figure 133)

Check the continuity between the dome light

switch connector terminals.
Repair or replace the switch when the result of
inspection is found abnormal.

Figure 134. Dome Light Switch Removal

 8-120 CAB AND CHASSIS ELECTRICAL

foe] Install or Connect [es] Remove or Disconnect (Figure 136)

To install, follow the removal steps in the reverse Preparation:Disconnect the battery ground
order noting the following point. cable.
* Push the switch with your fingers until locks
securely. 1. Door switch
« Remove the screw.
DOOR SWITCH « Disconnect the connector of the switch.

Inspect (Figure 135)

——

Check to see if there is any continuity between

the terminals and the body while operating the door ©
switch. Slide part
Repair or replace the switch, when the result of
inspection is found abnormal.

Slide

Terminal O Release /~, Push

“7
Termanal ®
« //*
Figure 136. Door Switch Removal

[oe] install or Connect

ee To instail, follow the removal steps in the reverse

order.

Con nector

on ‘
“2
N-2

Seeration Wo, 1 Body

Push

Release CO C)

Figure 135. Door Switch

 CAB AND CHASSIS ELECTRICAL 8-121

CAB INTERIOR LIGHT SWITCH

Inspect (Figure 137)
Check the continuity when the switch is in "ON"
position.

Terminal
Sw No.
ion
OFF
ON

Figure 137. Cab Interior Light Switch Check

[eo] Remove or Disconnect (Figure 138)

Preparation: Disconnect the battery ground

cable.

1. Cab interior light switch

* To release the lock, push the switch from
back side of switch panel.
* Disconnect the connector.

1. Cab Interior Light Switch

Figure 138. Cab Interior Light Switch Removal

fos] Install or Connect

To install, follow the removal steps in the reverse

order.
8-122 CAB AND CHASSIS ELECTRICAL

TRANSMISSION CONTROL
MODULE (TCM)
GENERAL DESCRIPTION
The circuit consists of the starter switch TCM, The controllable items are speed shift pattern,
inhibitor switch, kickdown switch, stoplight switch speed shift, lock-up, oil pressure for each line and
engine speed sensor, vehicle speed sensor, throttie exhaust brake operative timing.
sensor, OD switch and the relay. TCM also has TECH-1 diagnosis controlling
TCM, the key component of TCM, judges where function.
to shift speed and where to lock up shifting by the For details, refer to section 1A1 and 7A2
electric signals delivered from each one of the “AUTOMATIC TRANSMISSION”.
switches and sensors, and send controlling signals
to respective soloenoids.

TCM OUTPUT AND INPUT DIAGRAM

SHIFT LEVER

*OD SW

+ DIAGNOSIS CONNECTOR ACCEL PEDAL

+ EXHAUST BRAKE SW | | \ + THROTTLE POSITION SENSOR
soeoro nese esters tec sand '
pone, \ « KICK DOWN SW
+ CHECK TRANS LIGHT > J
_ ENGINE

BRAKE PEDAL TCM « + ENGINE SPEED SENSOR

+ STOPLIGHT SWITCH ———— iy gem lt

_ | + EXHAUST BRAKE CUT RELAY
f— >
TECH-1 a
“NS ?
TRANSMISSION .
POWER SOURCE
« STARTER SW
* VEHICLE SPEED SENSOR + BATTERY ( FOR MEMORY
«OIL TEMP SENSOR BACKUP}
* INHIBITOR SW Oo oO
+

Figure 139. TCM Output and Input Diagram

 B-52 OD OFF INDOCATOR LIGHT & CHECK
TRANS LIGHT (METER)

N-1 0D SW STARTER SW
; J-129 ATF SW
PARTS LOCATION

a NS
FUSE BOX ASM J-69 J-73 VEHICLE SPEED
F-8 . SENSOR
\ INHIBITOR

B-66 STOP
LIGHT SW

B-272 JOINT | xo
CONNECTOR SS

BATTER’

P-3

Figure 140. Parts Location

FL-1, FL-2 FUSIBLE LINK

RELAY BOX ASM

FL-1, FL-2 FUSIBLE LINK
J-9
/ B-231
B-7
/ B-76 KICK DOWN SW |! |
B-229
B-80 THROTTLE POSITION SENSOR B-79 DATA LINK CONNECTOR
CAB AND CHASSIS ELECTRICAL 8-123
8-124 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM

088A.

xP
Sr OSB/L
26 VEHICLE
az
z5 z6 0.30%. e 0 304. anese
B-229) 5
118-229) lezeal 28 o SBR “Cia OSBRA 5 Fi (WO. + l1
: asa ores a

SS) sape pape sg} py

LOGK UP SOL
Pwr 5 O.S8RB 7p——7] OSBRB 4

(3) RELAY ENG WARM CUT2

“ OslGNy 1STMd
Ha 0 SGM 1276-250)ad Bog fa 0.5BAVAL “fiea]} 0 5BR/R 2rrrt , —$--| li
— SHIFT SOL $2
0 58/R —7 — OSsB/A aie
(4) RELAY ENG WARM CUT2 20 H-a} 25 fa-229|
i ie | 2 CORY srg, [i OORT cr
= SHIFT SOL S1 a
0SUG 0.8LIG a
(1) vsv,Fiso a ed 2
.
osLG/B - wees
6-229 OSBNG gf a"y, OSBRIG a a
(3) RELAY EXH + Teac) —— o58R eegp} 0.588
a BRAKE CONT — 5-229 P88 AT] onl BO |
058/G a 0 5a/G - poe hm
° (2) RELAY,EXH BRAKE. CONT. = Sho] = 22 Te-225] oo 057 gf avg LINE PARESS SOL
[e-zag : {H-]} Li
e229 g 0.5L 2r real} OSU Iori A Ds K |

[Fe | 100 STOP LIGHT saad} 3 hale st} OIL TEMP SENSOR

STOP LIGHT 1608? SLY

uw PN, Tacescos er cce assem ees s
——— oo BRa -O 2
-foeeeag] G Loss
neSSG 38 jezed al} wa
OP esary Ll 86 fe 1216-23] ema OBL | bei
Tiayio 8G [ kia
7a LS |
[EBs] 104 SW.STOP LIGHT sp2
GAUGE BACK [§-299) (10) EOM ee Sg OLS lf B29 saa 1 a O SRL
fez [8-23 38a.
Oy
& .
8 [B2aq@) cco g—2BIS__187 aa

NS

a
°
a

718
0 SEY Lf Tp2ai

Ny
a
P
=a
SWKICKDOWN
ae 3 enna n | oer

2
CONNECTOR
{LLUM.CONT fags z TCM le-zzg| 8 . es BNO
nay tenn B44 A aac eo o5RW
B-160}3) — a f lea OEY Tee»
| S|> YRS
J

JOINT
SIS! ITC Th YP
z 3
eat
(229
|
18 OSG ups
_
B40
‘eo 18 lez 4 ———2
oN __y [esb |) METER
C- \ a b fit."
fa-2a0] 0.58R/8E__» [6-96 |(5) RELAY:EXH BRAKE CUT
Z| [2
RELAY;TAIL - BACK UP LIGHT
sarge r % SW:INHIBITOR
(Bez|s) «de
oH

( m)
(oy .sare 020:
3
yo. 0.30 of ea] a
i oSWwR.
{ray} 288
O.SW/R
-—5--0-
=. Pp

oporr lezo] 22S ST ro} SSR Are aft —_G

+) fs 08 aps) -
gue —¢\ af 28 ap
§ ” fa 0.8L
—o
“ K TRANS. rere
Tawar ES need HTB 280)
ee}! 2-280_freaqs 980 usagy 5 _.

an B51 2 Hee FY1h Teta9 . L

OHI! 1 osuR > SUR >
B-51
o.sviG O5v/G oN feze]p+ | 9]
[Heal P2258 2-6
aro ewe
SU Caf]. OSW
laze }2—2 a |

5
OSB fral Fe ” Oo Say isa]

[Tia]
45 6) RELAY.STARTER <}————a——nn
en RT|
0.58/78 8 P
OSL
3B

N N
i B-7

3G
BRACKET(LH)
HEAD UGHT

35zo
Figure141CircuitDiagram

Figure 141. Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-125

CONNECTOR LIST

[1] 212] «{s[sl7

Wileisislele 718]
Wo ponrpeparatsna

Figure 142. Connector List (1)

8-126 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

Figure 143. Connector List (2)

 CAB AND CHASSIS ELECTRICAL 8-127

WINDSHIELD WIPER AND WASHER

GENERAL DESCRIPTION
The circuit consists of the starter switch, the wiper motor to activate the wiper.
windshield wiper & washer switch, wiper motor, The washer motor squirts glass cleaning fluid
washer motor and the intermittent relay. while the washer switch is being pushed. The
When the wiper & washer switch is turned on with intermittent relay is used to control motion of the
starter switch on, the battery voltage is applied to wiper.

OPERATION OF WINDSHIELD WIPER

MOTOR (WHEN WIPER "LO" OR "INT"
POSITION)

1. Condition of view 3. Condition of Windshield

wiper switch Battery(+) —“LO* of “INT” wiper switch is wiper sw
Battery(+) “OFF”

le_sl_t
is "LO"or just "OFF"
“INT“position (Wiper motor
(Wiper motor is still
Lo THI To Tn
is starting to 3 operating
operate) ho M until auto-stop . a> 3
ie ' ®
position)

|
| ty
intermittent 7 Intermittent
relay relay

2. Condition of Windshield . Wiper motor Windshield

stops at auto- wiper sw
wiper motor is wiper sw ps Battery(+) “OFF”
operating Batterwi+) = “LO” of “INT”

L
stop position

L_— [Lo |H

| [ J
ot” . M

Intermittent
Intermittent relay
relay aL.

NOTE: Arrow marks “=> ” indicate the direction of current.

Figure 144. Operation of Windshield Wiper Motor

 FUSE BOX ASM
F-11
PARTS LOCATION

WIPER & WASHER SW

B-3 INTERMITTENT RELAY
8-128 CAB AND CHASSIS ELECTRICAL

a
<
E
[a
Spe

Figure 145. Parts Location

B-8 WASHER MOTOR

FL-1, FL-2 FUSIBLE LINK

B-17 WIPER MOTOR

RELAY BOX ASM
 CAB AND CHASSIS ELECTRICAL 8-129

CIRCUIT DIAGRAM

STARTER SWITCH

80A BOA p
RO ag a el
MAIN KEY Sw
i 2 8

g o-St|

sae
™N

S =ao
om

(F-14] 20A
WIPER, WASHER

+0440

=9To-
_
ip

Ps]
FRAME 0.851. 1.251

(ees WIPER, WASHER SWITCH

4 63] (COMBINATION SWITCH)
a 4

8
fee]
B psiaa2 O.85L/R

,ras qé 0.85L/0
- 83)
=
Lis

E
=oc
iu Lenssarettsreeticrtt at

ZZz ay 0.85 BRY a

s PM 8-9IF 3
suy
ao

. “esl 4 0.5L/B
vt
Loe 2
S
Ee
Q
=
we
uw
x

2
o™ a s
™
° =

a
w
N
3B 3B
HEADLIGHT BRACKET (LH) 'IH-—{
87 +

Figure 146. Circuit Diagram

8-130 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

[23 ea]
ES REE
ril2z2{3|¢
6je{7]s

8-7

Figure 147. Connector List

 CAB AND CHASSIS ELECTRICAL 8-131

DIAGNOSIS
QUICK CHART FOR CHECK POINT

1. WINDSHEILD WIPER AND WASHER

ee Check point} Fuse Wiper inter- Wiper | washer | cable

ee & washer) mittent
Trouble mode ae F-11 (20A) SW relay motor moter harness

1. Windshield wiper does not operate at OQ © O O

any switch position 1) (3) (4) (2)
2. Windshield wiper does not operate at O O O
"INT" position (1) (3) (2)
3. Windshield wiper does not operate at © O O
"LO" position (1) (3) (2)
4, Windshield wiper does not operate at C O O
"HI" position (1) (2) (3)
5. Auto-stop function of the windshield O O O ©
wiper motor does not operate (1) (4) (2) (3)

6. Rotation of the windshield wiper motor © O

does not stop (1) (2)
7. Windshield washer motor does not © © O
operate (1) (3) (2)

NOTE: Figure in parenthesis "( )" indicates the order of inspection.

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 CAB AND CHASSIS ELECTRICAL 8-133

2. WINDSHIELD WIPER DOES NOT OPERATE AT "INT" POSITION

e IS CONTINUITY IN THE WINDSHIELD WIPER &
WASHER SWITCH NORMAL?

YES NO ;

e DISCONNECT THE CONNECTOR OF THE REPAIR OR REPLACE WINDSHIELD WIPER &

INTERMITTENT RELAY WASHER SWITCH
e IS THERE CONTINUITY BETWEEN THE RELAY AND
THE WINDSHIELD WIPER & WASHER SWITCH
HARNESS SIDE CONNECTOR 6 AND 8 [B-69|,
OR 3 [B-9] AND 3 [B-69 JRESPECTIVELY?

L
Ye —
| REPLACE THE INTERMITTENT RELAY | REPAIR A POOR CONNECTION OR AN OPEN
CIRCUIT BETWEEN THE CIRCUITS
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 CAB AND CHASSIS ELECTRICAL 8-135

5. AUTO-STOP FUNCTION OF THE WINDSHIELD WIPER MOTOR DOES NOT OPERATE

« IS CONTINUITY IN THE WINDSHIELD WIPER AND

WASHER SWITCH NORMAL?

Des [No |
¢ DISCONNECT THE CONNECTOR OF THE WINDSHIELD WASMEN Sviitene THE WINDSHIELD WIPER &
WIPER MOTOR
e CONNECT THE MOTOR CONNECTOR 2[B-14] TO THE
BATTERY (+) TERMINAL, AND 1[B-11] TO THE BATTERY
(-) TERMINAL, AND THEN CHANGE THE CONNECTION
OF THE BATTERY (+) TERMINAL TO THE CONNECTOR 4
WHILE ROTATING THE MOTOR AT A LOW SPEED
e WHEN CONNECTING THE CONNECTOR TERMINALS 2
B-11] AND 5[B-11] IN THIS CONDITION, DOES THE
MOTOR STOP AT AUTO STOP POSITION?

Ls [NO |
@ TURN THE STARTER SWITCH ON REPAIR OR REPLACE THE WINDSHIELD WIPER
e IS THERE BATTERY VOLTAGE APPLIED BETWEEN THE MOTOR
WINDSHIELD WIPER MOTOR HARNESS SIDE
CONNECTOR TERMINAL 4[B-11] AND GROUND?

Ps co
e DISCONNECT THE CONNECTOR OF THE WINDSHIELD REPAIR A POOR CONNECTION AT THE
INTERMITTENT RELAY CONNECTORS OR AN OPEN CIRCUIT BETWEEN
« 1S THERE CONTINUITY BETWEEN THE RELAY HARNESS THE FUSE F-11 (20A) AND 4
SIDE CONNECTOR 7 AND THE WINDSHIELD WIPER
MOTOR HARNESS SIDE CONNECTOR 5 ?

iZ
YES Ne.
NO

| REPLACE THE WINDSHIELD INTERMITTENT RELAY | REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE CIRCUITS
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 CAB AND CHASSIS ELECTRICAL 8-137

7. WINDSHIELD WASHER MOTOR DOES NOT OPERATE

« |S CONTINUITY IN THE WINDSHIELD WIPER & WASHER

SWITCH NORMAL?

YES [No|

e TURN THE STARTER SWITCH ON REPAIR OR REPLACE THE WINDSHIELD WIPER &
¢ IS THE BATTERY VOLTAGE APPLIED BETWEEN THE WASHER SWITCH
WINDSHIELD WIPER & WASHER SWITCH HARNESS
SIDE CONNECTOR TERMINAL 1 [B-69 JAND THE
GROUND?

(el rao
e DISCONNECT THE CONNECTOR OF THE WINDSHIELD REPAIR A POOR CONNECTION AT THE _
WASHER MOTOR CONNECTORS OR AN OPEN CIRCUIT BETWEEN
e TURN THE STARTER SWITCH ON FUSE F-11 (20A} AND 1
® WITH THE WASHER BUTTON OF THE WINDSHIELD
WIPER & WASHER SWITCH DEPRESSED, IS THE
BATTERY VOLTAGE APPLIED BETWEEN THE WASHER
MOTOR HARNESS SIDE CONNECTOR TERMINAL 1[B-8]
AND THE GROUND?

ves (No|
| e Is GROUNDED SECURELY? REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1
AND 6

YES NO

© CONNECT THE MOTOR SIDE CONNECTOR 1 [8-8] OF GROUND IT SECURELY

THE WINDSHIELD WASHER MOTOR TO THE BATTERY
(+) TERMINAL, AND THE CONNECTOR 2 [B-8]TO THE (-)
TERMINAL
e DOES THE MOTOR ROTATE?

YES [No |

REPAIR A POOR CONNECTION AT THE CONNECTORS OR REPAIR OR REPLACE THE WINDSHIELD WASHER
AN OPEN CIRCUIT BETWEEN 2 AND MOTOR
 8-138 CAB AND CHASSIS ELECTRICAL

STARTER SWITCH

Refer to "START AND CHARGING" in this

Windshield wiper & Washer SW
section.

WINDSHIELD WIPER & WASHER SWITCH

(Figure 148)
With the starter switch on, the windshield wiper
and washer switch controls the start and stop
operation as well as the change of operating
speeds.
Both the windshield washer motor and the wiper
motor jointly operate while the washer button is Figure 148. Windshield Wiper & Washer Switch
pushed.

[5] Inspect (Figure 149)

Check the continuity between the connector
terminals of the switch.
Repair or replace the switch when the result of
inspection is found abnormal.

Switch side

Terminal No.
Washer SW Wiper SW 1 4

OFF
INT
LO
HI
OFF,INT,LO,HI

Figure 149. Windshield Wiper & Washer Switch Check

[eo] Remove or Disconect

Refer to "HEADLIGHT AND CORNERING LIGHT"

in this section.

| Install or Connect

Refer to "HEADLIGHT AND CORNERING LIGHT"

in this section.
 CAB AND CHASSIS ELECTRICAL 8-139

WINDSHIELD WIPER MOTOR

Inspect (Figure 150)
1. Operation in low speed
With the motor connector terminal 2 [B-11
connected to the battery (+) terminal and the
connector 1 to the (~) terminal, check to
see if the motor rotates in low speed.
2. Operation in high speed
With the motor connector terminal 3 [B-714]
connected to the battery (+) termina! and the
1. Glove Box
connector 1 |B-11] to the (—) terminal, check to
2. Windshield Wiper Motor
see if the motor rotates in low speed.
3. Stop operation Figure 151. Windshield Wiper Motor Removal
After stopping the windshield wiper in the
position on the way by confirming the operation
[oe] install or Connect
at the low speed in item No. 1.
When the connectors 2 [B-11] and 5 [B-11] are To instail, follow the removal steps in the reverse
connected, while connecting the motor order, noting the following points:
connector terminal 4 [B-71] to the battery (+) « Windshield Wiper Motor
terminal, check to see, if the motor rotates at When the crank arm is removed from the
low speed and stops at the auto-stop position. windshield wiper motor, tighten the motor shaft
Repair or replace the motor when the results of nut with the specified torque.
the above inspections are found abnormal.
Shaft nut torque N-m (lb-ft)
17 (12)

« Temporarily fit the motor by using one of the four

wiper motor fixing screws.
» Put the crank arm ball joint in the wiper fink hole
and fix them together while pulling the wiper link.

WINDSHIELD WASHER MOTOR

Inspect (Figure 152)

With the battery (+) terminal connected to the

washer motor connector terminal 1 and the (-)
Figure 150. Windshield Wiper Motor terminal to the connector 2 [B-8] , check to see if
the cleaning fluid pushes out.
[es] Remove or Disconnect (Figure 151) Repiace the tank/motor when the result of
inspection is found abnormal.
Preparation: Disconnect the battery ground
cable.

1. Glove box
Refer to "INSTRUMENT PANEL" of section 10D
"STEEL TILT CAB".
2. Windshield wiper motor
- Disconnect the connector.
« Remove four screws.
* Remove the ball joint between crank arm and
wiper link.

Figure 152. Windshield Washer Motor Check

 8-140 CAB AND CHASSIS ELECTRICAL

[+>] Remove or Disconnect (Figure 153)

Preparation:Disconnect the battery ground

cable

1. Instrument panel under cover

Refer to "INSTRUMENT PANEL.” of section 10D
"STEEL TILT CAB".
2. Washer tank
® —
« Disconnect the washer motor connector. 1. Instrument Panel Under Cover
« Disconnect the washer hose. 2. Washer Tank
« Remove three fixing screws. 3. Clip Band
3. Clip band 4. Windshield Washer Motor
4. Windshield washer motor
Hold the motor and pull it out from the washer Figure 153. Windshield Washer Motor Removal
tank.
: install or Connect

To install, follow the removal steps in the reverse

order,

INTERMITTENT RELAY
CIRCUIT DIAGRAM

Windshield wiper & washer sw

NO
lal7i3lileis

Intermittent
Starter sw. relay

Figure 154, Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-141

[a] Remove or Disconnect (Figure 155) WINDSHIELD WIPER ARM/BLADE

Preparation:Disconnect the battery ground feo] Remove or Disconnect (Figure 156}

cabie
. Rubber hose

OOM
. Cover
1. Glove box
. Wiper arm nut
Open the lid and remove the four screws.
. Wiper arm/Biade

&
2. Intermittent relay
- Press @ position with your finger and pry up
position with the tip of a screw-driver.
* When the relay moves up by about 2/3 of its
size, tilt and take off the relay to avoid
interference with the instrument panel.
« Disconnect the connector.

. Rubber Hose | 4

ON |
. Cover
. Wiper Arm Nut
. Wiper Arm/Blade
&

Figure 156. Windshield Wiper Arm /

Blade Removal

[>4] install or Connect

To install, follow the removal steps in the reverse

order, noting the following points.
instrument * Before installing the wiper arm/blade to the shaft,
panei rein-
forcement confirm that the motor stops at the auto-stop
position.
* Set the wiper arm/blade so that the tips of both
blades are positioned as shown in the illustratio
(figure 157).
« Tighten the wiper arm nut to the specified torque.

Wiper arm nut torque N-m (Ib-ft}

17 (12)

1. Glove Box
2. Intermittent Relay

Figure 155. Intermittent Relay Removal

foe] install or Connect Approx. 2.8in (70mm)

To install, follow the removai steps in the reverse

order. Figure 157. Windshield Wiper Arm /
Blade Installation
8-142 CAB AND CHASSIS ELECTRICAL

WINDSHIELD WIPER LINKAGE

LOCATION OF ROD AND PIVOT

Pivot (Wiper: LH) Pivot (Wiper: RH)

of

—3 0 7 \ 30 ¢ =

Rod Rod A CK Op |

q
S. sO; g

Wiper motor

Figure 158. Windshield Wiper Linkage

| Remove or Disconnect

Preparation: Disconnect the battery ground

cable

1. Wiper arm & blade

Remove the rubber hose, cover, nut and wiper
arm & blade (figure 159). Rubber seal

Retaining rubber

2. Pivot Nut

Figure 160. Pivot Nut Removal

3. Instrument panel assembly

Refer to "NSTRUMENT PANEL" of section 10D
"STEEL TILT CAB" (figure 161).

Rubber hose

1. Wiper Arm & Blade

Figure 159. Wiper Arm & Blade Removal

2. Pivot nut
Remove the rubber seal, nut and retaining
rubber (figure 160).

3. Instrument Pane! Assembly

Figure 161. Instrument Panel Assembly Removal

 CAB AND CHASSIS ELECTRICAL 8-143

4. Wiper motor
- Remove four screws. as 42"

- Disconnect the bail joint between the crank Pivot (Wiper: w == ——

arm and the wiper link (figure 162).
Vs

4 Ball joint

6. Wiper Link Assembly

noe
Figure 164. Wiper Link Assembly Removal (1)

Remove two retaining nut from right hand side

4. Wiper Motor
of pivot (figure 165),
Figure 162. Wiper Motor Removal

5. Instrument panel reinforcement — a

Pivot (Wiper: RH) [~) LO 6
Refer to "INSTRUMENT PANEL" of section 10D
"STEEL TILT CAB" (figure 163).

6. Wiper Link Assembly

Figure 165. Wiper Link Assembly Removal (2)

[oe] Install or Connect

5. Instrument Panel Reinforcement To install, follow the removal steps in the reverse
order, noting the following points.
Figure 163. Instrument Panel Reinforcement * Temporarily fit the wiper motor by using one of
Removal the four wiper motor fixing screw.
¢ Put the crank arm ball joint in the wiper link hole
and fix them together while pulling the wiper link.
6. Wiper link assembly
Remove two retaining nut from left hand side of * Fit the motor with four screws.
« Tighten the pivot nut with the specified torque.
pivot (figure 164).
Pivot nut torque N-m (Ib-in)
8 (70)

» Tighten the wiper arm nut with the specified

torque

Wiper arm nut torque N-m (lb-ft)

17 (12)
8-144 CAB AND CHASSIS ELECTRICAL

WIPER BLADE RUBBER foe] Instali or Connect

| Remove or Disconnect 1. Wiper blade rubber
install the click of the blade stay in the groove
1. Wiper blade
of the new rubber and slide it in. Complete
Push the wiper blade lock while pulling the
installation by pushing the click (figure 168).
wiper blade in the arrow direction (figure 166).
Finally, check that the click of the stay has
caught in the hoie of the rubber (figure 169).
NOTICE:When the wiper blade has been
2. Wiper blade
removed, wrap the tip of the wiper arm with
cloth, to avoid damaging the glass.

2. Wiper blade rubber

+ Puil the end of rubber and remove the
projection from the click of the blade stay.
+ Pull the rubber out in the same direction
(figure 167).

Figure 168. Wiper Blade Rubber installation (1)

Brade lock

Figure 166. Wiper Blade Rubber Removal (1)

~ Blade stay
/
Projection

Figure 169. Wiper Blade Rubber Installation (2)

Figure 167. Wiper Blade Rubber Removal (2)

 CAB AND CHASSIS ELECTRICAL 8-145

AUDIO AND CIGARETTE LIGHTER

GENERAL DESCRIPTION
The circuit consists of the starter switch, radio, When the cigarette lighter is pushed in with the
cigarette lighter and the relay. starter switch at either "ACC" or "ON" position, a
The audio circuit is designed for the current to circuit is formed in the cigarette lighter case to heat
flow through the receiver circuit when the radio the lighter coil. The cigarette jighter is spring back
switch is turned on with the starter switch in "ACC" to its original position after the lighter coil is heated.
or "ON". Current runs through the memory circuit
of the audio regardless of the position of the starter
switch.
 B-43 CIGARETTE LIGHTER ILLUMINATION i DIGITAL CLOCK
B-45 CIGARETTE LIGHTER
B-22 TAIL RELAY \ B44 |
\\ \ CIGARETTE LIGHTER | STARTER SW
RELAY BOX ASM (No. 1)
PARTS LOCATION
8-146 CAB AND CHASSIS ELECTRICAL

Figure 170. Parts Location

FUSE BOX ASM
F-6, F-7, F-15
RELAY BOX ASM |
B-28 RADIO & CLOCK
B-272 JOINT CONNECTOR FL-1, FL-2 FUSIBLE LINK
D-5 SPEAKER (LH)
 CAB AND CHASSIS ELECTRICAL 8-147

CIRCUIT DIAGRAM

STARTER SWITCH

FL-1} 804 FL-2| 50A ;

ga «MAIN KEYSW : Son! B67F
“1 OTB '3W/B es |
H-7 B-67 l

“ $ oe st
So Ss
Loy
o
2 ood
=— om

H-6_

+0+}o+ =
ia
P-2 |

LF-7| 10a 104 20A

TAIL LIGHT DOME LIGHT RADIO,
x CIGAR LIGHTER
= 3
- eo
FRAME 3 =
®
LO

Oo

aoO aQ
w oO
oO x
o| os «
ww
3
2 1

B-22 f B-22 1

RELAY; TAIL 2 { 2
a

f S
B-22 B-22 2
8
4 5
Qo

0.85LG/R s| da 0.5LG/R
x
— B-273] JOINT g
6 « O.5LG/R CONNECTOR a
SI oO 10 u 4 3 _ °°
S
%
a
ip f B-28 | B-28 B-28 B-28 ra
[eas]! [ea]!
QO
RADIO & CLOCK 5 <=

B-28 | 5-28 B-28 B-28 B-28

H@
F
= T
~T9 12 5 13 6
a 3 p43] [8-45]
e tk 3 a 8S Goin} Ss) O ay
of
= g4 3 S oO CO a
~<s a og
5 wy F 7 6 7 6 id
f= Zz < a [H-14] H-11 [x 2 | H-2 | S
3 E nt 3 Oo
9S 2 8 % es 868 «65S OS
Fe 6 “ ° ° “| Se 55
5 S “ , 2 a i i
3Q - 22
=e 22
=x 8
. 2 DZ
S — 2G 28
5 SPEAKER (LH) SPEAKER (RH)
HEADLIGHT BRACKET (LH) |}—{@7 } 282 8 28
(B-272] JOINT CONNECTOR

Figure 171. Circuit Diagram

8-148 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

t]2fal4 a13i2
si6|7|s aiije
9 ltepah2 ¢
C0u dts

Figure 172. Connector List

 CAB AND CHASSIS ELECTRICAL 8-149

DIAGNOSIS
1. CIGARETTE LIGHTER DOES NOT HEAT SUFFICIENTLY

| * IS FUSE F-15 (20A) NORMAL? |

a=
YES [NoT |
e 1S [B-7] GROUNDED SECURELY? | [ REPLACE THE FUSE

YES [ne

e REMOVE THE CIGARETTE LIGHTER | GROUND IT SECURELY

e SET THE STARTER SWITCH TO EITHER "ACC" OR "ON"
POSITION
« 1S THE BATTERY VOLTAGE APPLIED BETWEEN THE
BIMETAL AT THE CENTER OF THE CASE AND OUTER
OF THE CASE?

L
YES [xo |

» SET THE STARTER SWITCH TO EITHER "ACC" OR “ON” REPAIR A POOR CONNECTION AT THE
® IS THE BATTERY VOLTAGE APPLIED BETWEEN CONNECTORS OR AN OPEN CIRCUIT BETWEEN
AND GROUND? FUSE F-15 (20A) AND 1

do
= ie
| REPLACE THE CIGARETTE LIGHTER ASSEMBLY | REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1
B-45| AND

2. THE CIGARETTE LIGHTER DOES NOT SPRING OUT AFTER BEING HEATED
[ e IS THE FORM OF CIGARETTE LIGHTER NORMAL?

LL
YES =

REPLACE THE CIGARETTE LIGHTER ASSEMBLY | REPLACE THE CIGARETTE LIGHTER

(INCLUDE OUTER CASE)
 8-150 CAB AND CHASSIS ELECTRICAL

STARTER SWITCH

Refer to "START AND CHARGING" in this

section.

RADIO
[eo] Remove or Disconnect

Preparation:Disconnect the battery ground

cable

1. Center cluster (figure 173)

* Pull it to remove. Pry off three clips using tip 2, Radio
of screwdriver.
« Remove the cigar lighter power source and its Figure 174. Radio Removal
itumination connector.
[><] install or Connect
NOTICE:To remove the center cluster, do not
force to pry off three clips at upper portion of To install, folow the removal steps in the reverse
the center cluster. order.

ANTENNA

Inspect (Figure 175)

The metal A is connected to the pole D at the top

of the antenna through the core of the feeder.
The metal B is fitted in the feeder shielding the
core, and grounded at the screw C to avoid the
core hampered by noise.
Defective grounding would cause noise.

Feeder

Cc
Resin made parts

1. Center Cluster

Figure 173. Center Cluster Removal

Figure 175. Antenna Check

2. Radio (figure 174)

in checking, measure the following three points
« Remove two radio fixing screws.
with the circuit tester in the range of "resistence x 1
« Disconnect the connector and feeder plug. (Q)":

Between A and B
No continuity (No reading at the indicator) >
Normal
Continuity (A bite in the feeder. The core
grounded) —> Lower reception
 CAB AND CHASSIS ELECTRICAL 8-151

Between B and CG
[re] Install or Connect
Continuity (Indicator reading: OQ) -> Normal.
No continuity (Shielded core disconnected or To install, follow the removal steps in the reverse
defective grounding at the screw -» Hampered order.
by noise)
Between A and D SPEAKER
Continuity or no continuity
There are some antenna feeders and relay Inspect (Figure 177)
feeders with a condenser built in their
connections. Measuring resistance between 1. With the circuit tester set to the range of x 1
the two points does not result in correct (2), connect the circuit tester probes (red and
judgment. Connect temporarily another normal black) to the (+} and (—) terminals of the
antenna to the radio and check to see if its speaker.
reception is audible. Most antenna now 2. When the speaker is normal, a low buzzing
available are slide type. Rust at the screw C sound is heard.
and the cab panel where grounded would lead 3. When the speaker is defective, no sound is
no continuity, followed by lower reception. heard.
Keep this portion clean to avoid rust. However, the distortion or chattering of the
sound cannot be identified.
| Remove or Disconnect When the speaker is installed to the vehicle,
disconnect the connectors before checking.
Preparation:Disconnect the battery ground When no sound is heard, the following are
cable considered as the cause.
« The speaker wiring is disconnected at the
1. Antenna (figure 176) speaker terminals.
¢ Disconnect the joint connector. * The speaker body is defective.
* Remove the upper and lower side antenna * There is an open circuit somewhere in the
bracket. speaker harness on the vehicle side.
* Pull out the antenna feeder. « The speaker harness on the vehicle side is
grounded or caught up.
NOTICE:For easier fitting, tie the lead wire to
the end of the antenna feeder in advance. Remove or Disconnect (Figure 177)

Preparation:Disconnect the battery ground

cable
Antenna bracket

1. Door pad
Refer to "FRONT DOOR TRIM PAD" of section
10D "STEEL TILT CAB"
2. Speaker panel
Disconnect the speaker connector.
3. Speaker
4. Water proof sheet

Feeder
. Door Pad
Joint connector :
&anh-

Clip . Speaker Panel

1. Antenna . Speaker
. Water Proof Sheet
Figure 176. Antenna Removal
Figure 177. Speaker Removal
8-152 CAB AND CHASSIS ELECTRICAL

[><] Install or Connect

TAIL RELAY
To install, follow the removal steps in the reverse inspect (Figure 179)
order.
Check to see if there is any continuity between
the relay terminals (figure 160).
CIGARETTE LIGHTER Replace the relay when the result of inspection is
found abnormal.
[+9] Remove or Disconnect (Figure 178)
BD — @® vecccessecereee Continuity
Preparation:Disconnect the battery ground Ok Ge No continuity
cable (When battery voltage is applied between @) - @)
(6) eG) eee No continuity
1. Center cluster ek) ee Continuity
Refer to "RADIO" in this section.
2. Cigarette lighter assembly
Remove the nut, then remove cigarette lighter
assembly, bezel and outer case.

Figure 179. Tail Relay Check

1. Center Cluster
2. Cigarette Lighter Assembly

Figure 178. Cigarette Lighter Removal

| Install or Gonnect

To install, follow the removal steps in the reverse

order.
 CAB AND CHASSIS ELECTRICAL 8-153

METER AND WARNING /

INDICATOR LIGHT
GENERAL DESCRIPTION
The circuit consists of the starter switch, meter fuel gage, engine coolant temperature gage and the
assembly, vacuum tank switch, oil pressure switch, warning/indicator light.
brake fluid level switch, parking brake switch, The meter warning/indicator lights and their bulb
vehicle speed sensor, fuel tank unit, A/T shift sockets are a unit, they are installed from the back
indicator, electronic vacuum pump and thermo unit. of the speedometer assembly.
The meter assembly contains the speedometer,
B-23 RELAY; BUZZER CANSEL B-53 METER
N-6 PARKING BRAKE SW
\ B-52 METER
\ STATER SW
\\B-51 METE ‘\ | B-161
VACUUM PUMP /
\ \
B-36 RELAY; VACUUM\,
PUMP \ \
\
E-76
F-25 THERMO SENSOR
FUSE BOXASM \\ /7S f
F-7 NN NA/ /_ J-69 INHIBITOR SW
ZZ 3-32 VEHICLE SPEED SENSOR
8-154 CAB AND CHASSIS ELECTRICAL

B-55 METER
B-272 JOINT CONNECTOR

H-12 \ J-8 OIL PRESSURE SW

B-71 VACUUM TANK SW
B-85 BRAKE FLUID LEVEL SW
 CAB AND CHASSIS ELECTRICAL 8-155

CIRCUIT DIAGRAM - FOR HBB VEHICLE

n3

FERRO ace eI _ ines Sean

ers—O ace _| —_ane l Sec
EG! GAGE SENDER:
MILES CHECK SWITCH

18-264
8-264}

re leg
roy4 "|

elERPec} +I
B-264} O_O

FUEL TANK UNITASENSOR

FUEL LEVEL
7 open}
(6) (Boi bests amg wm []28| Hn)
—| [e-264]

He
Os8
S

FUEL GAGE
FUSE] F-6 [10A omer

HBB-HYDRAULIC BOOSTER BRAKE SYSTEM

RELAY TAH(§)

2p SPEEDMETER
FUSE] F-8 }10A bar 18-82

: 2 8)
TCM [B-229| (4)(4 saw 2 5

+P ~ VEHICLE SPEED SENSOR

ILLUAINATION(% Sp
RELAY TAIL(5) «ER ee a 4 ILLUMIMATION CONTROLLER (3)
0 SLG/R 1
BRL
Fy
OF
BEAM

Fuse[ F-7 }10A ore ss FRY oR uN [BP26|5)

0 BoG/E O
TURN RH
TURIN SIGNAL LIGHT
@ 1! FRY
SWITCH | B-70](13) Sea)
TUAN LH
TURN SIGIVAL LIGHT s-——
SWITCH [6-70] (5) “all [B-5)

EXHAUST BREAK
switch [69] @) # renlcal peop —£5)- _
18 OO —-e RELAY, CHARGEYS}

waz [B25 R 038g

10338
esi serv Efe 058 4
cHODE SW;PRESSURE

[F2a}108 1
INHIBITOR SW
0 sav cy RELAY:
GAUGE, BACK VACCUM —

[ s-61ott BUZZER farsa]

iB 28 fa-78 4° BUZZER
eheee

28
BRAKE BOOSTER a)
o———t ' - 0 58
CHARGE ¥
a ———
i= .

ess}, ——-f
a

JOINT CONNECTOR
STARTER SWITCH

Co
ACC
ON
st
oo

BRAKE FLUID LEVEL SWITCH Ni

OFF

of”
oOo

PARKING BREAK SWITCH

0 aWwG
a 0/0 OFF (A/T) pe bay ae es[-+— ot tl
pO sq} 22 co
i 6272:

OIL PRESSURE GIL PRESSURE SWITCH

FY
, © BealP 0.3L8
CHECK TRANS (ArT)

a (esi f®
¢ 3)

0858

0308
?B

CLOW
KEY SW
MAIN

INHIBITOR switch [ £69]

AF SHIFT INDICATORS

ryet
H_B-7
BRACKET(LH) I]
HEADLUGHT
FLAME-LH
(CENTER)

PLABo 1 erage RELAY, TAILS)

Figure 181a. Circuit Diagram

8-156 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM - EXCEPT HBB VEHICLE

o| [8
z\[z
MILES CHECK SWITCH

ENGINE COOLANT
ob | | TEMPERATURE GAGE 4
0 3Y8 Thyelth
a OSB EAy “

FUEL TANK UNIT&SENSOR

FUEL LEVEL
dEa Th 3S . orig
B51) AB 14 pee
esl waa elk; 0.58RVA
a
te
{he 3 cs
r
FUEL GAGE L_. — — — 2a
8
oi
4 olf sue Ue O5YR Ha
' eta
— sl} 0 8B 0 Bois

és § SPEEDMETEH = lier— ppm

2
z FUSE[ F-6 ]10A el
waa poem [
en a-22|}
10
OBER [es O58 (b-s2
d]S
ws _| yas fa-aa[ 28-6 [} faa] sie
z
5 «£
TCM |B-229) (4)
aH B55] N
cE ehh BIG O.5YIG
~” & wr 3 He pee
NZL | scl saa CS
ccs BRAG a |
+> ~ VEHICLE SPEED SENSOR
FLLUMIREATING§ Sp ff _
4 Lemma OSLGIB :
RELAY TAIL(5) +1852 om 13 52] ® # ILLUMINATION CONTROLLER () ‘
osGR |
Lory O SWIG |
sal 4 DR LUNIT [S-225}¢40)
a L osRy
FUSE] F-7 {104 «UG Y— oat paunit [B 2265)
o88ais TURN-RH
a __OOBA
SBAY ae ——
TURN SIGNAL LIGHT «— fry soon b > vuse [F26] ELELTRONIC;
SWITCH (13) o sa = ® BELOW pume VACUUM PUMP
TUIRNELH ®
TURN SIGNAL LIGHT a —°{lb85 ih
switcH ['B-70} (5) 0 5G/8 (} 4
EXHAUS! BRAKE
EXHAUST BREAK
B-5: fe
IW omnes
SWITCH 5-69 @)
vad lB a pot on | te meee is—oH] e
4 ee pape es sETeH §
j
i 9 0 SW RELAY, CHARGE(2}
088
25BM. cuss [R25]

VACCUM INHIBITOR SW
a RELAY, a
B-£9] BUZZER 8g
| BURZER) ie CANSEL 3
BRAKE BOOSTER
e¢— my

—@—» .
CHARGE ¥

& 2 £
BRAKE — 5
& aq apa fa-ae]| ~“E__
STARTER SWITCH

we owe = OT, 1 8
ale g BHAKE FLUID LEVEL SWITCH 5
°18 = PARKING BREAK SWITCH g
. 0.3WIG 3 3 7
OD OFF (AT) Pat B-725 5 oot daw LINE of} i
})———— —| ae ect eie THA B20} (@)
Ol, PRESSURE OW PRESSURE SWITCH

@ 206
LHS UG BtB Ys} He ot fii
GHP CK TRANS (A/T
w Tom[ 229) (8)
0 888
38

GLOW

oy
“4,
com [B23] (6)
AMT CHL TEMP (A‘T}
za
SOA

3)
wm]Bi
Epona.
gqt
~ £ 3
=~}
SiS
s
@ soar ES}
a 9g 4 0.58
O.5RIL {Je-#8 re
AA
o
x
oO 5
53} e
& SL §a
&x seen
bq-—|
19-53
oO
e
sae 1254 iE
a= a
ie
a

z
BRACKET(LH)
HEADUGHT

FRAME-LH
FLAME-LH
(CENTER)

(FRONT)

ph vA -fega] PSO.SLG/R eA ELAY, TALL

Figure 181b. Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-157

CONNECTOR LIST

| B-272 B-52

Ey
| _——_—_——
ole
AG

a
11213 4a) 5)38
713/94 10f Vi 12
13 | v4 [15| KORUED
19 [20 [24 | [a2 | ea
2531 |[2032[33
[27 || 34} 36 | 38 | 37 |[2838]{ za] 30
39] 46

Peet

Figure 182. Connector List (1)

8-158 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

=)
fre alsis (GGT
ale fahol nialia votaaiala

Ja [Pa | [Ps|

H-70
a)

=2 Stell

Ne
mist lee

wien fe
Bio |=
wen =
a

K oe |e
S @ in
=
2

=x

3
=
Gg

7) lm bealeldl
W2
ba
34
ba
5] 6} 7] 8} 9110;

Figure 183. Connector List (2)

 CAB AND CHASSIS ELECTRICAL 8-159

DIAGNOSIS
QUICK CHART FOR CHECK POINT

1. SPEEDOMETER

ee Check point Speedometer Vehicle speed Cable harness

Trouble mode ee sensor

1-1- Speedometer and odometer do not function

: O
(3) (7)© (2)O

4-2 Speedometer does not function O

(odometer is normal) (1)

4-3 Odometer does not function O

(Speedometer is normal} (1)

4-4 Speedometer needle fluctuates O O O

(May be wide fluctuation) (3) (1) {2)

1-5 Speedometer needle jumps erratically 3 a) 3

NOTE: Figure in parenthesis "( )" indicates the order of inspection.

2. ENGINE COOLANT TEMPERATURE GAGE

ee Check point Meter Coolant temperature | Thermo | Thermo Cable

Trouble mode oo ASM gauge unit stat harness
5.4 Engine coolant temperature gage O O O O
needle does not move (3) (4) (2) (1)
9-2 Engine coolant temperature gage O O O © O
reading is too low (or high) (4) (5 (3) (1) (2)

9.3 Needle overshoots O O O O

(or goes up to the "H" range) (3) (4) (1) (2)
NOTE: Figure in parenthesis "( )" indicates the order of inspection.

3. FUEL GAGE

_ Check point Meter Fuel tank Cable

Trouble mode —_ ASM Fuel gauge unit harness
O © O O
3-1 Fuel gage needle does not move (3) (4) (2) (1)

3-2 Even when the tank is filled up with fuel, O © O O

the needle does not reach "F" (3) (4) (2) (1)

3-3 When the tank is not full of fuel, O O O O

the needle overshoots (or goes to "F") (3) (4) (2) (1)

NOTE: Figure in parenthesis "( )" indicates the order of inspection.

8-160 CAB AND CHASSIS ELECTRICAL

4, WARNING/INDICATOR LIGHT

a, Check point : Parking | Brake Oil Fuel

ae Light : Vacuum | Cable
brake fluid pressure tank
Troublemode bulb | “sw SW SW unit SW | harness
4-1 When the parking brake lever la o
is pulled, the indicator light ©) i om
does not light up. (3)

4-2 Even when the parking brake :

lever is released, the indicator fi 6
light does not go off.
4-3 While the engine operating,

O
the oil pressure warning light

O
—ho

a
does not go off.

—
—
—
4-4 Even when the tank is full with

O
O
fuel, the fuel warning light

RS
—e
_—
~~
lights up.

—
=m
4-5 Even when the tank is empty, QO

Bi O
S O
the low fuel warning light (i)
does not light up.
4-6 Even when the brake fluid is
lower than specified level, the QO

O
O

level warning light does not (1)

nm
=—>

~_
©
=
—

light up.

4-7 Even when the vacuum tank O O

is empty vacuum warning (i) (2)
buzzer does not sound. i

NOTE: Figure in parenthesis "( )" indicates the order of inspection.

 CAB AND CHASSIS ELECTRICAL 8-161

1. SPEEDOMETER

1-1. SPEEDOMETER AND ODOMETER DO NOT FUNCTION

e DOES THE VEHICLE SPEED SENSOR OUTPUT

NORMALLY?

YES co

e ARE THE CIRCUITS BETWEEN THE VEHICLE SPEED | REPLACE THE VEHICLE SPEED SENSOR
SENSOR AND THE METER, AND THE FUSE F-25 (10A)
AND THE GROUND NORMAL?

an
[ves | P |
[No

REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT IN
THE CIRCUIT

|
REPLACE THE SPEEDOMETER

1-2. SPEEDOMETER DOES NOT FUNCTION (ODOMETER IS NORMAL)

| REPLACE THE SPEEDOMETER ASSEMBLY |

1-3. ODOMETER DOES NOT FUNCTION (SPEEDOMETER IS NORMAL)

| REPLACE THE SPEEDOMETER ASSEMBLY |

 8-162 CAB AND CHASSIS ELECTRICAL

1-4. SPEEDOMETER NEEDLE FLUCTUATES (MAY BE WIDE FLUCTUATION)

e DOES THE VEHICLE SPEED SENSOR

OUTPUT NORMALLY?

Lves | [no]
THE OSCILLOSCOPE WAVEFORM IS DEFORMED

REPLACE THE VEHICLE SPEED SENSOR OR REPAIR

A POOR CONNECTION AT THE CONNECTORS IN
THE CIRCUIT OR A FAILURE IN THE CABLE
HARNESS

| REPLACE THE SPEEDOMETER

1-5. SPEEDOMETER NEEDLE JUMPS ERRATICALLY

e DOES THE VEHICLE SPEED SENSOR

= 2
OUTPUT NORMALLY?

| THE OSCILLOSCOPE WAVEFORM IS DEFORMED

|
REPLACE THE VEHICLE SPEED SENSOR OR REPAIR
A POOR CONNECTION AT THE CONNECTORS IN
THE CIRCUIT OR A FAILURE IN THE CABLE
HARNESS

|
| REPLACE THE SPEEDOMETER
 CAB AND CHASSIS ELECTRICAL 8-163

Inspection of waveform by oscilloscope

1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 8
and 1 of the meter.

2. Instail a speedometer tester.

2. Turn on the starter SW.
3. Check the waveform at the time when the vehicle speed is at 60 Km (37 mph)

Approximate battery voltage

i
av

23.6 m sec. 2V or less

Leif ana _—

Figure 184. Speedometer check

8-164 CAB AND CHASSIS ELECTRICAL

2. ENGINE COOLANT TEMPERATURE (ECT) GAUGE

2-1 ECT GAUGE NEEDLE DOES NOT MOVE

IS THE CONNECTOR OF THE ECT GAUGE SENDER

CONNECTED SECURELY?

r= DISCONNECT THE CONNECTOR OF THE ECT GAUGE

SENDER.
ra+
[ CONNECT THE CONNECTOR SECURELY

CONNECT A 3.4W BULB BETWEEN THE HARNESS

SIDE CONNECTOR 3 |E-76 |AND THE GROUND OF
THE ECT GAUGE SENDER.
WHEN THE STARTER SW IS TURNED ON, DOES THE
ECT GAUGE NEEDLE MOVE ABOUT 10 SECONDS
AFTER THAT?

YES

e IS THE ECT GAUGE SENDER NORMAL? | e 1S THE CIRCUIT BETWEEN THE ECT GAUGE AND THE
ECT GAUGE SENDER NORMAL?

a REPAIR A POOR
CONNECTION AT THE
6)
REPLACE THE ECT
GAUGE SENDER
e 1S THERE A BROKEN
WIRE IN THE PRINTED
e
NO

REPAIR A POOR
CONNECTION AT THE
CONNECTOR CIRCUIT OF THE CONNECTORS OR AN
METER ASSEMBLY? OPEN CIRCUIT IN THE
CIRCUIT

[ves|
REPLACE THE PRINTED
CIRCUIT BOARD

CHECK THE ECT GAUGE

AND REPLACE IT WITH A
CORRECT ONE IF
NECESSARY
 CAB AND CHASSIS ELECTRICAL 8-165

2-2 ENGINE COOLANT TEMPERATURE (ECT) GAUGE READING IS TOO LOW (OR HIGH)

| # DOES THE THERMOSTAT OPERATE NORMALLY? |

YES co

e TURN THE STARTER SWITCH ON | REPLACE THE THERMOSTAT

2 WHEN INSERTING AND PULLING OUT THE
THERMOSTAT CONNECTOR 3[E-76| SEVERAL
TIMES, DOES THE INDICATION OF THE ECT
GAUGE VARY?

ao
YES m
e IS THE ECT GAUGE SENDER NORMAL? | REPAIR A POOR CONNECTION AT THE CONNECTOR
OF THE ECT GAUGE SENDER

[Lo
[ves x2.
e IS THERE AN OPEN CIRCUIT IN THE METER | REPLACE THE ECT GAUGE SENDER
ASSEMBLY PRINTED CIRCUIT BOARD

[ves | 9]
| REPLACE THE PRINTED CIRCUIT BOARD

|
CHECK THE ECT GAUGE AND REPLACE IT IF FOUND
DEFECTIVE
 8-166 CAB AND CHASSIS ELECTRICAL

2-3 NEEDLE OVERSHOOTS (OR GOES UP TO THE "H" RANGE)

@ DISCONNECT THE CONNECTOR OF THE ENGINE

COOLANT TEMPERATURE (ECT) GAUGE SENDER
@ WHEN THE STARTER SW IS TURNED ON, DOES
THE POINTER REACH TO THE "H" RANGE?

L
YES te
[NO

| REPLACE THE ECT GAUGE SENDER

« 1S THERE A SHORT CIRCUIT BETWEEN THE ECT
GAUGE SENDER AND THE ECT GAUGE?

YES [No|
e IS THE PRINTED CIRCUIT OF THE METER | REPAIR A SHORT CIRCUIT
ASSEMBLY GROUNDED SECURELY?

LL
[ves |
| REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD

|
CHECK THE ECT GAUGE AND REPLACE IT IF FOUND
ABNORMAL
 CAB AND CHASSIS ELECTRICAL 8-167

3. FUEL GAUGE
3-1. FUEL GAUGE NEEDLE DOES NOT MOVE

e IS THE CONNECTOR OF THE FUEL PUMP & GAUGE

_
SENDER [J-28 ]CONNECTED SECURELY?

YES
a.
e DISCONNECTED THE CONNECTOR OF THE FUEL | CONNECT THE CONNECTOR SECURELY
PUMP & GAUGE SENDER
e CONNECT A 3.4W BULB BETWEEN THE HARNESS
SIDE CONNECTOR 1 [J-28 JAND THE GROUND OF
THE FUEL PUMP & GAUGE SENDER
e WHEN THE STARTER SW IS TURNED ON, DOES THE
FUEL GAUGE NEEDLE FLUCTUATE AFTER ABOUT 90
SECONDS?

YES

I
* IS THERE CONTINUITY BETWEEN THE FUEL e 1S THE CIRCUIT BETWEEN THE FUEL GAUGE 10
PUMP & GAUGE SENDER CONNECTOR AND 1 [J-28 |GAUGE SENDER NORMAL?
TERMINALS 1 AND 2

[ ves | “NO we ps
REPLACE THE FUEL ° IS THERE A BROKEN
PUMP & GAUGE REPAIR A POOR
WIRE IN THE PRINTED CONNECTION AT THE
SENDER CIRCUIT OF THE CONNECTORS OR AN
METER ASSEMBLY? OPEN CIRCUIT IN THE
CIRCUIT

REPAIR A POOR
CONNECTION AT THE [ve] a

CONNECTORS OR AN
OPEN CIRCUIT CHECK THE FUEL
BETWEEN THE FUEL METER, AND REPLACE IT
PUMP & GAUGE iF NECESSARY
SENDER AND THE
METER

REPLACE THE PRINTED

CIRCUIT BOARD
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 CAB AND CHASSIS ELECTRICAL 8-169

3-3 WHEN THE TANK IS NOT FULL OF FUEL, THE NEEDLE OVERSHOOTS
(OR GOES UP TO "F")

* DISCONNECT THE CONNECTOR OF THE FUEL

GAUGE SENDER
@ WHEN THE STARTER SW IS TURNED ON, DOES THE
NEEDLE STILL POINT TO "F"?

e IS THE CIRCUIT BETWEEN THE FUEL GAUGE e REMOVE THE FUEL GAUGE SENDER
SENDER AND THE FUEL METER NORMAL? * DOES THE FLOAT ARM OPERATE SMOOTHLY?

L
YES — ae

e IS THE PRINTED REPAIR A SHORT e ARE THE RESISTANCE VALUES OF THE

CIRCUIT OF THE CIRCUIT IN THE FUEL GAUGE SENDER AT "E" AND “F"
METER ASSEMBLY CIRCUIT POINTS NORMAL?
GROUNDED
SECURELY?

[ ves | NO se
REPAIR OR REPLACE | REPLACE THE FUEL GAUGE SENDER
THE PRINTED CIRCUIT
BOARD

CHECK THE FUEL

GAUGE, AND REPLACE
IT IF NECESSARY
8-170 CAB AND CHASSIS ELECTRICAL

4. WARNING/INDICATOR LIGHT

4-1 WHEN THE PARKING BRAKE LEVER IS PULLED, THE INDICATOR LIGHT DOES NOT
LIGHT UP

e DISCONNECT THE PARKING BRAKE SWITCH

CONNECTOR
e CONNECT THE HARNESS SIDE CONNECTOR TO
THE GROUND
e¢ WHEN THE STARTER SWITCH IS TURNED ON,
DOES THE INDICATOR LIGHT LIGHT UP?

YES

e iS THE PARKING BRAKE SWITCH INSTALLED

TO THE CORRECT POSITION?
=e DISCONNECT THE D.R.L UNIT CONNECTOR 2
e 1S THE BATTERY VOLTAGE APPLIED BETWEEN THE
HARNESS SIDE CONNECTOR 5 AND GROUND?

NO

* REPAIR THE POOR @ DISCONNECT THE

CONNECTION OR OPEN METER CONNECTOR
CIRCUIT BETWEEN
2 [B-225] AND 1 * CONNECT THE
HARNESS SIDE
CONNECTOR 14
[ NO TO THE GROUND
- TO ® DOES THE INDICATOR
LI l ?
| REPLACE THE D.R.L UNIT | GHT LIGHT UP

re NO |

REPAIR THE POOR REPLACE THE BULB OR

CONNECTION OR OPEN REPAIR THE POOR
CIRCUIT BETWEEN CONNECTION AT THE
YES NO 14 AND 5 [B-225 SOCKET

| ADJUST THE INSTALLATION POSITION |

e WHEN THE PARKING BRAKE
IS OPERATED, IS THERE
CONTINUITY BETWEEN THE
SWITCH CONNECTOR 1
AND THE SWITCH BODY.

0a
REPAIR OR REPLACE THE PARKING
BRAKE SWITCH
 CAB AND CHASSIS ELECTRICAL 8-171

4-2 EVEN WHEN THE PARKING BRAKE LEVER IS RELEASED, THE INDICATOR LIGHT
DOES NOT GO OFF

e 1S THE PARKING BRAKE SWITCH INSTALLED TO THE

CORRECT POSITION, AND DOES IT OPERATE
NORMALLY?

L
YES
[No |
e WHEN THE PARKING BRAKE SWITCH CONNECTOR ADJUST THE SWITCH INSTALLATION POSITION, OR
DISCONNECTED, DOES THE INDICATOR LIGHT REPAIR OR REPLACE THE SWITCH
GO OFF?
|
_ 1
ne |
@ WHEN THE D.R.L UNIT CONNECTOR jB-225
DISCONNECTED, DOES THE INDICATOR LIGHT
GO OFF?

YES
[No]
REPAIR A SHORT CIRCUIT BETWEEN 2[B-225] AND e REPAIR A SHORT CIRCUIT BETWEEN 14
1 AND 5 [B-225]OR BETWEEN 14 [B-52] AND
2[B-85 |

| REPLACE THE D.R.L UNIT |

4-3 WHILE THE ENGINE IS OPERATING, THE OIL PRESSURE WARNING LIGHT DOES
NOT GO OFF
e IS THE ENGINE OIL PRESSURE NORMAL?
|

YES co
e WITH THE OIL PRESSURE SWITCH CONNECTOR | REFER TO THE “ENGINE” SECTION
DISCONNECTED, DOES THE WARNING LIGHT
GO OFF?

co
YES
e WHILE THE ENGINE IS OPERATING, IS THERE REPAIR A SHORT CIRCUIT BETWEEN 1 [J-8 JAND
CONTINUITY BETWEEN THE OIL PRESSURE SWITCH 1 (B-52
] (METER)
CONNECTOR AND THE BODY GROUND?

NO |
| REPLACE THE OIL PRESSURE SWITCH
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HOOd V Hivd3y YO ‘81Nd SHL JOW Ids | EIWWYON LINN ANVL 7404 SHE SI a
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iNO G3NYNE V¥ SAVH LHOM ONINYVM AHL S300 *
dN LHOM LON
S300 LHDM SNINYWM 14N4 MO SH ‘ALdW3 SI YNVL TaN4 SHL NAHM N3AR S-7
LINO SNL Tanda SHL DW Id5 |
(WSLS) [6S-d] OL ONY
[82-F] Z SHOLOANNOOD JIS SSANYVH LINN WNW
TaN AHL NSIMLIG LINDYIO LYOHS V Hivdau | CTIWWHON LINN ANVL T3N4 AHL SI |
[on | S3A
2440
09 LHONM ONINYWM FHL S40 ‘G3LOaNNOOSIC
sg} [8z-r} YOLOSNNOD LINN NV. 1SN4 SHLNAHM °
dN SLHDSI1
LHD DNINYVM 14M SHL “TANS HLIM T1Nd SI ANVL T4Nd SHL NSHM NAaAS 9-7
WOlHLOI13 SISSVHO GNV GVO 221-8
 CAB AND CHASSIS ELECTRICAL 8-173

4-6 EVEN WHEN THE BRAKE FLUID IS LOWER THAN SPECIFIED LEVEL, THE LEVEL
WARNING LIGHT DOES NOT LIGHT UP

| IS THE GROUND [B-7] SECURELY? |

* DISCONNECT THE CONNECTOR OF THE BRAKE | GROUND [B-7] SECURELY |

FLUID SWITCH
e IS THERE CONTINUITY BETWEEN THE SWITCH SIDE
CONNECTOR TERMINALS?

YES [L. .
@ 1S THE FITTING CONDITION OF THE WARNING LIGHT REPAIR THE SWITCH, OR REPLACE THE BRAKE
BULB AND THE SOCKET NORMAL? FLUID TANK

[ves [No
REPLACE THE BULB, OR SECURELY FIT THE
SOCKET

REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
THE BRAKE FLUID SWITCH HARNESS SIDE
CONNECTOR 2 [B-85|AND 14[B-51|

4-7 EVEN WHEN THE VACUUM TANK IS EMPTY, VACUUM WARNING BUZZER DOES
NOT SOUND

« IS VACUUM SW NORMAL?

e IS THERE BATTERY VOLTAGE APPLIED BETWEEN 1 | REPLACE THE SWITCH

AND THE GROUND WHEN STARTER SWITCH
IS ON POSITION?

L
YES NO |

REPLACE THE WARNING BUZZER INSTALLED ON REPAIR A POOR CONNECTION AT THE

THE METER ASSEMBLY CONNECTORS OR AN OPEN CIRCUIT BETWEEN
11[B-51] AND 1
8-174 CAB AND CHASSIS ELECTRICAL

STARTER SWITCH EXHAUST BRAKE SWITCH

Refer to "START AND CHARGING’ in this Refer to "ECM" in this section.

section.

TURN SIGNAL LIGHT SWITCH

Refer to "TURN SIGNAL LIGHT, HAZARD
WARNING LIGHT AND STOPLIGHT" in this
section.

METER ASSEMBLY
LAYOUT FOR GAUGES, WARNING,
INDICATOR AND ILLUMINATION LIGHTS

Warning / indicator lens 1

‘, \

\ \
‘se
A
(— Speedometer
2 > YP =) |

Q *" eeEEacEE
9

Coolant temperature gage A/T shift indicator

Warning / indicator lens 2

Ee 20 > was)
Casi ft oe A

Warning / indicator lens 3 for CANADA DIESEL FUEL ONLY

& 2 » Ve wee OO |
cae@) | Be
(20) Fuel gage
(For M/T)
Speedometer for CANADA

Warning / indicator lens 4 for CANADA

¢ 0 OO ABS
caen@ BM

Figure 185. Meter Assembly Layout

 CAB AND CHASSIS ELECTRICAL 8-175

BULB LOCATION FOR WARNING LENS

©)
S27;| | BRAKE i! =O | [BAe] | phd} | 92
| | |
\ | |
O | |
az ——\——
aoe ——
eel

be

OSE, 98060096
poy, Thea Py - :
/| / | /
| [2] [>| fa [faa] [oo] [ans

Figure 186. Bulb Location for Warning Lens

8-176 CAB AND CHASSIS ELECTRICAL

TABLE FOR METER CONNECTOR TERMINAL CONNECTIONS

O
TTT as

eooeeee

@eeeeee *

@90900Q00
r
'

io
t
‘

200000008 °4
‘
t

[Bes
Terminal Connected to Tomminal Connected to

1 _ 6 A/T Shift indicator D

2 Ground 7 _
3 A/T Shift indicator P 8 A/T Shift indicator 2
4 A/T Shift indicator R 9 A/T Shift indicator 1
5 A/T Shift indicator N 10 illumination (-+)

[251 | [ 8-55 B52

Terminal Connected to Torin Connected to Tominal Connected to

4 EXH BRAKE 1 Speed pulse input 1 Oil pressure

2 A/T Oil temp 2 Speed pulse out-put 2 Buzzer
3 _ 3 Speed sensor (+) 3 Charge
4 _ 4 ECT unit (GAGE) 4 D.R.L
5 Check trans 5 Fuel tank unit (GAGE} 5 IHlumination (+)
6 Glow 6 _ 6 -
7 ABS 7 Ground 7 lilumination (—)
8 IGN (+} 8 Turn signal (LH) 8 —
9 O0/D OFF 9 Beam (—) ”
10 FUEL TANK UNIT 10 Beam (-+} 10 Ground
11 Booster 1 Turn signal (RH) 1 _

12 - | 12 - 12 | 48
13 _
14 Brake ECT - Engine Coolant Temperature

Figure 187. Meter Connector Terminal

 CAB AND CHASSIS ELECTRICAL 8-177

[es] Remove or Disconnect (Figure 188, 189, 190) x Install or Connect

Preparation: Disconnect the battery ground To install, follow the removal steps in the reverse
cable order.

1. Meter cluster SPEEDOMETER (Figure 191)

2. Meter assembly
Remove the five screws.
Disconnect the meter connectors.

. Q ' Geseesaea8)
See een ee
\ :
\ ‘ Trip and
odo meter
N knob.

Figure 1941. Speedometer

1. Meter Cluster
The speedometer is made up of the cross coil
Figure 188. Meter Cluster Removal type ammeter (movement) that cisplays indications,
the stepper motor that drives and adds up the
odometer and trip meter, and the driving circuit
{printed circuit board) that makes exchanges
between the pulse signals and the current.
Odo meter alternates with trip meter by pushing
knob.

ON-VEHICLE SERVICE
Check the meter display accuracy and the
operation of the odometer with the speedometer
tester.

Meter display
2. Meter Assembly
Tester display speed parmissible level
Figure 189. Meter Assembly Removal 20 MPH 18.3 — 21.7 MPH
40 38.3 — 41.7
60 58.3 - 61.7
80 78.8 — 82.8

NOTICE: Inappropriate tire inflation may affect

the accuracy of the odometer.
(To conduct this test, refer to the tester
manufacturer's instruction manual.)
Since the meter display permissible levels
above are specifications solely for the meter,
they are to be used as reference values when
conducting on-vehicle service.

Figure 190. Meter Connector Disconnection

8-178 CAB AND CHASSIS ELECTRICAL

Inspect (Figure 192)

Remove the speedometer from the meter
assembly and measure the resistance and the
current consumption between each terminal.
Replace the speedometer when the result of
inspection is found abnormal.

SENSOR 4Pulse output GB

Tembal Resistance value

IGN-GND 58 + 20k

SEN-GND 70 + 20kQ

4P-GND oo

Figure 192. Speedometer Check

 CAB AND CHASSIS ELECTRICAL 8-179

COOLANT TEMPERATURE GAUGE

CIRCUIT DIAGRAM

Coolant temperature gauge

Thermo unit

Figure 193. Circuit Diagram

inspect

Remove the coolant temperature gauge from the

meter assembly, and measure the resistance value
between each terminal (figure 194).
Replace the coolant temperature gauge when the
result of inspection is found abnormal.

IGN GND UNIT

Terminal symbol Resistance value

IGN — UNIT 55Q + 20%

UNIT — GND 2250 + 20%

IGN — GND 2800 + 20%

Figure 194. Coolant Temperature Gauge Check

 8-180 CAB AND CHASSIS ELECTRICAL

[+>] Remove or Disconnect (Figure 195)

Preparation:Disconnect the battery ground

cable

1. Meter assembly
Refer to "METER ASSEMBLY’ in this section.
2. Meter glass
Remove it by pushing the catches with your
finger.
3. Meter plate 1. Meter Assmbly
Remove it by pushing the catches with your 2. Meter Glass
finger. 3. Meter Plate
4, Coolant Temperature Gage
4. Coolant temperature gauge
Remove three screws securing the meter at the
back side. Figure 195. Coolant Temperature Gauge Removal

| Install or Connect

To instail, follow the removal steps in the reverse

order.

FUEL GAUGE

CIRCUIT DIAGRAM

Fuel gauge

IGN SIO.

}
\, NAA Fuel tank unit

+090 -

- 9

Figure 196. Circuit Diagram

Inspect (Figure 197)

Remove the fuel gauge from the meter assembly,
and measure the resistance value between each
terminal.
Replace the gauge when the result of inspection
is found abnormal.
 CAB AND CHASSIS ELECTRICAL 8-181

UNIT GND IGN

Terminal symbol Resistance value

IGN — UNIT 902 + 20%

UNIT — GND 155Q + 20%

IGN — GND 245Q + 20%

eq LLL
Figure 197. Fuel Gauge Check

[es] Remove or Disconnect (Figure 198) WARNING LENS

Preparation:Disconnect the battery ground [+9] Remove or Disconnect (Figure 199)

cable
Preparation: Disconnect the battery ground
cable
1. Meter assembly
Refer fo "METER ASSEMBLY’ in this section.
1. Meter assembly
2. Meter glass
Refer to "METER ASSEMBLY’ in this section.
Remove it by pushing the catches with your
2. Meter glass
finger.
Remove it by pushing the catches with your
3. Meter piate
finger.
Remove it by pushing the catches with your
3. Meter plate
finger.
Remove it by pushing the catches with your
4. Fuel Gauge finger.
Remove screws securing the gauge at the back
4. Warning lens
side.
[oe] install or Connect

To install, follow the removal steps in the reverse

order.

. Meter Assmbly
. Meter Glass
WN

. Meter Plate
. Fuel Gage

1. Meter Assmbly ‘
2. Meter Glass a
Figure 198. Fuel Gauge Removal 3. Meter Plate
4. Warning Lens

Figure 199. Warning Lens Removal

8-182 CAB AND CHASSIS ELECTRICAL

WARNING LIGHT BULB, INDICATOR Inspect (Figure 202)

UGH BULB AND ILLUMINATION LIGHT
ULB 1. Connect the connector terminal 1 to the
battery (+) terminal and connect the connector
| Remove or Disconnect (Figure 200) terminal 2 to the battery (~) terminal.
2. Connect a resistance of 1.3 kQ between
Preparation: Disconnect the battery ground
connector terminal 1 and connector
cable
terminal 3 [J-32].
1. Meter assembly
CAUTION: Be extremely careful not to connect
Refer to "METER ASSEMBLY" in this section.
the battery (+) terminal to the connector 3 [J-32].
2. Socket and bulb
This may damage the vehicle speed sensor.
Hold the bulb socket by hand and rotate it
counterclockwise to remove them from the
3. Rotate the shaft of the vehicle speed sensor
meter body.
slowly and measure the voltage between 3
3. Bulb
<A and 2 with a digital tester or
Pull out the bulb from the socket.
oscilloscope.

Check the output is more than 12.5V and less than

1.5V.

Replace the sensor when the result of inspection

is found abnormal.

(2)
Figure 200. Bulb Removal

x Instali or Gonnect

To install, follow the removal steps in the reverse

order.

VEHICLE SPEED SENSOR

The vehicle speed sensor is installed on the rear
portion of the transmission or transfer case.
The number of pulses generated is four pulses
per one rotation of the pinion shaft.

Figure 202. Vehicle Speed Sensor Check

[es] Remove or Disconnect (Figure 203)

Preparation: Disconnect the battery ground

cable

1. Vehicle speed sensor

Disconnect the connector.

Figure 201. Vehicle Speed Sensor

 CAB AND CHASSIS ELECTRICAL 8-183

Figure 203. Vehicle Speed Sensor Removal

foe] install or Connect

1. Tighten the vehicle speed sensor to the

specified torque.

Vehicle speed sensor torque N-m (lb-ft)

25 (18)
Figure 204. ECT Gauge Sender Check
CAUTION: Tightening must be made at the
hexagonal part of the sensor. OIL PRESSURE SWITCH
To tighten the connector itself would cause
damage. inspect

ENGINE COOLANT TEMPERATURE (ECT) Check the continuity between the switch terminal
GAUGE SENDER and the body ground with the starter switch is OFF
position (figure 205). Replace the switch when the
inspect result of inspection is found abnormal.

Measure the resistance between the sender

terminal and ground (figure 204).

Temperate on 50 (130) | 115 (239)

Resistance (Q) 226 24-29

NY iS

Figure 205. Oil Pressure Switch Check

Circuit Inspect (Figure 206)

1. Start the engine
2. When disconnecting the oil pressure switch
connector when connecting the harness side
connector to the ground, check to see if the oil
pressure warning light lights up. When the light
will not light up, check the circuit between the
meter and the oil pressure switch, and repair an
open circuit if necessary.
8-184 CAB AND CHASSIS ELECTRICAL

build-in switch type to warn the driver of low fuel

level (about 5 liters left in the tank) by illuminating
the fuel warning light.

Figure 206. Circuit Check

FUEL GAUGE SENDER (Figure 207)

Figure 207. Fuel Gauge Sender
The tank unit varies the internal resistance g g de
according to the float position (fluid level) to
operate the fuel meter needle. Also availabie is the

& *

Inspect (Figure 208) 2. Check if the low fuel warning switch turns on
(Level Switch type of warn low fuel level) and off at the specified positions. If found
defective, replace the fuel gauge sender.
1. Check the resistance between the connector
terminals 1 and 3 while shifting the
float from “E” to “F” point.

{|
ws
\
2.8in(7 2.0mm)

\. mA
6.9in(244.1mm)

E
E
6

=
§ Float Resistance
8 : Position value (0)

7 342.1
32.5448
110 + 7.7

Float ‘
4 1.2 in
Low fuel level warning switch (29.3 mm)

Figure 208. Fuel Gauge Sender Check

 CAB AND CHASSIS ELECTRICAL 8-185

28 in(72.omm)
9.6in(244.1mm)
16.5in(420.0mm)}

Float Resistance
Position value (Q)}
F 3+ 2.1
1/2 32.54 4.8
E 1047.7

OAin
. (9mm)

™N. OFF
ESA EH
4
on
/ Lain
Float {29.3mim}

Low fuel level warning switch

Figure 209. Fuel Gauge Sender Check

| Remove or Disconnect (Figure 210)

Preparation: Disconnect the battery ground

cable

1. Fuel gauge sender

* Disconnect the connector.
« Remove five screws.

1. Fuel Gauge Sender

Figure 211. Fuel Gauge Sender Removal

| Install or Connect

To install, follow the removal steps in the reverse

order.

1. Fuel Gauge Sender

Figure 210. Fuel Gauge Sender Removal

 8-186 CAB AND CHASSIS ELECTRICAL

VACUUM SWITCH
[oe] install or Connect (Figure 212)

When the pressure value is below 250 + 30mm

Hg (33.3 + 4.0 kPa), check to see if there is
continuity between the terminal and the ground. If
no continuity, replace the switch with a normal one.

Figure 212. Vacuum Switch Check

[+9] Remove or Disconnect

Preparation: Disconnect the battery ground

cable

1. Vacuum switch
« Disconnect the connector.
*» Remove the vacuum switch.

[+s] Install or Connect

Apply liquid gasket to the screw portion of the

switch to prevent vacuum leak.
 CAB AND CHASSIS ELECTRICAL 8-187

VACUUM WARNING BUZZER Inspect

Inspect 1. Confirm there is continuity between the switch
connector terminals when the brake fluid in the
Apply battery voltage to the buzzer connector
tank is between 60 — 75 cc level.
terminals to check the buzzer sound.
2. Turn the switch on, disconnect the brake fluid
Replace the buzzer when the result of inspection
switch connector and connect the harness side
is found abnormal.
connector terminals.
| Remove or Disconnect (Figure 213) Then confirm that brake warning light turns on.
lf found defective, replace the tank, or repair a
Preparation: Disconnect the battery ground poor connection or an open circuit between the
cable connector terminals.

1. Meter assembly | Remove or Disconnect (Figure 215)

Refer to "METER ASSEMBLY’ in this section.
Preparation:Disconnect the battery ground
2. Vacuum warning buzzer
cable
« Disconnect the connector.
* Remove the buzzer fixing screw.
1. instrument panel assembly
Refer to "INSTRUMENT PANEL" of section 10D
"STEEL TILT CAB".
2. Brake fluid tank (Brake fluid switch)
» Disconnect the switch connector.
* Remove four fixing nuts.
* Drain brake fluid in the tank.
« Disconnect the tubes.
SSEG00oa0000
( seeccgccs tt CAUTION:Be very careful not to allow the brake
fluid to come in contact with painted surfaces or
resin parts surfaces.
1. Meter Assmbly Os °
2. Vacuum Warning Buzzer

Figure 213. Vacuum Warning Buzzer Removal

be] install or Connect

To install, follow the removal steps in the reverse

order.

BRAKE FLUID SWITCH

1. Instrument Panel Assembly

2. Brake Fluid Tank (Brake Fluid Switch)

Figure 215. Brake Fluid Switch Removal

| Install or Connect

To install, follow the removal steps in the reverse

order, noting the following points.

1. Bleed the air from brake and clutch fluid pipe

line.
2. Check to see if the brake fluid level in the tank
Figure 214. Brake Fluid Switch
with-in specified level.
3. Check to see if brake warning light comes on
when starter switch is turned on and then
warning light go off after the engine running.
8-188 CAB AND CHASSIS ELECTRICAL

PARKING BRAKE INDICATOR LIGHT

Parking brake lever
The parking brake indicator light is connected in
series with the parking brake switch installed to the Parking brake
parking brake lever bracket. switch
The light comes on when the parking brake lever
is pulled, and goes out when the parking brake
lever is fully released.

NOTICE: The parking brake indicator light

iltuminates to warn the driver that the parking
brake is on. This light does not indicate the
condition of the operability of the parking brake.
Figure 217. Parking Brake Switch Check
Circuit inspect (Figure 216)

1. Disconnect the parking brake switch connector. [+>] Remove or Disconnect

2. Connect the harness side connector terminal to
Preparation: Disconnect the battery ground
the ground.
3. Check to see if the indicator lignt comes on with cabie
the starter switch "ON".
1. Parking brake switch (figure 218)
Check the bulb or the harness when the result
+ Disconnect the connector.
of Inspection is found abnormal.
* Remove the fixing screw.

Parking brake lever

{ Connector

Figure 216. Circuit Check 1. Parking Brake Switch

Figure 218. Parking Brake Switch Removal

PARKING BRAKE SWITCH
[oe] Install or Connect
inspect (Figure 217)

1. Disconnect the parking brake switch connector. To install, follow the removal steps in the reverse
2. Check to see if there is any continuity between order.
the switch terminal and the body ground with
the circuit tester connected between them.

When parking brake applied Continuity

When parking brake released No continuity

Repair the parking brake switch or replace it

when the result of inspection is found abnormal.
 CAB AND CHASSIS ELECTRICAL 8-189

VACUUM PUMP
Inspect (Figure 219)
Connect the vacuum pump connector terminal
No.1 to the battery (+) terminal and No.2 to the (-)
terminal and then check vacuum pump function.

O o-
- +
1. Instrument Panel Cluster
2. Meter Assembly
3. Vent Duck
4. Side Defroster Nozzle

Figure 220. Meter Assembly Removal

Figure 219. Vacuum Pump Check

[+9] Remove or Disconnect (Figure 220, 221, 222)

Preparation: Disconnect the battery ground
cable

1. Instrument panel cluster

* Release seven locks at back side of the
instrument panel cluster.
2. Meter assembly ~ §.Stiffener "Vacuum punp
Vee
* Remove five screws.
3. Vent duct Figure 221. Stiffner Removal
» Remove antenna cable from the clips.
4. Side defroster nozzle
5. Stiffener (figure 221)
6. Vacuum pump with bracket
* Disconnect the connector and vacuum pipe.
* Remove three bolts.
7. Vacuum pump (figure 222)

7. Vacuum Pump

Figure 222. Vacuum Pump

8-190 CAB AND CHASSIS ELECTRICAL

HEATER, AIR CONDITIONING,

CONDENSOR FAN AND CERAMIC
HEATER (M/T VEHICLE ONLY)
GENERAL DESCRIPTION
The air conditioning circuit consists of A/C When Fan Contro! Knob (Fan Switch) is put on with
compressor, condenser fan, A/C switch, fan switch, Temp.Control Lever being in the “FULL HOT”
blower motor, pressure switch, electronic position (FULL HOT Switch on) Ceramic Heater
thermostat and blower resistor. When the engine is within Heater Unit generates heat, raising a heater
running, the A/C starts to work with both the A/C blow-off temperature to enhance heating
and fan switches "ON", followed by the engagement performance.
of the magnetic clutch of the A/C compressor. It
stops to work when either the fan switch or the A/C
FULL HOT Switch OFF.
switch turns "OFF". In addition, the A/C system has
the function of temporary stop of its operation by
, ON
function of the pressure switch when sensing
abnormal rise of the refrigerant pressure in the Fan Switch OFF,
system.
+ ON
Thermoswitch (Engine)
(CON” with engine OFF
coolant temp. being
80°C or lower)

ON
Ceramic Heater “ON” Ceramic Heater “OFF”
 RELAY BOX ASM (No. 1)

\ B-21 HEATER & A/C RELAY

B-37 A/C THERMO RELAY B-39 A/C SW
PARTS LOCATION

\ B-25
FUSE BOXASM \ DIODE
F-1, F-2 \

\
B-14 BLOWER ‘oro /

B-15 ELECTRONIC
THERMOSTAT ~
B-i3 BLOWER RESISTOR,
RELAY BOX ASM (No. 2)
H-31-—7—

Figure 223. Parts Location

B-13477
a WT <.
B-272 JOINT CONNECTOR, BATTERY
P-3
CONDENSOR FAN Xx é \ \
FL-1, FL-3, FL-5 FUSIBLE LINK

RELAY BOX ASM

J-17 RELAY;CONDENSER FAN
J-14 RELAY;CERAMIC HEATER
CAB AND CHASSIS ELECTRICAL 8-191
 RELAY:
RELAY:ENGWARMCUT [J-15]6) ~« M/T VEHICLE ONLY CERAMIC HEATER

3W/G
THERMO SWITCH
[FL-3] 60a F-22] 20a
GLOW 1.25B/L CONDENSOR
ee FAN

RELAY; RELAY;
RELAY; A/C THERMO CONDENSOR FAN
HEATER & A/C [F-2] 104
CIRCUIT DIAGRAM

FL-4 80A ® irae Wasa 0.856)

MAIN 3L eae
BW, SW 2 °at : oO O.86GAW ES Oo
—
RELAY: [F-1] 25a B37t- 90 8-37]
CHARGE (5} HOO 4 HEATER

S0BL
obo

0.5BR
Ine

0.5G/V

0.5P/G
G-4

PRESSURE SWITCH
3G

0.5B
|
O.85t

=
=
=hm
8-192 CAB AND CHASSIS ELECTRICAL

0.85G/0
EI
losGay fell

FRAME B-14,
osc

AIC SWITCH
CONDENSOR FAN

MAGNETIC CLUTCH
a «[e]
IE!

ELECTRONIC THERMOSTAT

{COMPRESSOR}
O5GNY
0.58

Figure 224, Circuit Diagram

3Wi/G

0.5G/W
8
CERAMIC HEATER

0.85B
lel

4 OFF
2B

[B-272] JOINT
FAN SWITCH
CONNECTOR
HEADLIGHT 3B ft le
S]]s_0.5G/¥ [s]|-__0.5GV

BRACKET (LH) I/-—-Le-7t

38

FRAME-LH (CENTER) tI [2 }
' INSTRUMENT PANEL
! REIN FOR CEMENT iI {e139}
t
 CAB AND CHASSIS ELECTRICAL 8-193

CONNECTOR LIST

B
ms
Le
|

(eae) (as)
4 T

10/11] 92{13[14

Figure 225. Connector List

8-194 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

J-14 H-31

[=]
7) &
<_|
oO
e
(MBP T/M)
|
Los)
|

G&&
(MXA T/M)

—_—
IFIEIES
5/6i7/8

Figure 226. Connector List

 CAB AND CHASSIS ELECTRICAL 8-195

SERVICE TERMINAL
GENERAL DESCRIPTION
The circuit consists of the starter switch, power The service terminal connector is provided for
source relay and the connector for the service installation of optional equipment (S). This circuit
terminal. incorporates a 20A fuse. Make sure that the total
current of all installed parts does not exceed 20A.

STARTER SWITCH
OFF. 5

BATTERY (+) ~« os
fl ACC - ON

barren YO rn
FUSE (20A)

: £ POWER SOURCE
e RELAY

SERVICE {
TERMINAL

ES =

i 1 ' OPTIONAL
f EQUIPMENT (S)
(TOTAL ALLOWABLE
| ' CURRENT : 20A )

NOTE : Arrow marks " ==> " indicate the direction of current.

Figure 227. Service Terminal Circuit

 PARTS LOCATION

FUSE BOX ASM F-15,F-16

B-159 SERVICE TERMINAL
\ STARTER SW
8-196 CAB AND CHASSIS ELECTRICAL

RELAY BOX ASM (No. 2)

B-272 JOINT CONNECTOR

Figure 228. Parts Location

E
x
>

ai

RELAY BOX ASM

FL-1, FL-2, FUSIBLE LINK

 CAB AND CHASSIS ELECTRICAL 8-197

CIRCUIT DIAGRAM

STARTER SWITCH
OFF
FL-1] 80A BOA
ga «MAIN KEY SW : / Lf ACC | fip-67/4
| 2

4
“
=
wo
OF O
awe Uap H-7
He B-67
one
@ O ST

ip} 2
H-6 —_t
oS

=i

+dtto+
p

3
=O+}0= 20A
[F-16] 20a RADIO,
| POWER SOURCE CIGAR LIGHTER

Pelt >
FRAME 8
o

a
uty
“
a 0.5R/Y

5 2

B-34 B-34

RELAY;
° POWER SOURCE
B-34

1
Es B-34

4
z|
its)
§
=

oO
3 3

=
5Oo
«c
wo
N

6 '
= =

B-159 r-
S
4
3
on
SERVICE TERMINA 3 a
(POWER SOURCE) ca N
°
A
i
Q

<< a
o uu
E
a
8 <
4 | (8-272 oSO
JOINT CONNECTOR
2

HEADLIGHT BRACKET (LH) i] }—38—

—{ 6-7

Figure 229. Circuit Diagram

8-198 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

12 H-7 zit

1472/3 }4 4}3i2i1
bie17 |s O17 (eis
3) it 11S
£ u H-8
7] 1

Figure 230. Connector List

 CAB AND CHASSIS ELECTRICAL 8-199

ANTI-LOCK BRAKE SYSTEM

(ABS)
GENERAL DESCRIPTION

The Anti-lock Brake System (ABS) works on all four and adjust brake pressure to maintain best braking.
wheels. A combination of wheel speed sensor and This system helps the driver maintain greater
Electronic Brake Control Module (EBCM) can control of the vehicle under heavy braking
determine when a wheel is about to stop turning conditions.

10

baer ee enn

bw ean may
Seen

Figure 231. ABS Circuit

Legend
(1) Hydraulic Line (7) Load Sensing Proportioning Valve (LSPV)
(2) Electronic Line (8) Battery
(3) Electronic Brake Control Module (EBCM) (9) ABS Warning Light
(4) Front Whee! Speed Sensor (10) Brake Switch
(5) Rear Wheel Speed Senser
(6) Hydraulic Unit
8-200 CAB AND CHASSIS ELECTRICAL

PARTS LOCATION

5 te
=
2 5
uw Q
” 5
<
i
va

-z
ra

a>
é
3
a
:=
~
za.
” =< a
WT) a = O
a 5
re roo
Li = UW O
Cc
FecGa =
e
s Oe H cz
62D a
+ mM & ><
> F i >
Si On
ee Or <
— Ow
1 orn
xr eo4tm

=
“
oS a
@o i
45
am

B-7
ze Oo
Ww k-
ef z=
xz B-67
O
©
oO
~ =
wo Q
Yo wn
ce —
t v
o co
w
Le
5ma 2uw. cc
wo
O ip
O
& os
ee
©
LL. o~ =
il Ls
OH
>

UL '
o
O
z
z

= oO x oO ov
E a) 2 Foc
<x onmo Zz uu Aa
o O t ©
Oo 4 oc ©
a So
7 a u. a
1]
a~— aa nir Ni
ao a]
LL.

Figure 232. Parts Location

 CAB AND CHASSIS ELECTRICAL 8-201

MEMO
8-202 CAB AND CHASSIS ELECTRICAL

CIRCUIT DIAGRAM

BOA
ABS SWiL
STARTER SW

ab BoA —[FL-2] 0A OFF Won

1 2 ACC
ae No BNO 8 [¥-7}- 242 Ip-eq}18 a [e-67}
3 38h
GAUGE, . BACK
= ON

2 Oo” st
a |
3 258
(Paj} | (P:3)
(P-2]
z
Bley

108
®) STOP LIGHT
_ ABS(BAT) 1.25W/G >

3 —-
eAL Te
fz a
E 6-51
=
== 28 =z
FRAME e 1 512
= 9
& [pe g

S
Zz =

sy
=QO g< im
og
=9g g= <q |8-51
gg
=Oo Qg=

zz <
5s

e5lo Bool jg) nN

«
N "
=
“
= iw= __
a
x.
z 2
g « 5 O.SY
7 w °

Zz w p13 (5-113) >

a2 =
= ag = S
g
oS
é zg Ls
M
5 y 26_|25 [24 113 | 12 16 3 14
a 6-110] [6-109] |B-1 709] [8-170] [5-110 [B-11 B-11 B-109
o
” EBCM EBCM

6-11 B-
10
EXH:BRAKE SW

@
a
° g”
Qo
o
%2
x
0 —-}-—--— >

2||a79 ;
5
3} [B70] [679 &aly fe
si4
NN,

E
Ts ~

5%
az

i
ae
2 2 x=
o o Ed B36 Bx
4 3
+-v$rc-Ccor 2 =

3 2
8 3
i

# iz]

B-272| _17 8 ¥
[t———+] 2
ae

JOINT CONNECTOR 2
ose
HEADLIGHT 11 {6-7 3B
BRACKET(LH)

Figure 233a. Circuit Diagram

 CAB AND CHASSIS ELECTRICAL 8-203

HYDRAULIC UNIT

SOLENOID VALVE
RELAY MOTOR RELAY

2k
<
Ss
2

%ua

RL AR

SPEED SENSOR

-272
JOINT CONNECTOR
HEADLIGHT H 8-7
BRACKETILH)
FRAME-LH |} 11 5-9
(CTR)

Figure 233a. Circuit Diagram

8-204 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

Ca |2]3[4]5]6]7] ag olin para

r nS El ri Lp

B-79 [3-109 [B-110]

ennenee
Chl ae
iTetss'stel78]
TI
V12}314/5]
617] 8) 9) 10] 49/12 HEBBE 8} 9|to|lr4
Wo oni papatansre

a
ty
NE 13|) 14/15) 16)17/ 18/19] 20)21

[|
tp2{3)4
S617 18) 9h
10| 11] 12} 13/14

Figure 234. Connector List

 CAB AND CHASSIS ELECTRICAL 8-205

POWER WINDOW
GENERAL DESCRIPTION
The circuit consist of the starter switch, power the window.
window switch for each of the windows and power The driver’s power window switch has a built-in
window motor. one-touch operating circuit which allows to
When the starter switch is turned on, the battery automatically open the window by operating the
voltage is applied to each of the power window switch to the AUTO position.
switches through the circuit breaker and the power When the driver's power lock switch at the driver
window relay on the circuit. side is depressed, the power source to the
By operating the switches of each window to passenger's power window switches will be shut off
select “UP” or “DOWN”, the revolving direction of and passenger’s side power window motor will not
the power window motor changes to open or close operate if the switch is operated.

OPERATION OF PASSENGER SIDE WINDOW

By power window sw By power window sw.

- Passenger side ~ Driver side

Battery(+} Battery{+}
L }

eS
Power window sw. ~ Oriver side yh Power window sw. - Driver side

fr . =

|
Driver
side
1) sw
|, Tet To
Lack sw.

Passenger
side sw. \
, a
; Verte] L
| ="tidesw. || af
Up Down Up Down

ye (

Passenger Passenger
side sw. side sw.

NOTE: Arrow marks “c———7>” indicate the direction of current

Figure 235. Operation of Passenger Side Window

 RELAY BOX ASM (No. 2)
FUSE BOX ASM
B-307 POWER WINDOW RELAY

\ STARTER SW
D-7 POWER WINDOW SW (RH)
PARTS LOCATION

\
D-3 POWER WINDOW SW (LH)
| “ m

| _
8-206 CAB AND CHASSIS ELECTRICAL

H-2 S \ bs

4 F-26 QX

Figure 236. Parts Location

8-272 JOINT CONNECTOR

RELAY BOX ASM

FL-1, FL-2 FUSIBLE LINK

D-2 POWER WINDOW MOTOR (LH)
CAB AND CHASSIS ELECTRICAL 8-207

(HY) {H1?
YO.LOW MOGNIM H3MOd YOLOW MOGNIM HaMOd
HOLOANNOD iNiOr[2Zz-4]
NMOG dn NMOQ an oe HHI ons) Haus
—_ —
= | {ea}hr (H) izowus LHOMavaH
za zo
z t
< zg} 8
== = a=
28

wn
=
2B

6
a
2 z ‘
2S _fea]_feal

Figure 237. Circuit Diagram

= NAAOG afi
6
aQ
ye ay q 4
6 ec
a
=
18
~
ot: 1 Ti
tH} [ie] 1 i
aa a (TR TDN)
6 «
pie

w
N
ot

w
N aH
1,25L/B

= Ed
on LINDHID OLN
NMOG an z=

2B
ons He 2. a 8
°
’
ox
Qf
Ze
2
6
@
[2 ~ol
fs —
jo;o;o;9 =
sa fz PhOhI ui
[eal | |
(eal | j Ea)

0.38
Ss + OTTO +
3
Lamy
MS 3001 MOGNIM §
ed
—) NIV
MESO, _N8E_oal a voe [t-13]
CIRCUIT DIAGRAM

a
{H7) MS MOGNIM YaMOd > wove & NOY Paletk
Tz-u| a 390nvo_ 59
TLRY a/1sz't S vot [32-3] fi
#3
MS HALYVIS
Taz
‘pao MOQNIM Y3MOd
A aE we me
MOGNIM YAMAOd ‘AW144 vaz 2-4]
8-208 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

ca rar] [ear]

=O oe!) Bsiee cep

Ne

~
a
a
~~

oe

Figure 238. Connector List

 CAB AND CHASSIS ELECTRICAL 8-209

DIAGNOSIS
QUICK CHART FOR CHECK POINT
Power window | Power window
Check point! Fuse Fuse | Power SW motor Cable
F-25 F-26 | window) —”. .
Trouble mode — (0A) (25A) relay Driver Passen- Driver Passen- harness
side jigerside; side | ger side

. O O O © O
All windows do not operate
per am | @ | @~ Fe) (4)
Lock SW does not function oy

Driver side window

Window does not operate % 5

One-touch operation does not O

operate (1)

Window operates in only one O

direction (1)

Front passenger side window

Window does not operate ry oy 3

Window does not operate when O O

operating the driver side SW (1) (2)
Window does not operate when O O
operating the passenger side
SW (1) (2)
Window operates in only one oO O
direction when operating the 3
driver side SW (1) (2)
Window operates in only one O O
direction when operating the (2) 4
passenger side SW ° (1)
NOTE: Figure in parenthesis “( )" indicates the order of inspection.
8-210 CAB AND CHASSIS ELECTRICAL

ALL WINDOWS DO NOT OPERATE

¢
| ¢ 1S FUSE F-25 (10A) NORMAL?

YES

[ * IS THE FUSE F-26 NORMAL? | | REPLACE THE FUSE

YES Le
1,

[ » 1S THE POWER WINDOW RELAY NORMAL? | REPLACE THE FUSE

T oe
e |S [B-7] SECURELY GROUNDED? | | REPLACE THE RELAY |

a Ce
GROUND | IT SECURELY |
DISCONNECT THE POWER WINDOW SW CONNECTOR
ON THE DRIVER SEAT SIDE
e TURN THE STARTER SW ON
e IS THE BATTERY VOLTAGE APPLIED BETWEEN THE
HARNESS SIDE CONNECTOR 6 [D-3] AND THE
GROUND

YES O70°
e IS THE POWER WINDOW SW ON THE DRIVER SIDE REPAIR A POOR CONNECTION AT THE
NORMAL? CONNECTORS OR AN OPEN CIRCUIT BETWEEN
6 [D-3] AND 5 [B-307

YES

e IS THE BATTERY VOLTAGE APPLIED BETWEEN | REPLACE THE SWITCH |

AND THE GROUND?

ae
No |

REPAIR A POOR CONNECTION AT THE

CONNECTORS OR AN OPEN CIRCUIT BETWEEN
8 [D-3]
AND [B-7]
 YSMOd ONY [€-d] | SIVNIWYSL YOLOANNOOD
HYOLOW JdIS SSANYVH N3SMLIG LINDYIO NddO NV HO
MOQCNIM Y3SMOd 3HL 39V1d3Y HO YIWd3y SHOLOSNNOD 3H1 LW NOLLOANNOSD YOOd V ulvd3u
L
| “ON | SAA
EMOQUNIM
3HL JO NOLLOSYIO .NMOG. AHL NI 3LVLO"
YOLOW 3H. S300 “IWNIWYAL (-) SHL O. [2-d] |
ONV IWNIWHSL (+) SHL OL[Z-d] Z@ DNILOANNOO
N3HM YO) MOGNIM SHL 40 NOILOAYIG «df» FHL
Ni 3iVLOY YOLOW 3HL S300 “IWNIAHAL (-) SHL OL
[2-0] 2 GNV TWNIWHAL (+) ANSLLVE JHL OL[2-C] 1
HOLOSNNOD HO.LOW AHL ONILOINNOD NAHM *
dais LV3S YAAINC SHL NO 3Q!S LVW3S HSIAO SHL NO YOLOW MOCNIAA
HO.LIMS AMOGNIM YAMOd SHL JOW1dsd4 YSMOd SHL AO YOLOANNOO SHL LOANNOOSIO *
Can]
= S3A
ZIVAIHON JGIS Lvas
YIAIYO JHL NO HOLIAS MOQNIM YAMOd FHL SI ¢
3LvuadO LON S30G 3dIS Y3AINC SHL NO MOGNIM
agiS 1V3S Y3AING JHL NO
MS MOQCNIM YSMOd FHL IOV 1day YO HiVddY
NOILONN4 LON S30d MS 49071
bL2-8 IWOINLOATS SISSVHD ONV GVO
 YOLOANNOD HO.LOW 3H ONY
MS MOGQNIM Y3MOd 3dIS H3DNISSWd JHL (Zd] v anv [E-d] » yO)
N33M1L3¢ LINDHID NddO NV YO SHOLOANNOD [Z-d] z anv [€-d] § N3SML3d LINDUIO N3dO NV YO
3HL LY NOILOSNNOD YOOd ¥ Hlvd3H SHOLOSNNOOD SHL LY NOILOJNNOOD YOOd V YlVd3y
cas ar
[9-G] Z GNV[9-d] | SHOLOINNOOD Jats
HOLOW SSANHVH 3HL N3SMLI8 ALINNILNOD ANY 3HSHL
MOGNIM HAMOd 3HL 30W1d3H HO Hivd3H SI} ‘NOLLISOd TWHLNAN SHL LY HOLIAAS SHLHLIM ©
S3A
(éMOGNIM
3H 40 NOLLOSYIG NMOG 3HL NI SLVLOY
HO.LOW 3H S300 ‘IWNIWYSL (-) SHL OL [9-G] 1
ONY IWNIWYAL (+) SH OL[9-G] Z DNILOANNOOD
N3HM HO) éMOGNIM 3H1 4O NOLLOGHIG .df., FHL
NI ALVLOY HOLOW 3HL S300 “TWNIWUAL (-) SH OL
[9-G] Z GNV IWNIWAL (+) ANSLLVE 3HL OL[9-G] |
YO.LOSNNO9 HOLOW 3HL ONILOSNNOD NSHM
YO.LOW MOGNIM H3MOd 3GIS HJDNISSVd
MS 3H 30V1d44 HO Ulva | INOU4 FHL IO YHOLOSANNOD JHL FAOWSY ©
dt
[oN SIA
MS AHL 39V1d3y YO Ylvd3ad | | CTVINYON AAS MOCNIAA YSMOd S.HYAAIUC SHL SI ¢
ON SSA
2TVINHON MS
AAQGNIM YAMOd AGIS HADNASSWVd LNOYS SHLSI ¢
3ivuadO LON S30d 3d!1S YSDNASSVd LNOYS SHL NO MOGNIM
WoOl8LOaTa SISSVHD GNV BVO 212-8
 CAB AND CHASSIS ELECTRICAL 8-213

STARTER SWITCH
Refer to “START AND CHARGING?” in this section.

POWER WINDOW SWITCH-DRIVER SIDE

Circuit Inspect (Figure 239)
Disconnect the switch connectors to check the
voltage and the continuity between the harness
side connector terminals.

| D-3 |

42 A Harness side
4;3/6 718

Termi- Wire Item Connect-

nal color Connected to to be ing Checking conditions Standard
No. checked terminal
1 L
3 m Driver seat side motor 1-2
Continuity oo
. . - Continuity
4 G/Y_| Passenger side power (resistance) 4-5
5 R/Y | window SW 5-4
6 L/B | Power window relay Voltage 6-Ground | Starter SW “ON” Battery voltage
Continul
8 | B | Ground resistanes) | 8-Ground - Continuity

Figure 239. Circuit Check

Inspect (Figure 240)

Check the continuity between the connector

terminals of the switch.
Repair or replace the switch when the result of
inspection is found abnormal.
 8-214 CAB AND CHASSIS ELECTRICAL

Switch side

Window! Driver side Passenger side

tint 6 | 1] 2/8) 61514] 8

UP

Figure 240. Power Window Switch-Driver Side Check

[+>] Remove or Disconnect

Preparation:Disconnect the battery ground

cable.
1. Switch (Figure 241)

- Insert the screw driver to the cut off portion to

remove the switch.
- Disconnect the connector

Figure 241. Power Window Switch Removal

 CAB AND CHASSIS ELECTRICAL 8-215

[oe] Install or Connect

To install, follow the removal steps in the reverse

order.

POWER WINDOW SWITCH-

PASSENGER SIDE
Circuit Inspection (Figure 242)

Disconnect the switch connectors to check the

voltage and the continuity between the harness
side connector terminals

Termi- Wire Item Connect-

nal color Connected to to be ing Checking conditions Standard
No. checked terminal
1 L/B_ | Power window relay| Voltage 1-Ground | - Turn “ON” the starter SW Battery voltage
Continuity - Turn “OFF” the passenger side wo
(Resistance)| Ground | sw at the driver side SW Continuity
2 R/Y | Driver side SW - Turn “ON” the starter SW
Voltage 2-Ground | - Turnto “UP” the passenger Battery voltage
side SW at the driver side SW
Passenge side Continuity . _ ae
3 LY motor (Resistance) 36 Continuity
Continuity 4G a|- Turn “OFF” the passenger side | Continuity
(Resistance)| “roun SW at the driver side SW
4 G/Y_ | Driver side SW - Turn “ON” the starter SW
- Turn to “DOWN” the
Voltage 4-Ground passenger side SW at the Battery voltage
driver side SW
Passenger side Continuity . _ .
5 BR/Y motor (Resistance) 5-3 Continuity

Figure 242. Circuit Check

inspect (Figure 243)

Check the continuity between the connector

terminals of the switch.
Repair or replace the switch when the result of
inspection is found abnormal.
 8-216 CAB AND CHASSIS ELECTRICAL

D-7

(ol oooh

Switch side

Terminal
SW position No.
UP

OFF

DOWN

Figure 243. Power Window Switch-Passenger Side Check

[+>] Remove or Disconnect Inspect

Preparation:Disconnect the battery ground Before checking to see if the motor functions
cable. correctly, be sure to check the circuit through the
connector of the driver's power window
1. Switch (Figure 244) switch.
If the motor does not operate smoothly, either the
- Insert the screw driver to the cut off portion to motor or the circuit between the switch and the
remove the switch. motor is defective.
- Disconnect the connector.

esa 1. Circuit inspection of the driver side window

switch (Figure 245)

Disconnect the switch connector and apply

battery voltage to the harness side connector
terminals to check its function.

Figure 244. Power Window Switch Removal

Se ooo0cey7 )8

Harness side

[>e] instali or Connect Connecting terminal Operation

1 (LW) 2 (L)
To install, follow the removal steps in the reverse
Oo @® DOWN
order.
® 9 UP
DRIVER SEAT SIDE POWER
WINDOW MOTOR Figure 245. Circuit Check
 CAB AND CHASSIS ELECTRICAL 8-217

2. Inspection of the driver seat side motor

(Figure 246) [oe] install or Connect

Remove the motor connector and apply battery To install, follow the removal steps in the reverse
voltage to the motor side connector terminals to order.
check its function.
Replace the motor when the result of inspection is FRONT PASSENGER SEAT SIDE
found abnormal.
POWER WINDOW MOTOR
Inspect

Before checking to see if the motor functions

correctly, be sure to check the circuit through the
—| front passenger’s switch connector and the
O-
- 4

driver’s power window switch connector [D-3].

If the motor does not operate smoothly, either the
motor or the circuit between the switch and the
motor is defective.

1. Circuit inspection of the front passenger

seat side window (Figure 248)
. > Terminal No. Disconnect the switch connector and apply
Direction 1 2
of operation battery voltage to the harness side connector
DOWN Oo | @ terminals to check its function.
UP @ eo

Figure 246. Driver Seat Side Motor Check

[+9] Remove or Disconnect (Figure 247)

Preparation:Disconnect the battery ground a ——

cable. CEELT] Harness side

1. Window Regulator Assembly

Refer to Section 10 “BODY” for Window Connecting terminal | Direction of
Regulator and Glass. 3 (L/Y) 5 (BR/Y) operation
2. Power Window Motor 9 ® DOWN
Remove three screws. @ oO UP

Figure 248. Circuit Check

2. Circuit inspection of the driver seat side

switch (Figure 249)

Disconnect the switch connector and apply

battery voltage to the harness side connector
terminals to check its function.

Figure 247. Power Window Motor Removal

8-218 CAB AND CHASSIS ELECTRICAL

1. | Window Regulator Assembly

Refer to Section 10 “BODY” for Window
Regulator and Glass.
2. Power Window Motor
Remove three screws.
Harness side

Connecting terminal | Direction of

4 (GY) 5 (R/Y) operation
@ 9 DOWN
© ® UP

Figure 249. Circuit Check

3. Inspection of the front passenger window

motor (Figure 250)

Disconnect the motor connector and apply battery

[B)
voltage to the motor side connector terminals to
check its function. Figure 251. Power Window Motor Removal
Repair or replace the motor when the result of
inspection is found abnormal.
[>«| install or Connect

To install, follow the removal steps in the reverse

order.

[os|

;
Direction —— —_Lermrinat No.)
n
of operatio ae
© @
DOWN
@ ©
UP

Figure 250. Passenger Side Motor Check

[+>] Remove or Disconnect (Figure 251)

Preparation:Disconnect the battery ground

cable.
 CAB AND CHASSIS ELECTRICAL 8-219

POWER DOOR LOCK

GENERAL DESCRIPTION
The circuit consists of the door lock switch, of ail the doors.
actuator for the front passenger door, rear doors When the driver’s door lock switch is turned on,
and the door lock controller. current flows for about one second to the door lock
The door lock controller is always provided with actuator of each door connected in parallel with the
battery voltage. The key or the inside lock knob on controller to activates the actuator to lock and
the driver’s door can activate the lock mechanism unlock the door s.

OPERATION OF DOOR LOCK CONTROLLER

When locking When locking

the door. the door.

Battery(+) Battery(+)
a A

Relay;Door lock v Relay;Door lock v

7 Saget

oO
ed To actuator
To actuator
(Actuator
(Actuator

=
operates to

v
operate
unlock

oO
[=> to lock side)
position)
‘\

Loy

§ !
Door lock sw. Door lock sw.
ijp—_|e*

{Lock position) (Unlock position)

NOTE: Arrow marks “>” indicate the direction of current

8251x003
Figure 252. Operation of Door Lock Controller
8-220 CAB AND CHASSIS ELECTRICAL

PARTS LOCATION

D-4 FRONT DOOR LOCK SWITCH (LH)

FL-1 FUSIBLE LINK
RELAY BOX ASM
B-272 JOINT CONNECTOR

a<
(G55OF
ax
3O74 z6
a)

ov Og
vt) <= Mw
Sr
th bb
Oz
anaes

Figure 253. Parts Location

 CAB AND CHASSIS ELECTRICAL 8-221

CIRCUIT DIAGRAM
FL-1] 80A 4BA
MAIN 2 POWER DOOR LOCK
H-6
8w 5w Sw 3W

&
oto + 8

— oF O-—

RELAY:
{+4

DOORLOCK fe72
Sie
B]

FRAME ' =
qT 1S

3 A a pak

[8-12 6-12 j8:12]

“y 5 o

a
oO ce x
4 rc = e =
o a qo aQ a
& % 8 8
o o o oO

0.3G/B
g
rm
% ao
4 4 3

(es) [2] Ez]

g
G
5
o
= =
«
=
2 3 Fy
a
a
a
o
3
oa

ww 5 6 1 2 1
Q 5 a

Zz e1g°
2 =
x“ ad
| S| x x 5 s
3 w 2. oO s 8

DOOR LOCK Sw 5 g 9 z| |
3 o Z
a

° [I & =

Bal DOOR LOCK SWITCH & DOOR LOCK

mn “a ACTUATOR-LH ACTUATOR-RH
wn o
3 "
a

m
NN

HEADLIGHT BRACKET (LH) | 3B 4 B-272

JOINT
FRAME-LH (FRONT) || 5B CONNECTOR

Figure 254. Circuit Diagram

8-222 CAB AND CHASSIS ELECTRICAL

CONNECTOR LIST

jel)
| tap

aja

iL@i™
ow ie

oF
ef

T
Qo

1, 2)3 41516
7| 8 | 9 [10g 41/1211

Figure 255. Connector List

 CAB AND CHASSIS ELECTRICAL 8-223

DIAGNOSIS
QUICK CHART FOR CHECK POINT

.
Check point |
Door Door lock actuat
Fuse ror lock sw cont er
F-27 (15A) (Driver a Rear Rear Cable
Trouble mode mS controller) side) aeee (RH) (LH) | harness
1. All the doors do not lock and © oO O
unlock (1) (2) (3)
2. All the doors do not get O O
locked (or unlocked) (1) (2)
3. Driver side door does not get O O
locked (or unlocked) (1) (2)
4. Front passenger side door O O
does not get locked (or (1) (2)
unlocked)
5. Rear door-RH side does not O O
get locked (or unlocked) (1) (2)
6. Rear door-LH side does not oO O
get locked (or unlocked) (1) (2)

NOTE: Figure in parenthesis “( )” indicates the order of inspection.

 8-224 CAB AND CHASSIS ELECTRICAL

1. ALL THE DOORS DO NOT LOCK AND UNLOCK

[ » IS FUSE F-27 (15A) NORMAL? |

YES Me
e 1S THE DOOR LOCK SWITCH NORMAL? | | REPLACE THE FUSE
rent

YES

_
° IS GROUNDED SECURELY? | | REPLACE THE DOOR LOCK SWITCH
fT

YES
fa

e DISCONNECT THE CONTROLLER CONNECTOR | GROUND IT SECURELY

» 1S THE BATTERY VOLTAGE APPLIED AT THE 6
AND GROUND?

YES ca
e IS THE DOOR LOCK CONTROLLER NORMAL? | REPAIR A POOR CONNECTION AT THE
CONNECTORS OR AN OPEN CIRCUIT
BETWEEN FUSE (15A) AND 6

YES NoNO |
REPLACE THE DOOR LOCK CONTROLLER
REPAIR A POOR CONNECTION AT THE CONNECTORS
OR AN OPEN CIRCUIT BETWEEN 1 AND
 CAB AND CHASSIS ELECTRICAL 8-225

2. ALL THE DOORS DO NOT GET LOCKED (OR UNLOCKED)

| © IS DOOR LOCK SWITCH NORMAL? |

* DISCONNECT THE DOOR LOCK CONTROLLER REPAIR OR REPLACE THE DOOR LOCK
CONNECTOR SWITCH
« IS THERE CONTINUITY BETWEEN 5 [B-12] AND
4([B-12] OF HARNESS SIDE CONNECTORS

YES 9}
-
| REPLACE THE DOOR LOCK CONTROLLER | AONE CrOnS OR AN OPENS SCUTEN
THE CIRCUIT

3. DRIVER SIDE DOOR DOES NOT GET LOCKED (OR UNLOCKED)

| REPLACE THE DOORLOCK SWITCH _|

4. FRT PASSENGER SIDE DOOR DOES NOT GET LOCKED (OR UNLOCKED)
5. RR DOOR-RH SIDE DOES NOT GET LOCKED (OR UNLOCKED)
6. RR DOOR-LH SIDE DOES NOT GET LOCKED (OR UNLOCKED)

| REPLACE THE DOOR LOCK ACTUATOR |

8-226 CAB AND CHASSIS ELECTRICAL

DOOR LOCK RELAY

The door lock controller sends out to each door
lock actuator the lock/unlock signals received from
door lock switch of driver seat side.

Figure 256. Door Lock Relay

Circuit Inspection (Figure 257)

Check the voltage and the continuity between the
controller harness side connector terminals.

[B-12

Harness side

Termi- Wire Item Connect- ; .

nal i Connected to to be ing Checking conditions Standard
No, | COlOF checked | terminal
Door lock SW Driver seat side Unlock Continuity
7-Ground
7 R/G | (Unlock) r door Lock No continuity
Door lock SW Driver seat side Unlock No continuity
5-Ground
8 G/B | (Lock) Conti- door Lock Continuity
1 B Ground (Rosie 1-Ground - Continuity
tance) Continuity
3 BR/Y ae 3-2 - {There is some
nioc resistance)
Continuity
;
BR/R
Actuator 2-3 - (There is some
2 resistance)
(Lock)

R Fuse F-27 (15A) Voltage | 6-Ground - Battery voltage

6

Figure 257. Door Lock Relay Circuit Check

 CAB AND CHASSIS ELECTRICAL 8-227

Inspect (Figure 258) DOOR LOCK SWITCH

Remove the connector of the door lock controller,
(DRIVER SEAT SIDE)
and check the continuity and the voltage between The door lock switch on the driver’s door is
the controller side connector terminals. connected with the door lock cylinder and the inside
lock knob with a rod. The switch sends lock/unlock
(Connect the © terminal of the battery to 6
signals to the door lock controller.
[B-12] and the© terminal to 1 B-12])
1 (B-12/- 2 [B-12)......... Continuity
1 [B-12/- 3 |B-12)......... Continuity
Door lock ASM

(Then, ground 5 [B-12])

2 [(B-12]......... Voltage for approx. 1 second
Door lock SW

(Disconnect the ground of 5 , and ground 7

B-12] .)
3 [B-12)......... Voltage for approx. 1 second

Replace the controller when the result of inspection

is found abnormal.
Figure 260. Door Lock Switch

Inspection (Figure 261)

Check to see if there is any continuity between

the connector terminals of the door lock switch.
Replace the switch when the result of inspection
is found abnormal.
Controller side

Figure 258. Door Lock Relay Check

| D-4 | alele Switch side

Inspect (Figure 259)

After confirming that there is continuity between — Terminal

the harness side connector terminals 3 [B-12] and 2 Operation ~~_No.| 1 2
of the door lock controller, apply battery
voltage to each of the terminals to conduct the Lock Oo1@®
operation test.
When the door lock will not operate, check the Unlock ® | oO
door lock actuator for any trouble.

Figure 261. Circuit Check

Harness
side [+>] Remove or Disconnect

Connecting terminal .
Refer to Section 10 “CAB” for “DOOR LOCK
Operation ASSEMBLY (front and rear)’.
3 (BRY) | 2 (BRIR) per
@ e Untock Install or Connect
9 @) Lock
Refer to Section 10 “CAB” for “DOOR LOCK
Figure 259. Circuit Check ASSEMBLY (front and rear)”.
 8-228 CAB AND CHASSIS ELECTRICAL

DOOR LOCK ACTUATOR Inspection (Figure 263)

Receiving forward or reverse current from the Apply the battery voltage to the connector
door lock controller, the door lock actuator locks or terminals of the door lock actuator to check the
unlocks the door with the rod connected to the door operation.
tock mechanism. When the door lock actuator is checked on the
vehicle and there is no continuity, and when the
door lock actuator itself is checked and no trouble
Door lock ASM
is found, check the circuit between the door lock
actuator and the door lock controller for any failure.

Actuator

Figure 262. Door Lock Actuator

Door lock ASM

5

Actuator side

Door| _ FRT
Passenger
Actuator
Connector
No. D-8
Operation emi" o,| 1 | 2
Lock CO; @
Unlock @®; oO

Figure 263. Door Lock Actuator Check

Remove or Disconnect

Refer to Section 10 “CAB” for “DOOR LOCK

ASSEMBLY (Front and rear)”.

[>+| Install or Connect

Refer to Section 10 “CAB” for “DOOR LOCK

ASSEMBLY (Front and rear)”.
MEMO
MEMO
 CAB AND CHASSIS ELECTRICAL 8-229

WIRING DIAGRAM

[F-15]15a
WIPER WASHER

JOS ONS
METER BACK

vor
RADIC DIGAP.

HOLES LROM dOLS

RELAY:HEAD

HOLIMS LHOM TWNOIS NEAL

(Houmas
RELAY;ID LIGHT
COMBINATION SWITCH
HAZARD
SARs
LICENSE PLATE LIGHT

CAB INTERIOR SWITCH

0.85R,
FRONT COMBINATION LIGHT RELAY REAR COMBINATION LIGHT(LH) REAR COMBINATION LIGHT(RH)

(Or GvSH

(wan ovaH
‘VILHONT OW3H
TURN SIGNAL LIGHT(RH) CORNERING
I I

DOOR SWITCH(LH} | : |
TAIL
i I
PARKING BRAKE SWITCH t I
TURN SIGNAL LIGHT

ENGINE STOP MOTOR D.R.L UNIT

ALHDIT ONIHANOD.
CLEARANCE LIGHTILH)
FRONT COMBINATION LIGHT

[E22] 158
CONDENSOR FAN
OAR AIG THERMO EP gh PE Rar my my Sm sim mmm
RADIO& CLOCK ji] ¢ @—4 1:8 7 ©] i 1 AIRCON = ogge fel ossew | | = =6=66l6jll0l0l0lm™™lldfll OS iwc washenswtce } oF fpf) SPP lll

RELAV,HORN

SunSSSkd

WDSO
CIGARETTE SERVICE TERMINAL i

Nz YOSNBQNOO'AVIAY
LIGHTER &
OPTION an
{Fi-3]60a

&&2
GLOW

5
LYLSONUZHL OINOULO373
MS

MIDS 0
RELAY, HEATER & A'C

(He) NHOH

(HD) NOH
RELAY, EXHAUST BRAKE

—yy4 yosNaQNoa
oSWwiR excite

YOLOW YaHSYM,
EXHAUST BRAKE
LLNO SNINEYM
°

VEHICLE,
3NIDN3' AVIS
HOLIMS SAVES LSNWHX2
(HOLIMS NOLLYN!€¥409)

THROTILE
weet e ey ree geeen--- POSITION
BLOWER RES'STOR FAN SWITCH
ASAWHX2'AV
“OULNOOS YES

HBBOIL OD OFF
LEVEL SWITCH
0.5LG/R, SENSOR g
°
TSH

BART GIN DAYS

W39 HOIK

‘VIAST 134
aove Wand
AT SHIFT

BATTEERY

HOUMS
MS

NMOC YD
3
WR

DATA LINK
way

CONNECTOR
BATYA OLLENOWW
SH¥uE LSNYHXS

.
‘

ind
HOLS FUNSSRd HO

HOUMAS SuNS3ud_

JINN OWSYHL
fo - gag - |

ONCHLO313

RELAY,CHARGE
0 BEW
Bae'o

Sr een nN FOR HBB OPTION VEHICLE ONLY

THERMO = =RACK ENG SPEED | FYRV.EGR:

SENSOR SENSOR SENSOR
DIAGRAM A/T
 CAB AND CHASSIS ELECTRICAL 8-231

WIRING DIAGRAM

[Fis}sa
SWITCH WAIPER WASHER. [&-19]10A [F-9 }10a [Fig}ioa
METER.BACK

dOLSONS
STOP LAMP TAH LAMP

voi[er-]
[Fa 15a
RADIC DIGAP

HOUMS HEMT dOLS

1D LIGHT(1)
RELAV HEAD

HOLMS LHI
{HOLS
RELAY;ID LIGHT
COMBINATION SWITCH
HAZARD WARNING
SWITCH LIGENSE PLATE LIGHT

TWNDIS NEAL
CAB INTERIOR SWITCH
085R
FRONT COMBINATION LIGHT RELAY REAR COMBINATION LIGHT(LH} REARAR COMBINATION
COMBINATION LIGHT(RH)
LIGH]
—

(inHON OvSH
TURN SIGNAL LIGHT(RH) CORNERING LIGHT

DOOR SWITCH(IH}
LIGHT(LH) 1 rate | Ytai,
|
PARKING BRAKE SWITCH |
TURN SIGNAL LIGHT TURN.

(AHE' NOLLYNIGNOS.
D.R.L UNIT

AHS1T ONSEN
CLEARANCE LIG!
FRONT COMBINATION

[F-22] 158
GONDENSOR FAN RELAY, BUZZERCANCEL

[EL2 j50a RADIO & CLOCK

KEY SW

BACK UP LIGHT SWITCH(M/T)

BUNSSAUd

WWOS 0
CIGARETTE SERVICE TERMINAL !
(POWER SOURCE) |

Nd BOSNAONOS'AYIBY
LIGHTER: UGHT.RH}
[FL-3]80a [FL3]soa OPTION 4
MAIN GLOW

LWLSOWHAH) OINOYLISIS:
MS

AVDS O
RELAY, HEATER & AG.

du} NOH
WIPES
RELAY EXHAUST BRAKE

yy BOSNZCNOO

HOLOW B34SYM
EXHAUST BRAKE
SMIONA ‘AYIad
AND ONIN
HOMMS Jx¥d9 LSNWHXS
(HOLIMS NOLLYNIBINCD)

BLOWER RESISTOR: FAN SWITCH

YALVSH SIAVHRD

ASNWHXAAVTSY
TOULNODaHvHS

HBBOIL
LEVEL
SENSOR
HOLIMS HOLNTS

7BA31 GINS ayvua

WV38 HOI

WAAdT 3S
BATTERY
MS

aid HANOYA
“AVIBE
HOMMS T3437 Gd
AAWA SU3NOWW
SUE LSNWHXS

KOSNAS (3ad§ JTOIHSA

HOLIMS SUNSS3Yd WO.

diwnid
HOMUMS SYNS3Kd

LINN OW3dH2
3
6a

+
HOUMS TWELNSN

OINOHLOTTS
SXVEE

RELAV CHARGE

GENERATOR | eG tT LER EP tte ene

LE ae GEE ee ee eee ee eee ee en ene ee eee en en ee ne ee enn eee!

THERMO RACK ENG SPEED EVAV,EGR

SENSOR SENSOR SENSOR

DIAGRAM M/T
 METRIC AND FASTENER INFORMATION 9-1

SECTION 9

METRIC AND FASTENER INFORMATION

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS
SUBJECT PAGE
Metric Fasteners..............sccsesssssssescssssscssearensserstarssssseevssoeussssessocscensassestarstasnsasacsesesestucseatarsusnsustsanevansussensausessseees 9-1
Replacement Fastener .............sscesscecssssessesesssssssesssassenessrsssensassssusessaueasseansesseesessarsssasassesecavavessservassensusenseses 9-1
Fastener Strength Identification 0.0.0.0... scesssssssssssssssssssesssossessessverscscncacueessrersuensgresovarsessscuseessusssusgessenasecsesesee 9-2
Prevailing Torque Fasteners ............cccssessesssosssassessesessssensseresseseresscessosscasassnsevasuresnesouataveusarseceseazesauensstanseneaesess 9-2
Six-Lobed Socket Head Fasteners...........:.ccessseseres sued cede seeenaneesansdnnensaursauy suesacauensasseueesanseseettentseniseseiseasenseaceaes 9-3
Decimal and Metric Equivalent............cccscsscsssessssesscesssesssenssusessassesssucessessssscasaraesssssasscecenecsuasersessasseasaseseesecseses 9-4
Conversion Table ..........cscssesssenssnsersssecssatsarssentsssseatsessasnsesssssssassensevsuvesuusasunausesseatasaracsssstoverseacavenssesesanseacesensuee 9-5

METRIC FASTENERS

REPLACEMENT FASTENERS Original equipment metric fasteners (except

During vehicle maintenance, any fasteners used “beauty” bolts, such as exposed bumper bolts, and
to replace older ones must have the same cross recess head screws) are identified by a
measurements and strength as those removed, number marking indicating the strength of the
whether metric or inch system. (The numbers on material in the fastener as outlined later.
the heads of metric bolbs show their strength. The
inch system bolts use radial lines to show this.)
(figure 3).
nf

'

mall

wt
aS
ted
ee

Fasteners taken from the vehicle should be saved

© ©
fa

VS

for reuse in the same spot when possible. Where a

fastener cannot be used again, take care to choose
a replacement that matches the old one. For
information and help, see your dealer.
©
©
“©

Satara
sateennseinn

CAUTION: This vehicle is primarily dimensioned

in the metric system. Most fasteners are metric
2 3
and many are very close in dimension to well-
known inch system fasteners. Mismatched or 1. Strength Class 4.8
incorrect fasteners can result in damage to the 2. Strength Class 8.8
vehicle or possibly personal injury. 3. Strength Class 9.8

Figure 1. Fastener Identification Chart

9-2 METRIC AND FASTENER INFORMATION

FASTENER STRENGTH IDENTIFICATION

N-m (lb-ft)

Strength 4.8 8.8 9.8

Class
Refined Non-Refined

Bolt
identification

Bolt oN
Diameter x g 2
Pitch (mm)

M 6x1.0 4- 8( 3- 6) 5- 10( 4 7) —
M 8 x1.25 8- 18( 6 13) 12- 23( 9 17) 17- 30( 12- 22)
M10 x1.25 21- 34( 15— 25) 28- 46 ( 20- 34) 37- 63 ( 27— 46)
* M10 x1.5 20- 33 ( 14— 25) 28- 45( 20- 33) 36— 60( 27- 44)
M12 x1.25 40- 74 ( 36- 54) 6i- 91 ( 45— 67) 76-114( 56— 84)
* M12 x1.75 45- 69 ( 33- 51) 57— 84( 42- 62) 72-107( 53- 79)
M14 x1.5 77-115( 56- 85) 93--139( 69-103) 114-171 ( 84-126)
* M14 x2.0 72-107( 53- 79) 88-131 ( 65~ 97) 107-160( 79-118)
M16 «1.5 104—157 ( 77-116) 135-204 (100—150) 160-240 (118-177)
* M16 x2.0 100—149( 74-110) 130-194( 95-143) 153-230 (113-169)
M18 «1.5 151-226 (111-166) 195-293 (144-216) 230-345 (169-255)
M20 x1.5 206-310 (152-229) 270-405 (199~299) 317-476 (234-351)
M22 x1.5 251-414 (185-305) 363-544 (268-401) 425-637 (313-469)
359-539 (265-398) 431-711 ( (318-524 ) 554-831 (409-613)

Figure 2. Metric Bolts Torque Standard

NOTICE: The asterisk * indicates that the bolts are soft materials such as casting, etc.
used for female-threaded parts that are made of

PREVAILING TORQUE FASTENERS

A prevailing torque nut is designed to develop an RECOMMENDATIONS FOR REUSE

interference between the nut and bolt threads. This
is most often accomplished by distortion of the top 1. Clean, unrusted prevailing torque nuts and bolts
of an all-metal nut or by using a nylon patch on the may be reused as follows:
threads in the middle of the hex flat. A nylon insert a. Clean dirt and other foreign material off the
may also be used as a method of interferences nut or bolt.
between nut and bolt threads. b. Inspect the nut or bolt to ensure there are
A prevailing torque bolt is designed to develop no cracks, elongation, or other signs of
and interference between bolt and nut threads, or abuse or overtightening. (if there is any
the threads of a tapped hole. This is accomplished doubt, replace with a new prevailing torque
by distorting some of the threads or by using a fastener of equal or greater strength.)
nylon patch or adhesive. c. Assemble the parts and hand start the nut or
bolt.
 METRIC AND FASTENER INFORMATION 9-3

d. Observe that, before fastener seats, it e. Tighten the fastener to the torque specified
develops torque per the chart in figure 2. in the appropriate section of this manual.
(If there is any doubt, replace with new 2. Bolts and nuts that are rusty or damaged should
prevailing torque fastener of equal or be replaced with new parts of equal or greater
greater strength.) strength.

SIX-LOBED SOCKET HEAD FASTENERS

Six-lobed socket head (Torx) fasteners are used Tools designed for these fasteners are available
in some applications on vehicles covered in this commercially. However, in some cases, if the
manual (figure 3). The door striker bolt is of this correct tool is not available, a hex socket head
design as well as the dragfoiler mounting bolts in wrench may be used.
some cases.

T - internal Drive
E - External Drive

Figure 3. Six-Lobed Socket Head (Torx) Fasteners

9-4 METRIC AND FASTENER INFORMATION

DECIMAL AND METRIC EQUIVALENTS

Fractions Decimal Metric. Fractions Decimal Metric.

in. MM. In. MM.

1/64 015625 39688 33/64 516625 13.09687

1/82 .03125 £9375 17/32 53125 13.49375
3/64 046875 1.19062 35/64 546875 13.89062
1/16 0625 1.68750 9/16 5625 14.28750
5/64 078125 1.98437 37/64 578125 14.68437
3/32 .09375 2.38125 19/82 99375 15.08125
7/64 -109375 2.77812 39/64 609375 15.47812
1/8 125 3.1750 5/8 625 15.87500
9/64 140625 3.57187 41/64 640625 16.27187
5/32 15625 3.96875 21/32 £65625 16.66875
11/64 171875 4.36562 43/64 671875 17.06562
3/16 1875 4.76250 11/16 6875 17.46250
13/64 203125 5.15937 45/64 703125 17.85937
7132 21875 5.55625 23/32 11875 18.25625
15/64 234375 §.95312 ATI64 734375 18.65312
1/4 200 6.3500 3/4 750 19.05000
17/64 265625 6.74687 49/64 765625 19.44687
9/32 28125 7.14375 25/32 18125 19.84375
19/64 296875 7.54062 51/64 796875 20.24062
5/16 3125 7.93750 13/16 8125 20.63750
21/64 328125 8.33437 53/64 828125 21.03437
11/32 34375 8.73125 27/32 84375 21.43125
23/64 359375 9.12812 56/64 .859375 21.82872
3/8 375 9.52500 7/8 875 22.22500
25/64 390625 9.92187 57/64 890625 22.62187
13/32 40625 10.31875 29/32 £90625 23.01875
27/64 421875 10.71562 59/64 921875 23.41562
7/16 A375 11.11250 15/16 9375 23.81250
29/64 453125 11.50937 61/64 .953125 24.20937
15/32 46875 11.90625 31/32 96875 24.60625
31/64 484375 12.30312 63/64 984375 25.00312
1/2 .500 12.70000 i 1.00 25.40000
 to get equivalent to get equivalent
Multiply by number of : Multiply by number of:
LENGTH ACCELERATION
Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec2 (m/s2)
Foot 0.304 8 meters (m) inch/sec2 0.025 4 meter/sec2
Yard 0.914 4 meters
Mile 1.609 kilometers(km) TORQUE

AREA Pound-inch 0.112 98 newton-meters (N-m)

Pound-foot 1.355 8 newton-meters
inch2 645.2 millimeters? (mm?) POWER
6.45 centimeters? (cm?)
Foot? 0.092 9 meters2 (m2) Horsepower 0.746 kilowatts (kW)
Yard2 0.836 1 meters2
PRESSURE OR STRESS
VOLUME
inches of water 0.249 1 kilopascals (kPa)
inchs 16 387 mms Pounds/sq.in. 6.895 kilopascals
16.387 om3
0.016 4 liters (I) ENERGY OR WORK
Quart 0.946 4 liters BTU 1055 joules (J)
Gallon 3.785 4 liters Foot-pound 1.355 8 joules
Yard? 0.7646 meters? (m3) Kilowatt-hour 3 600 000 joules (J=one W)
or 3.6x108
MASS
CONVERSION TABLE

LIGHT
Pound 0.453 6 kilograms (kg)
Ton 907.18 kilograms (kg) Foot candle 1.076 4 lumens/meter2 (Im/m2)
Ton 0.907 tonne (t)
FUEL PERFORMANCE
FORCE
Miles/gal 0.425 1 kilometersi/liter (km/)
Kilogram 9.807 newtons (N) Gal/mile 2.352 7 liter/kilometer (I/km)
Ounce 0.278 0 newtons
Pound 4.448 newtons VELOCITY

TEMPERATURE Miles/hour 1.609 3 kilometers/hr. (km/h)

Degree Fahrenheit (t °F-32)+1.8 degree Celsius (C)
METRIC AND FASTENER INFORMATION 9-5
MEMO
 STEEL TILT CAB 10D-1

SECTION 10D

STEEL TILT CAB

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE
Cab DOSCTIPtION ......ccscsscenersesenenecoceresesanessorsuraueseossussnoeenstasnecsineenseaeaansnsecosensoensasenseeeneausanessuetsaneraesatesseeszersans 10D- 2
Design and Construction....... seunneuansensenensuesssenuesccunesocensesasuasacouauoncatasnentnsoesesdcesateusesansensacanesentaaetansnaen 10D- 2
WINGOWS .......ccerensssssesssersonsnnscocsussensensecensoassaeoesensasenssususennessarasanausensnnsanenesnanadeasaneassuaesecssentonserssseneestansanss 10D- 2
Diagnosis of Steel Tilt Cab.........cscccrsssscsneressrsnsanersesssessanaensecenseesaessasoasssecasassaneneecnosantsnesuetaneneasenenengraunsesesa 10D- 2
On-Vehicle Service ..........cecsenesssossenetenensonessnvssnassanesaesesstsvacenussusneurousavensnnessoassaasnsnesenorsnensdentascesessnesonensasnsensene 10D- 5
Calo INteTiOl 0... cesesstrensessersaesssesesecsssusnsunesnsenadssanernusereressaseasenseusedenensseneasenanensnantonnnenesonseassceceuaneseaasacenennees 10D- 5
Driver's S@att ......csccssccccuccueneeecessusesseetunenasennessunnnesiusavsnsnassesersees usasoasauavonaaaracorseusaadsneeaeereneesesanensoussanteanaeans 10D- 5
Passenger Seat .......:..ccscssccsssersssessstssesenenessnsssnnrsecesenssnsaseanconmetcoussenennnenses eanvosuenansaseoeeeentaseceaesastensaenes 10D- 6
Seat Belts:Side Seat Belt Toque .........:cccccesescssnecesussssnnsvecseussesosssessaessensuneeseussasoesuteesesencasensunsaansaasarne 10D- 7
Front Genter and Driver Side Seat Belt BUCKIC............ccscsssssssessscrsssstensersorsansssceaaeseneanoenanescesentes 10D- 8
Front Center Seat Belt Tongue and Passenger Side Seat Belt Buckle ..................cccssscrcsssrssssesoeceas 10D- 9
InstruMent Panel .........:::csssrcssnessecssssessensanenssoesesocenstesnsessnaeosasucanucesensessenaneesieesaneesssnanodsssannennensensagonensnas 10D-10
Instrument Panel Reinforcement ............ccccssccssssesccnnenssnnoesussoonsssenssesenenennaeassessesananeenssaanensensensnaeaenanes 10D-13
Healining ......ssssescsssscensescersenressssssvacentoceseantannpenaresasusuausearsecetsaeseanencaeeneesouneseeteseuasenssesaeasanesuseesenantenznsanens 10D-15
DOOPS.......0-:sscsserccsnssstsenuensasscnessneesensesesessusneauacesssnassearerscessueneeatanensuencesrenecasauanaaeapasesnanseedueseneneeesneansaesoguenseeanas 10D-16
DOSCHIPtION ......ccccesenccessneceesaneetesnsnesssecconsacuensecasorenenesneessuenssneonenssates alonesapransecensseaesseesuensseescensoeesearsenteaes 10D-16
DOP ....csssttessotensssnecsssuesunersooresucesensansnsosussounaesscasssecasusensessuossuuaenasonsaessanedaanesasansssscasessaansdnnneeteneaunensaneennene 10D-16
LOCK MOChANISIN.......:cccecccsssecssscerusecsesssasensneessenseesccouseseneraseesscoesaunasdusenseesauanaannsesessonneeaeeaanaosenensacss coctaneaee 10D-18
Lock Cylinder and Outside Door Release Handle ..........s:csssssscssnssssseanesnnsessecererscersaresseseeensens vtvanesene 10D-19
Tri Panel .....cescccseescescserenssasecssesscesennenaussesesonecseasaanusaasencassseazaeseaesansassnasnsaedsencenersuasnnpenencesenseenenacenestns 10D-20
Window and Window Regulator ASSEMDIy .............ccsseornescorsnnrsennnsssnneeneesareouenscaseceeusensneneatansessens 10D-22
Calo MOUnitS ........::sccccsstessccensersussenrassunenenuressersmenecauteseucenmeedessedesniesonareunnseneneensesaancneeessaesesanousesssnauesesesasasssons 10D-25
Rear Mount Brackets and Cushions ...........:csssssessssssnssenensssssersenerssaesensssuseveessauossasecseessssueentarsensensenss 10D-25
Cab Mounting Lever ......ssccccscsesrecrsssssnssussscenarsesersuansecausseanenensssoveatesoasentssesutesedonteatesatsseussonesnenaseaeenateane 10D-26
Hold-Down M@ChaniSi ......ccccecssssesesccnsencesansocasesscensseneeausousasesousrsorsonenenensseoeasecseanensuaeesdsuensussansseasnansas ven 10D-27
Lock ASSEMDLY .....::ssescesesccsnessescessensienesenerstsersese atneseacnsesvauessenousanenssensreaueninensenunsseeanessonsuatesearausansenaeeoee 10D-27
Cab Replaceiment........scsccscsssecaneseesenserssacersensesonnsecenssorseessnecenesoanseusersnuecastonsenssensesssuncensuescenustenesassusuauaneneos 10D-29
SpecifiCatloms. .......ccccascocresscsenncsessnssoresscsssnsvsenseesensesevsedsarsustesuteddseaonersosenesueosuasens anecerssenaaresersasarsevsasasuesseraneaes 10D-31
Fasterier TOrques.........cscssusceresscrscessesecansrtocessntsenscesausenssisasassanscatuavenseeenectasancevensecantestasarsserseserancesseneeae 10D-31
10D-2 STEEL TILT CAB

CAB DESCRIPTION
DESIGN AND CONSTRUCTION WINDOWS
The Steel Tilt Cab Model (figure 1)is all steel Door windows are covered in this section under
welded construction. The cab fully surrounds the "Doors". All other windows are covered in CAB
engine and can be titled 45 degrees to expose the MAINTENANCE (SEC.2B) under "Stationary
engine for servicing. Cab tilting is aided by a torsion Glass".
spring and lever that extended across the front frame
rails. For more details, see "Torsion Spring and
Lever Replacement ", later in this section. The rear
of the cab rests on two mount brackets which are
bolted to the frame rail on both sides of the truck.
The brackets contain rubber cushions which act as
shock-absorbers. A latch-type hoid-down
mechanism locks the cab firmly on both brackets.
The combination brake fluid/ciutch fluid reservoir
is located inside the cab, on the left side of the
dash.

Figure 1 Steel Tilt Cab

DIAGNOSIS OF STEEL TILT CAB

TROUBLE POSSIBLE CAUSE CORRECTION

Cab Tilts with 1. Broken torsion bar lever. 1. Replace the lever.
Difficulty. 2. Broken torsion bar. 2. Replace the torsion bar.

Cab will not Tilt. 1. Safety catch is not released. 1. Lower the cab complately; release
the safety catch, and then release the
nold-down catch.
2. Hold-down mechanism is not 2. Release the hold-down mechanism.
released. (it may be necessary to adjust the
mechanism.)
3. Torsion spring is broken. 3. Replace the torsion spring.
4. Broken support bracket. 4. Replace the bracket.
5. Broken torsion bar lever. 5. Replace torsion bar lever.

Cab does not Stay 1. Hold-down mechanism is not Lower the cab complately.
Firmly in the Driving latched.(Cab is held only by the
Position; It safetycatch.)
JIGGLES Up and 2. Worn or missing cushion(sjat the | 2. Install new cushion(s).
down rear cab support.
 STEEL TILT CAB 10D-3

DIAGNOSIS OF STEEL TILT CAB (CONT.)

TROUBLE POSSIBLE CAUSE CORRECTION

Seat will not move Obstructed adjustment mechanism. Remove the obstruction.

oh
2. Frozen or obstructed guide rails. 2. Replace obstruction and/or remove
the seat and the adjustment
mechanism . Clean the guide rails
and lubricate.
3. Broken adjustment lever. 3. Replace the adjustment machanism.

Seat moves only on | 1. Broken or disconnected control wire | 1. Replace or connect the wire.
One Side from the adjustment lever to the
opposite side of the seat.
2. Obstructed guide rail. 2. Remove the obstruction.
3. Obstructed adjustment mechanism. | 3. Remove the obstruction.

Seat is Hard to 1. Tension spring is broken or 1. Remove or connect the spring.

Move disconnected.
2. Rusty or obstructed guide rails. 2. Remove the obstruction and/or
lubricate.

Seat will not Stay in | 1. Missing or disconnected adjustment | 1. Remove or connect the spring(s).
Desired Position springs.
2. Broken adjustment lever. 2. Replace the adjustment machanism.

Door wili not Latch 1. Door is out of alignment. 1. Align the door.
or Latches with 2. Striker is out of alignment. 2. Align the striker.
Difficulty 3. Cam of the locking mechanism is in 3. Unlock the door, pull the outside
the closed position. handle, and manually rotate the
cam.
4. Locking mechanism is not attached 4. Tighten the attaching screws of the
securely to the door. locking mechanism.
5. Cam of the locking mechanism is 5. Straighten the cam or replace the
bent or broken. tocking mechanism.

Door will not Lock 1. Disconnected lock rod between the 1. Connect rod. Use a new clip.
outside handle and locking ,
mechanism.
2. Arm of the lock cylinder has not 2. Remove the lock cylinder and install
properly engaged thelug of the as directed later in this section.
locking mechanism.
3. Lug of the locking mechanism is 3. Replace the locking mechanism.
broken.
4. Frozen lock cylinder. 4. Lubricate the lock cylinder or
replace.

Door will not Open 1. Door out of alignment. 1. Align the door.
but It is Unlocked 2. Striker bolt out of alignment. 2. Adjust the striker bolt.
(Door Handles do 3. Frozen jocking mechanism. 3. Remove the locking mechanism and
not Work Freely) lubricate or replace it.
10D-4 STEEL TILT CAB

DIAGNOSIS OF STEEL TILT CAB (CONT.)

TROUBLE POSSIBLE CAUSE CORRECTION

Door will not Open, Disconnected rod from the door release lf disconnected from the release
It is Unlocked, but mechanism to the locking mechanism. mechanism, remove the mechanism
Release and connect the rod to it. If
Handle/Lever Works disconnected from the locking
Freely mechanism, connect the rod.

Door is Hard to Frozen hinge-dirty or incorrect 1. Clean the hinge and lubricate.
Open lubricant.
2. Door is out of alignment. 2. Align the door.

Door Window is 1. Rusty or dirty regulator. 1. Remove the regulator, clean and
Difficult to Move lubricate.
2. Obstructed run channel. 2. Remove obstruction.

Door Window will 1. Obstructed or frozen regulator. 1. Remove the regulator, clean and
not Ciose Nor will lubricate.
Regulator Handle 2. Obstructed regulator guide channel. | 2. Remove obstruction.
Work 3. Obstructed run channel. 3. Remove obstruction.
4. Misaligned run channel. 4. Reposition run channel bracket
and/or division channel.

Door Window will 1. Stripped window regulator handle. 1. Replace handle.

not Move but 2. Stripped window regulator shaft. 2. Replace regulator.
Regulator Handie 3. Regulator roller is not in the guide 3. Remove regulator and install as
Moves Freely channel. outlined in this section.
4. The teeth of the regulator gear are 4. Replace regulator.
broken.
10D-5 STEEL TILT CAB STEEL TILT CAB 10D-5

ON-VEHICLE SERVICE
CAB INTERIOR
Adjustment mechanism should be kept clear and procedures are covered in CAB MAINTENANCE
lubricated with Lubriplate or equivalent. Cleaning Section 2B).
DRIVER’S SEAT

. Cap nut and plain washer (Rear side)

a
. Cap nut and plain washer (Front side)

WH
. Seat assembly
. Reclining lever

NOOR
. Reclining cover
. Seat back assembly
. Seat rail

Cab floor@

Figure 2. Driver's Seat Removal or Installation

fe] Remove or Disconnect (Figure 2) 6. Seat back assembly (6)

7. Seat rail (7)
1. Cap nut and plain washer (Rear side) (1) » Remove the 2 bolts.
* Slide the seat forward and remove the cap nut.
2. Cap nut and plain washer (Front side) (2) x install or Connect (Figure 2)
* Slide the seat backward and remove the cap
nut. To install, follow the removal steps in the reverse
3. Seat assembly (3) order, noting the following points:
4. Reclining lever (4) 1. Before installing the seat ASM, apply grease to
« Remove the one screw. the backward half of the cab-side seat rail (view
5. Reclining cover (5) at (A) ) and set the claw on the seat frame side
* Remove the one screw. (view at @) ).(Figure 2) After that, tighten the
cap nut with plain washer.
 10D-6 STEEL TILT CAB

2. Tighten the cap nut to the specified torque.

View® .
Seat rail Tighten
NY - Cap nut to 25 N-m (18 Ib-ft).
RIN
—<— Forward Crease
View®)

Cab-side —~e=))- Seat frame

Figure 3. Grease application

PASSENGER SEAT

4 . Seat cushion assembly

2. Center seat back assembly
3. Passenger seat back assembly
4. Hinge bracket

Figure 4. Passenger Seat Removal or Installation

[eo] Remove or Disconnect (Figure 4) . Peck tay fixing screw and remove the seat

1. Seat cushion assembly (1) _ §. Passenger seat back assembly (3)

* Raise the cushion and remove the clips and » Remove the 2 hinge fixing bolts.
peel off the fasteners at 5 positions and pull out » Remove the 2 fixing bolts and remove the hinge
the seat beit from the band. assembly. -
2. Center seat back assembly (2) * Remove the fixing screws and remove the seat
- Remove the 2 hinge fixing bolts. back tray.
» Remove the 2 fixing bolts and remove the hinge 4. Hinge bracket (4)
assembly + Remove 2 fixing bolts.
10D-7 STEEL TILT CAB STEEL TILT CAB 10D-7

| Install or Connect (Figure 4) View @ Shown in Figure 3.

To install, follow the removal steps in the reverse
order, noting the following points;

1. Tighten each hinge of the seat back with the

specified bolts securely and specified torque.

Tighten

* Each hinge bolts to 13 N-m (9 lb-ft).

. Check the direction of seat cushion fixing clip. Seat cushion
PM

. Pass the seat belt through the seat cushion band. Vehicle
G

. Install
: the seat cushion in the following order: f .
&

ront side
(Figure 5)
1 Dk! > KO > 3kd KH
Figure 5. Clip installation

SEAT BELTS:SIDE SEAT BELT TONGUE

©
NY

3 Tl
—

in b l
N |
Seat belt |
tongue side
ASM We
} WIS
\
i

5 i

5). 1 ay ™

aA D ~
a
1. Seat belt lower ancher bolt
PS
—~ SN
2. Rear piller lower trim cover
3. Through bolt anchor cover Seat belt lower anchor bolt mounting hole
4. Seat belt upper anchor bolt
5. Retractor fixing bolt

Figure 6. Side Seat Belt Removal or Installation

10D-8 STEEL TILT CAB

| Remove or Disconnect (Figure 6)

FRONT CENTER and DRIVER SIDE
SEAT BELT BUCKLE
1. Seat belt lower ancher bolt (1)
2. Rear piller lower trim cover (2)
* Remove the 2clips and pull up the cover.
/ JK 1. Fixing bolt
3. Through bolt anchor cover (3)
4. Seat belt upper anchor bolt (4)
5. Retractor fixing bolt (5)
* Remove the bolt and pull out the upper bracket
of the retractor from the panel. 3. Seat belt
warning
connector
| install or Gonnect (Figure 6)

To install, follow the removal steps in the reverse a eo ak Detent

order, noting the following points:
1. Apply the sealant around the seat belt lower
anchor bolt mounting hole.(Figure.7)
Figure 9. Front Center and Driver Side Seat Belt
Buckle Removal and Installation
Ali-periphery sealing along [es Remove or Disconnect (Figure 9)
the floor surface mounting hole
1. Fixing bolt (1)
\ | Floor panel
2. Center seat belt buckle (2)
3. Driver side seat belt buckle (3)

uf : x Install or Connect (Figure 9)

To install, follow the removal steps in the reverse

order, noting the following points:
1. Apply the sealant around the seat belt lower
anchor bolt mounting hole.(Figure 10)
Figure 7. Sealant application

2. Install the lower anchor in the specified direction All-periphery sealing along
and tighten it to the specified torque.(Figure 8} the floor surface mounting hole

Tighten \ Ftoor panel

* Anchor bolt to 45 N-m (33 Ib-ft)

NOTICE: install the seat belt iower anchor so
that it may not run on the anchor detent bead i
Vehicle front side
Figure 10. Sealant application

09 | et 2. install the anchor in the specified direction and

tighten it to the specified torque.(Figure 11)
(Left side) (Right side) Tighten
* Anchor bolt to 45 N-m (33 Ib-ft)

Figure 8. Anchor Direction

 STEEL TILT CAB 10D-9

Vehicle front side

All-periphery sealing along
the floor surface mounting hole

Floor panel

| I;| pa
Driver side seat Center seat belt buckle
belt buckle

Figure 11. Anchor Direction Figure 13. Sealant application

2. Install the anchor in parallel to the running

FRONT CENTER SEAT BELT TONGUE direction of the vehicle and tighten the
and PASSENGER SIDE SEAT BELT mounting bolt to the specified torque.
BUCKLE
Tighten

* Anchor bolt to 45 N-m (33 Ib-ft)

1. Fixing bolt

2. Passenger side
seat belt buckle

3. oS seat belt
Se\\S
tongue

Figure 12. Front Center Seat Belt Tongue and

Passenger Side Seat Belt Buckle
Removal and Installation
[+] Remove or Disconnect (Figure 12)

1. Fixing bolt (1)

2. Passenger seat belt buckle (2)
3. Center seat belt tongue (3)

foe] Install or Connect (Figure 12)

To install, follow the removal steps in the reverse

order, noting the following points:
1. Apply the sealant around the seat belt lower
anchor bolt mounting hole. (Figure13)
10D-10 STEEL TILT CAB

INSTRUMENT PANEL

. Meter cluster

—
. Center cluster
. Grove Box

anand
. Under cover
. Meter assembly
. Front cover
. Instrument side grommet

COnN
. Idling control cable
. Instrument Panel assembly
10. Vent duct
11. Instrument panel extension
12. Illumination control knob
13. Side defroster nozzle
14. Fluid tank cover
15 6 15. Relay lid

Figure 14. Instrument Panel Removal or Installation

 STEEL TILT CAB 10D-11

[->] Remove or Disconnect (Figure 14)

1. Meter cluster (1) (Figure 15)

« Pull the main unit toward you and remove the
Al Drink holder
clips at 7 positions. Remove each switch
connector. When switches are mounted on the
Guide
switch cover, remove the connectors.
* Remove the vent grille, switch cover and each ’/

switch from the cluster proper.

Clip
position OC

i
i |
;!
I
i
t A ee,
Ashtray
{
< >
Cigarette lighter { ral
|a ~"

Se Clip section

Be
Se
== SF ih,

Center cluster

Figure 16. Center Cluster Removal or installation

& T 3. Glove Box (3) (Figure 17)

* Open the lid and remove the 4 mounting screws.
Then, remove the main unit.

=
* Remove the left and right stays, remove the 3
mounting screws, and remove the lid.
* Pull out the pin from the lid and remove the
spring and lever.
NOTICE: The Instrument panel assembly of
Figure 15 Meter Cluster Removal or installation
this item can be removed without
2. Center cluster (2) (Figure 16) disassembling each of the parts of above
* Pull the main unit toward you and remove the items 1 to 3.
clips at 4 positions, clips [B] at 2 positions,
cigarette lighter power source and ashtray
lighting connector.
* Remove the drink holder, control unit cover (or
giove compartment), ashtray and cigarette
lighter from the center cluster proper.
NOTICE: Remove the clips with a bladed
screwdriver.

Spring ———-».-

oe

Figure 17 Glove Box Removal or Installation

10D-12 STEEL TILT CAB

4. Under cover (4) (Figure 18).

* Pull the main unit toward you and remove the
clips [A] at 4 positions and clips [B] at 2
positions. First remove the hoe .
NOTICE: The above parts of 1 to 4 can be
removed in any order, or each of them can be
removed independently.

Figure 18 Under Cover Removal or Installation

Figure 19. Meter Assembly Removal or installation
5, Meter assembly (5) (Figure 19)
. Front cover (6)
« Remove the 5 mounting screws.
. Instrument side grommet (7)
+ Remove the connector.
* Remove the screws and pull out the instrument
NOTICE: To remove only the meter assembly,
side grommet.
it can be attained by removing the cluster.
. Idling control cable (8)
« Remove the clip on the accelerator pedal side.
. Instrument Panel assembly (9) (Figure 20)
* Remove the 12 mounting bolts.

instrument panel f

Figure 20. instrument Panel assembly Removal or Installation

 STEEL TILT CAB 10D-13

10. Vent duct (10) 14. Fluid tank cover (14)

* Remove the mounting screws. * Pull out the fluid tank cover.
11. Instrument panel extension (11) 15. Relay lid (15)
» Remove the mounting screws and clips.
12. Itlumination control knob (12) [oe] Install or Connect (Figure 14)
+ Pull the controller bezel to release the locks and
disconnect the connector. To install, follow the removal steps in the reverse
13. Side defroster nozzle (13) order, noting the following points:
* Push out the side defroster nozzle from the rear 1. After installing each connector, check the
side of the instrument panel assembly. operation of each equipment.

INSTRUMENT PANEL REINFORCEMENT

. Instrument panel assembly

. Instrument center/side stay

Oa & Oh
. Defroster nozzle/ventilation duct

COn
. Intermediate duct
. Brake/clutch fluid reserve tank
. Washer tank/bracket
. Instrument reinforcement assembly
. Instrument support bracket
. Body harness/controller/radio
wey
ee
ae

re nt mete mee ce ee
Numbers ©-@ denote the order of removing bolts.

Figure 21. Instrument Panel Reinforcement Removal or Installation

10D-14 STEEL TILT CAB

| Remove or Disconnect (Figure 21)

1. Instrument panel assembly (1)

« Refer to “Instrument panel assembly ” in this
Section.
2. Instrument center/side stay (2)
» Remove the mounting bolts @) - @.
3. Defroster nozzle/ventilation duct (3)
- Refer to “Heater/Air Conditioner Workshop
Manual”.
4, Intermediate duct (4)
5. Brake/clutch fluid reserve tank (5)
* Remove the level switch connector and remove
the 4 nuts.
» Extract the fluid and remove each tube.
CAUTION: Don’t apply the brake/clutch fluid to
the resin portions and painted portions in any
case.
6. Washer tank/bracket (6)
* Remove the washer motor connector and
washer tube and remove the two bolts fixing the
bracket and the one bolt in the lower part of the
tank.
7. Instrument reinforcement assembly
« Remove ail the connectors of electrical
equipments included in the body harness and
the connectors and [H-12]| and that
joint the body harness and other harnesses. For
connector numbers and positions, refer to
Section 8 “CAB AND CHASSIS ELECTRICAL”.
» Remove the mounting bolts @) - ().
» Remove each air conditioner control cable. For
removal, refer to Section 1 “HEATING AND AIR
CONDITIONING”.
8. Instrument support bracket
» Remove the bolts @2 ,@3) and remove the
instrument support bracket from the instrument
reinforcement assembly .
9. Body harness/controller/radio
« Remove the body harness/controller/radio from
the instrument reinforcement assembly. Refer to
Section 8 “CAB AND CHASSIS ELECTRICAL”.

| Install or Connect (Figure 21)

To install, follow the removal steps in the reverse

order, noting the fallowing points:
1. Perform air bleeding for the brake and clutch.
2. Tighten each boits to the specified torque.

[A] Tighten
* Clutch pedal bracket upper bolt @ to 37 N-m
(27 |b-it).
* Steering column bracket bolt (@) to 20 N-m (14
Ib-ft).
» Brake pedal bracket upper bolt @) to 42 N-m
(31 Ib-ft).
 STEEL TILT CAB 10D-15

HEADLINING

1. Roof ventilator grille

2. Clip
3. Front retainer/clip
4. Head lining
5. Insulator

Figure 22. Headlining Removal or Installation

. : 2. Clip (2)
[eo] Remove or Disconnect (Figure 22) 3. Front retainerictip (3)
1. Roof ventilator grille (1) (figure 23) : Remove the clips at 5 positions and remove the
* Remove the one mounting screw and pull out retainer.
the clips at 4 positions. 4. Head lining (4)
5. insulator (5)
Front side ——»
fe install or Connect (Figure 22)
To install, follow the removal steps in the reverse
order.

& Roof panel

Roof ventilator
grille

/
Clip

Figure 23. Roof ventilator grille Removal

10D-16 STEEL TILT CAB

DOORS
DESCRIPTION
Doors on these vehicles are mounted to the cab allows the door’s rear alignment.
by a pair of hinges. The cab’s door frame has Most of the door components, such as window
floating cage plates that allow forward up and regulator, window, lock, handles and trim panel can
down, and in and out adjustment of the door. An be serviced with the door on the vehicle.
adjustable striker plate in the rear of the frame
DOOR

1
. Head lamp grille
2 . Front combination lamp
3 . Ornament corner piece
4 . Front corner panel
5 . Door harness connection
6 . Door check arm
7 . Front door assembly

Figure 24. Door Assembly Removal or Installation

fra] R Disconnect (Figure 24) 5. Door harness connection (5)

emove or Misco g * To remove the door on the passenger’s seat
1. Head lamp grille (1) side, remove the glove box and disconnect the
» Pull out the head lamp grille toward you. connector. (Figure 25) .
2. Front combination lamp (2) * To remove the door on the driver’s seat side,
the 3 mounting screws and connectors. disconnect the connector from the bottom side
* Remove
3. Ornament corner piece (3) of the instrument panel. (Figure 26)
« Remove the cover and 3 mounting bolts.
4. Front corner panel (4)
+ Remove the 3 mounting screws and pull out the
front corner panel.
 STEEL TILT CAB 10D-17

Figure 28. Front door Assembly

* Remove the 2 mounting bolts for each hinge on

the rear side while the door is open.(Figure 29)

Figure 26. Driver's seat side

6. Door check arm (6) (Figure 27)

* Remove the 2 mounting bolts on the door side.

tf SAB ANN
- _ Check arm

== |
Door harness
XN connectign —

Front door
‘X \ \
ASM X \
6
a Figure 29. Door Mounting Bolts
x install or Connect (Figure 24)
Figure 27. Door check arm To Install, follow the removal steps in the reverse
order, noting the following points:
7. Front door assembly (7) 1. Tighten the mounting bolt to the specified
» Remove the front side of the 3 mounting bolts torque.
for each hinge while the door is closed.(Figure
28) Tighten
NOTICE: To prevent scratches, support the al 9g
door with a waste cloth or wooden piece. « Mounting bolts to 25 N-m (18 Ib-ft).
10D-18 STEEL TILT CAB

LOCK MECHANISM

1. Trim panel
2. Water-proof sheet
3. Glass run rear channel
4. Lock mechanism

Figure 30. Lock Mechanism Removal or Installation

: . 4. Lock mechanism (4)
fe Remove or Disconnect (Figure 30) * Disconnect each link (Figure 32) and remove
1. Trim panet (1) the 3 mounting screws.
« Refer to “Trim panel” in this Section. of
2. Water-proof sheet (2) (Figure 31) View @ Shown inFigure * ide nandie
- Peel off the water-proof sheet carefully with a
cutter or knife. Take care not to damage it when Link al
‘ . th TEMOV.
peeling it off. position

Door lock ASM

Figure 31. Water Proof Sheet Removal

Door lock cylinder
3. Glass run rear channel (3)
* Pull out the 2 mounting screws. Figure 32. Lock Mechanism Removal
 STEEL TILT CAB 10D-19

[oe] Install or Connect (Figure 30) Tighten

To Install, follow the removal steps in the reverse * Fixing bolts to 13 N-m (113 Ib-in) ~18 N-m (13
order, noting the following points: tb it)
1. Tighten the Fixing bolt to the specified torque. 2. After installation, check the operation.
LOCK CYLINDER AND OUTSIDE DOOR RELEASE HANDLE

1. Trim panel
2. Water-proof sheet
3. Outside door release handle
4. Lock cylinder

Figure 33. Lock Cylinder and Ouysid Door Release Handle Removal or Installation
4. Lock cylinder (4)
| Remove or Disconnect (Figure 33)
* Disconnect the link and pull out the clip.
1. Trim panel (1)
fos] Install or Connect (Figure 33)
« Refer to “Trim panel” in this Section.
2. Water-proof sheet (2) (Figure 31) To Install, foliow the removal steps in the reverse
» Refer to “Lock mechanism” in this Section. order, noting the following points:
3. Outside door release handle (3) (Figure 34) 1. Tighten the Mounting bolt to the specified torque.
* Disconnect the link and remove the 2 mounting
bolts. Tighten

« Mounting bolts to 13 N-m (113 Ib-in) ~18 N-m

(13 Ib ft)

of" ee

Outside door
release handie

Figure 34. Outside Door Release Handle Removal

10D-20 STEEL TILT CAB

TRIM PANEL

CARY
Grommet

1. Guard bar
2. Regulator handle
3. Inner waist seal
4. Screw
5. Door pull case
6. Trim panel

Figure 35. Trim Panei Removal or Installation

5. Door pull case (5)

[J Remove or Disconnect (Figure 35) * Remove the 2 mounting screws.
1. Guard bar (1) NOTICE: The above parts 2 ~ 5 can be
- Open the grommet and remove the 2 screws. removed in any order or each of them can be
2. Regulator handle (2) removed independently.
3. Inner waist seal (3) 6. Trim panel (Figure 36) -
» Remove each clip from the rear side with a * Remove the clips at 13 positions.
bladed screwdriver. Note that excessive force
will cause deformation.
4. Screw (4)
 STEEL TILT CAB 10D-21

2. Align the front end together with the 4 claws in the

upper part of the trim panel and insert the clips in
©) Ctip position sequence starting from the front end clip. Note
that applying force in transverse direction will
cause deformation.(Figure 38)

© Ctip position

NIT
- Waist seal inner waist seal
sectional shape
Trim panei

Figure 36. Trim Panel Clip position

| Install or Connect (Figure 35) Door trim
pad claw
To Install, follow the removal steps in the reverse
Room
order, noting the following points: side em trim panes
1. Adjust the trim panel clip to the mounting hole on
the door panel side and install the trim pad so as
Figure 38. inner Waist Seal Installation
to provide any float, skewness or door harness
bite.(Figure 37}

Figure 37. Door Panel Clip Hole position

10D-22 STEEL TILT CAB

WINDOW AND WINDOW REGULATOR ASSEMBLY

. Trim panel
. Speaker
. Door pull case bracket
. Door-out one-way valve
. Water-proof sheet
. Outer waist seal
Glass
. Window regulator
. Glass run
. Glass run rear channel
ne

Speaker connector
4

Figure 39. Window and Window Regulator Removal or Installation

NOTICE: it is a good practice to crisscross
cracked glass with strips of masking tape before
removing it ; this will help hold the glass together. {Window 4
regulator
| Remove or Disconnect (Figure 39)

1. Trim panel (1)

* Refer to “Trim pane!” in this Section.
2. Speaker (2)
« Remove the 3 screws and 1 clip and disconnect
the connector.
. Door pull case bracket (3)
B®

, Door-out one-way valve (4)

. Water-proof sheet (5) (figure 31)
an

« Refer to “Lock mechanism ” in this Section.

. Outer waist seal (6) Figure 40. Mounting Screw position
. Glass (7)
=~

« Lower the glass to a position where the * Lower the front side of the glass. After the front
mounting screw can be seen, and remove the 4 side of the glass comes off from the glass run,
screws.(Figure 40) pull up the rear side of the glass.(Figure 41)
 STEEL TILT CAB 10D-23

[oe Install or Connect (Figure 39)

To Install, follow the removal steps in the reverse
order, noting the following points:
1. Align the notch (@) of the glass run lip with the
door outer waist line @) . Align the glass run slit ©)
with the door B and fit the glass run between @)
and @) . Next, align the notch ©) of the glass run
lip with the door outer waist line ©) and fit the
glass run between @) and © . Fit the glass run in
the channel within the door. (Figure 35 on next
page)
Fit the glass run with the lip toward the outside
of the vehicle.
2. While the front side of the glass is lowered, insert
the glass into the door panel. First, insert the rear
side of the glass into the glass run, then insert the
front side into the glass run. Raise the front side
gradually along the giass run.

NOTICE: When reusing the glass run, apply

the sealant to the range shown in the figure.
Figure 41. Door Glass Removal (Figure 44)

8. Window regulator (Figure 42) 3. Temporarily tighten the window regulator

* Remove the 5 mounting screws. mounting screw @) (basic hole) and tighten () to
©) firmly. Lastly, tighten @) (basic hole) firmly
(Figure 43) and tighten it to the specified torque.

Tighten
« Fixing bolts to 7 N-m (61 Ib-in)

L@ Glass run rear channel

jo mounting screw
Le
V7 tide regulator
“mounting screw
position

Figure 42. Window Regulator Removal

9. Glass run
* Pull out the glass run from the door frame
groove.
10. Glass run rear channel
* Pull out the 2 mounting screws. Figure 43. Window Regulator Installation
CAUTION: Always wear heavy gloves when
4. Check the water-proof sheet for breakage.
handling glass to minimize the risk of injury.
10D-24 STEEL TILT CAB

Sealant application range

( Glass guide >

ae L_© alll |

al rit
¢ c
U W
Sealant
\,
\ Outside Inside Outside | inside

Glass run
Outside inside
Giass guide

Figure 44. Glass Run Installation

 STEEL TILT CAB 10D-25

CAB MOUNTS
The cab is mounted to the frame at four points :
with two pivot brackets on the front and a pair of = Remove or Disconnect (Figure 45)
fastening brackets at the rear. Rubber cushions are 1. Cab mounting rear bracket
mounted on the rear brackets to help absorb road * Remove the nut and pull up the bracket.
shock. - Remove the bolt from the cab-side bracket.
The attaching bolts of all mount brackets should 2. Mounting rubber
be checked for tightness at regular intervals. A * Remove the 4 bolts.
loose bracket will allow the cab to shift and 3. Cab mounting bracket
eventually cause the failure of other cab mounting « Remove the 2 bolts and the 4 nuts.
components.
[oe] install or Connect (Figure 45)
REAR MOUNT BRACKETS AND
CUSHIONS To Install, follow the removal steps in the reverse
order, noting the following points:
Periodically check for worn or broken mount 1. Tighten the mounting bolts to the specified
cushions. Replace the cushions as necessary. torque.
Shims can be added or removed to adjust bracket 2
height and keep the cab level and securely Tighten
mounted. - Mounting bolts [A] to 88 N-m (65 {b-ft).
« Mounting bolts [B] to 50 N-m (37 Ib-ft).
« Mounting bolts [C] to 81 N-m (60 Ib-ft).

Figure 45. Rear Mounting Brackets and Cushions

Removal and Installation
10D-26 STEEL TILT CAB

CAB MOUNTING LEVER

1. Cab assembly
2. Cab mounting bracket fixing bolt
3. Cab mounting lever assembly
4. Anchor arm
5. Anchor arm fixing bolt

Figure 46 Torsion Spring and Lever Removal or Installation

The torsion spring and lever act to assist in | install or Connect (Figure 46)
raising and lowering the cab. The spring is a steel
bar splined to a torsion lever and to an anchor plate To Install, follow the removal steps in the reverse
which is bolted to the cab pivot mount. The torsion order, noting the following points:
lever is bolted directly to the cab. As the cab is 1. When installing the anchor arm, align the match
lowered, the torsion lever twists the torsion spring mark with the missing tooth of the torsion bar.
against the anchor plate and provides a 2. Tighten the each bolts to the specified torque.
counterforce.This prevents the cab from falling too
quickly and also reduces the effort needed to raise FQ] Tighten
the cab.
* Mounting Bolts [A] to 118 N-m (87 Ib-ft).
CAUTION: The torsion spring is loaded when the » Fixing Bolts [B]to 83 N-m (61 lb-ft).
cab is in the operating position. All torsion spring
Service is to be performed only with the cab in the
raised position.

[+9] Remove or Disconnect (Figure 46)

1. Cab assembly (1)

- Refer to "Cab assembly” in this section.
2. Cab mounting bracket fixing bolt (2)
» Remove the left-hand 4 bolts and right-hand
4 bolts (upper = 2, side = 2)
3. Cab mounting lever assembly (3)
4. Anchor arm (4)
5. Anchor arm fixing bolt (5)
 STEEL TILT CAB 10D-27

HOLD-DOWN MECHANISM
LOCK ASSEMBLY

Cab lock controi unit fixing bolt

ASM fixing nut

Adjust nut e@

N ak
<<
Wave washer

1 Snap pin

Cab tock controi unit fixing bolt

1. Hand lever hook rod

2. Hook rod assembly
3. Cab lock assembly
4. Cab lock control unit assembly
Tiit handle fixing bolt 5. Tilt handie assembly

Figure 47. Lock assembly Removal cr Installation

The torsion spring is loaded when the cab is in 1. Hand lever hook rod (1)
the operating position. To prevent the cab from « Pull out the snap pins and remove the washers
tilting forward, hold-down hooks and secondary and wave washers.
catch are mounted to the back of the cab. 2. Hook rod assembly(2)
Instructions for cab tilting are in the Owner’s and 3. Gab lock assembly(3)
Driver's Manual. * Remove the 3 fixing nuts.
4. Cab lock control unit assembly(4)
«= Remove the 3 fixing bolts.
| Remove or Disconnect (Figure 47) 5. Tilt handle assembly(5)
* Remove the 3 tilt handle fixing bolts.
Preparation:
* Uniock the tilt lever.
» Mark the position of the lock assemblies on both
sides of the cab.
 10D-28 STEEL TILT CAB

[oe] Install or Connect (Figure 47) Tighten

1. Tilt handle assembly (5) : Fixing Bolts to 19 N-m (14 Ib-ft).
2. Cab lock control unit assembly (4) 4. Hook rod assembly(2)
3. Cab lock assembly (3) (Figure 48) 5. Hand lever hook rod (1)
* When installing the Cab lock assembly, - Change the control lever position from (@) to ©)
Temporarily tighten the rear mounting @ with and hold the control lever so that @)may touch
the left and right cab lock ASM mounting nuts in the bracket. At that time, adjust the lock nuts
the order shown in the figure, tighten @) to @ to (©)and @)and tighten them to the specified
the specified torque, and lastly tighten () firmly. torque so that both @) and (may touch the
bracket. (Figure 49)

A _-~ Rear mounting

ie
3. Cab Tock ASM
(leftside!)
{right side)
@
@
@
©
. ODO
DO
©
@

Figure 48. Cab Lock Assembly Installation

1. Hand lever
hook rod

Controllever / -
oh

\ \_ So
ay
@; rs
yt ° 2. Hook rod ASM

© ©
4. Cab lock control
unit ASM
AaB

Bracket

Figure 49. Hook rod assembly and Hand lever hook rod Installation
 STEEL TILT CAB 10D-29

CAB REPLACEMENT

Details 1

Cab-side front
mounting rail

\
2 Frame-side mounting lever
\_ JS
1. Cab stay pin and nut 2. Gab mounting bolt 3. Cab ASM

Figure 50. Cab Replacenent

1. Heater hose/air conditioner piping
[+ Remove or Disconnect (Figure 50) * Refer to “Heating and Air Conditioning” in
Preparations; Section 1.
; 2. Accelerator control cable
« Before removal or installation of the cab ASM, - Refer to “Fuel System” in Section 6C.
remove the following connections. The Perform the work surely according to the
removal order is free. However, perform each procedure fit for the mounted engine.
step surely referring to each workshop 3. Brake fluid piping
manual.
10D-30 STEEL TILT CAB

* Refer to “Hydraulic Brakes” in Section 5A.

4. Hydraulic clutch piping
* Refer to “Clutch” in Section 7C.
5. Transmission control cable / linkage
¢ Refer to the Sections ranging from Section
7A.
» Perform the work surely according to the
procedure fit for the mounted engine.
6. Parking brake control cable
* Refer to “Parking Brake” in Section 5C.
7. Steering linkage
* Refer to “Steering Linkage” in Section 3B1.
8. Harness connector/frame earth bolt
* Refer to “Cab and Chassis Electrical” in
Section 8.
« After disconnecting all the above connections,
tilt the cab for a tilt cab vehicle or remove the
rear mounting connection for a non-tilt
vehicle. For removal of the rear mounting,
refer to “Cab mounts” in this Section.

1. Cab stay pin and nut

2. Cab mounting boit
3. Cab ASM

x Install or Connect (Figure 50)

To Install, follow the removal steps in the reverse
order, noting the following point.

Tighten
* Bolts to 82 N-m (61 Ib-ft).
 STEEL TILT CAB 10D-31

SPECIFICATIONS
FASTENER TORQUES

Instrument Panel Reinforcement Front Door fixing bolts

Brake Pedal

prackers
eats Sh
F Fy A YO TT
AG eo oo =
<
ea ice)
Ne reage
LU
GF 3
ct m7)Loe
On ee Bhs oa. aS cI ; f
cI Sy ( 72 ep} }y a
PS a ay WE se fi
HAZCA NS /
‘eT rt
Steering “ \ i
Ca
Colum eS Ce Th !
\ Brackets L_25(18)_] =a | I
Seat Belt fixing bolts
Window Regulator fixing bolts

\
44 (33

Bracket

NN
Seat belt
tongue side
ASM

Front Mounting fixing bolts

118 (87
PIE)

Figure 51. Fastener Torques

MEMO
MEMO
MEMO
 PUBLICATION NO.

mr NPRD-O0SKAO1 -C1.54
Printed in U.S.A
NPDO1-WSM-CO01