Toyota Forklift

TOYOTA FORKLIFT
REPAIR MANUAL
TOYOTA MOTOR CORPORATION
FOREWORD
This repair manual applies to the Toyota F o rk lift 4FG10, 4FG15, 3FG20, and
3FD 30 series, and covers the procedures essential fo r performing the inspec
tion, adjustment, and repair on the engine, chassis, and material handling
system w ith special attention directed to overhaul.
I t is emphasized that this manual be fu lly utilized to preserve the high standard
o f performance and du rab ility originally b u ilt into the Toyota fo rklifts, and to
maintain top operating condition through appropriate maintenance.
The vehicles as o f March 1980 have been used as the standard in the prepa
ration o f this manual. A ll subsequent m odifications shall be n o tifie d to you
through the Toyota Parts and Service News.
The follow ing repair manuals should be as reference in connection w ith this
manual.
TOYOTA 4P ENGINE REPAIR M A N U A L No. 95649
TOYOTA 5R ENGINE REPAIR M A N U AL No. 95648
TOYOTA 5P ENGINE REPAIR M A N U AL No. 95647
TOYOTA 2J ENGINE REPAIR M N A U AL No. 95646
TOYOTA MOTOR CORPORATION

SECTION INDEX
NAME
GENERAL
ENGINE
CLUTCH
TOROUE CONVERTER
TRANSMISSION & DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
MATERIAL HANDLING SYSTEM 1
APPENDIX 1
’
GENERAL
Page
VEHICLE EXTERIOR VIEWS ............................................ .................. 0- 2
VEHICLE LISTING ............. ................................................................... 0- 3
FRAME NUMBERING SYSTEM .. ............................................... 0- 5
LOADING CURVE ................................................................................... 0- 6
VEHICLE DIMENSIONS ................ ................................................ °“ 7
TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS .. 0- 9
ABBREVIATIONS AND OPERATIONAL TIPS .............................. 0 -1 1
RECOMMENDED LUBRICANT Q UANTITY & KIND .................. 0 -1 2
PERIODIC MAINTENANCE ................................................................. 0 -1 3
LUBRICATION CHARTS .............. ....................................................... 0 -2 1
- 5 -
VEHICLE EXTERIOR VIEWS
Fig. 0-2 Rear V iew

0 -3
VEHICLE LISTING
Payload Model Engine Type Drive System Remarks
4FG10
4P
11" Clutch
©
02-4FG10 Torque Converter ©
40-4FG10 11” Clutch ©
1.0 Ton 5R
3FD10 11" Clutch ©
2J
02-3FD10 Torque Converter ©
4FG14
4P
11" Clutch ©
1.35 Ton
40-4FG14
5R
11" Clutch ©
3FD14
2J
11" Clutch ©
02-3FD14 Torque Converter ©
4FG15
4P
11" Clutch ©
40-4FG15 11" Clutch
©
1.5 Ton 5R
3FD15
2J
11" Clutch ©
02-3FD15 Torque Converter
©
FG18
4P
11" Clutch ©
02-FG18 Torque Converter ©
1.75 Ton
40-FG18
5R
11" Clutch ©
42-FG18 Torque Converter ©
FD18 11" Clutch ©
2J
02-FD18 Torque Converter ©
3FG20 11" Clutch (PS) (PB) (P()

4P
02-3 FG 20 Torque Converter © ©
40-3 FG 20 11" Clutch (PS) (PB) @
5R
2.0 Ton
42-3 FG 20 Torque Converter © @
60-3 FG 20
5P
11" Clutch © © @
3FD20 11" Clutch (PS) @ @
2J
02-3 FD 20 Torque Converter © ©
- 7 -
0 -4
Payload Model Engine Type Drive System Remarks
FG23
4P
11" Clutch
© @ ©
02-FG23 Torque Converter
© ©
40-FG23
5R
11" Clutch
© ©©
2.25 Ton
© @
60-FG23
5P
11" Clutch © © ©
© @
FD23
2J
11" Clutch
© ©©
02-FD23 Torque Converter
© ©
3FG25
4P
11" Clutch © ©©
02-3FG25 Torque Converter © ©
40-3 FG 25
5R
11" Clutch © @ @
2.5 Ton
42-3FG25 Torque Converter © ©
60-3 FG 25 11" Clutch
@
©
©
5P
62-3FG25 Torque Converter © @
3FD25
2J
11" Clutch © © ©
02-3FD25 Torque Converter © @
FG28
5P
11" Clutch © © ©
02-FG28 Torque Converter © ©
2.75 Ton
FD28
2J
11" Clutch © © ©
02-FD28 Torque Converter © ©
2FG30
5P
11" Clutch © © ©
3.0 Ton
©
©
©
3FD30 11" Clutch

2J
02-3FD30 Torque Converter © @
(PS) : Power Steering Standard Equipment
(PB) : Power Brake Standard Equipment
(P£) : Power Clutch Standard Equipment
- 8 -
0 -5
FRAME NUMBERING SYSTEM
li
Fig. 0-3 Frame Serial Num ber Location
Fig. 0-4 Frame Serial Num ber
FRAME NUMBERING SYSTEM
Payload
1.0 ~ 1.75 Ton 2.0 ~ 2.5 Ton 2.75 & 3.0 Ton
Engine Type
4P Engine FG18-20011 3FG25-20011 —
5R Engine 40 FG 18-20011 40 3FG25-20011 —
5P Engine — 60 3FG25-20011 2FG30-20011
2J Engine FD18-20011 3FD25-20011 3FD30-20011
- 9 -
0 -6
LOADING CURVE
k g -c m lb-in
r
1 Ton
& 2200
2000
177 in
—^
q m pM
(Hie1600 I
TO 80 90 100 110 120

5?: 1200
20 24 28 32 36
lbf.B IQ ~
2700
t 2300
1.35 Ton 12100
so 60 70 80 90 100 110 120

1 20 24 28 32 36 40
1600 - 4 i| jb r—
1300
6.0 m
1.5 Ton I 1100

" m
|! I 24 28 32 38 40
34SE &
1.75 Ton
70 80 90 100 110 1 28 32 36 40 44
1W.8'"
4000
m n
107in *
2 Ton s 1
Is k
rr
._ Ltd
60 60 70 80 90 100 110120 130 2 0 2 4 2 8 32 3 6 4 0 4 4 4 8 6 2
60001-167.6iltea
s
s W m Sw
2.25 Ton a
80 60 70 80 90 100 110 120 130

c J .T T 1
24 28 32 36 40 44 48 62
t—8 jin l’. |

‘s
a O k
2100 _ 4.6 m s
i 1900
i
2.5 Ton 1700 S
B:; 1300
A « 900
-
60 60 70 80 90 100 110 120130 20 24 28 32 36 40 44 48 62
I P
2.75 Ton
i 60 70 80 90 100 110 120 130

I 28 32 36 40 44 48 62
3000
2700
# 2400
i- i- i
3 Ton M
— M 2100
s= 60 70 80 90 100 110 120 130

£ 20 24 28 32 36 40 44 48 52
Fig. 0-5 Loading Curve Fig. 0-6 Loading Curve
- 10 -
0 -7
VEHICLE DIMENSIONS
-------------- z
-----
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- 11 -
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- 12 -
0 -9
TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS
Nominal Specified Torque kg-cm (ft-lb)

Type Diameter Pitch
Specified Tightening Range
6 1.0 47 3.39) 40- 70 2 .9 - 5.1)
8 1.25 111 8.01) 100- 160 7 .2 - 11.6)
10 1.25 225 16.2) 190 ~ 310 1 3 .7 - 22.4)
4T 10 1.5 214 15.5) 180- 300 1 3 .0 - 21.7)
12 1.25 (ISO) 441 31.8) 350 - 550 2 5 .3 - 39.7)

Bolts w ith " 4 " mark
on head 12 1.5 389 28.1) 350 ~ 500 2 5 .3 - 36.1)
12 1.75 374 27.0) 300 ~ 500 2 1 .7 - 36.1)

Part No. example
9 1 0 0 0 -4 0 0 0 0 13 1.5 508 36.7) 450- 700 3 2 .5 - 50.5)
14 1.5 633 45.7) 500 - 800 36.1 - 57.6)
14 2.0 593 42.8) 470 — 770 3 3 .9 - 55.6)
16 1.5 957 69.1) 750 ~ 1100 5 4 .2 - 79.4)
16 2.0 906 65.4) 710 — 1060 5 1 .3 - 76.5)
6 1.0 71 5.13) 60 ~ 90 4.3 — 6.5)
8 1.25 166 12.0) 150- 220 1 0 .8 - 15.9)
10 1.25 337 24.3) 300 — 450 21.7 — 32.5)
10 1.5 322 23.2) 270- 420 1 9 .5 - 30.3)

5T
12 1.25 (ISO) 662 47.8) 500 — 800 36.1 - 57.6)
Bolts w ith " 5 ” mark
12 1.5 584 42.2) 500 ~ 700 36.1 - 50.5)
on head
12 1.75 561 40.5) 480 — 680 3 4 .7 - 49.1)
Part No. example
13 1.5 763 55.1) 650 ~ 900 46.9 — 65.0)
9 1 0 0 0 -5 0 0 0 0
14 1.5 890 64.3) 700 - 1050 5 0 .5 - 75.8)
14 2.0 950 68.6) 750 — 1100 5 4 .2 - 79.4)
16 1.5 1436 103.7) 1200 — 1700 8 6 . 6 - 122.7)
16 2.0 1358 98.0) 1 1 5 0 - 1650 8 3 . 0 - 119.1)
6 1.0 71 5.13) 60- 90 4.3 — 6.5)

6T
8 1.25 166 12.0) 150- 220 1 0 .8 - 15.9)
Bolts w ith " 6 ” mark
10 1.25 337 24.3) 300- 450 2 1 .7 - 32.5)
on head
10 1.5 322 23.2) 270- 420 1 9 .5 - 30.3)
Part No. example
12 1.25 (ISO) 662 47.8) 500 — 800 36.1 - 57.6)
9 1 0 0 0 -6 0 0 0 0
12 1.5 584 42.2) 500- 700 36.1 — 50.5)
12 1.75 561 40.5) 480- 680 3 4 .7 - 49.1)
- 13 -
0 -1 0
Nominal Specified Torque kg-cm (ft-lb)

Type Pitch
Diameter Specified Tightening Range
6 1.0 95 ( 6.86) 80 ~ 120 ( 5.8 ~ 8.7)
8 1.25 221 ( 16.0) 200- 300 ( 14.4 ~ 21.7)
10 1.25 449 ( 32.4) 400- 550 ( 28.9 ~ 39.7)
7T 10 1.5 429 ( 31.0) 370- 520 ( 26.7 ~ 37.5)
12 1.25 (ISO) 883 ( 63.8) 750 ~ 1050 ( 54.2 — 75.8)

Bolts w ith " 7 " mark
on head 12 1.5 778 ( 56.2) 700 - 900 ( 50.5 ~ 65.0)
12 1.75 748 ( 54.0) 680- 850 ( 49.1 ~ 61.4)

Part No. example
9 1 0 0 0 -7 0 0 0 0 13 1.5 1017 ( 73.4) 800 — 1200 ( 57.6 - 86.6)
14 1.5 1267 ( 91.5) 1000 — 1500 ( 72.2 ~ 108.3)
14 2.0 1186 ( 85.6) 950 ~ 1400 ( 68.6 ~ 101.1)
16 1.5 1915 (138.3) 1 5 0 0 -2 3 0 0 (1 0 8 .3 - 166.1)
16 2.0 1811 (130.8) 1 4 0 0 -2 2 0 0 (101.1 - 158.8)
Note:
1. Example 91 1 1 1 - 4 0 6 2 0
----------- Bolt length under head (mm)
----------------- Bolt nominal diameter (mm)
2. The torques specified above are fo r tightening steel material.

In case o f tightening materials other than steel, or when the bolt is subjected to heat,
vibration, or other stresses, appropriate corrections should be made to the values in
the above list.
- 14 -
0 -1 1
ABBREVIATIONS AND OPERATIONAL TIPS
Abbreviation (Code) Meaning
ASSY Assembly
LH Left Hand
OPT Option
O/S Oversize
PS Power Steering
RH Right Hand
SAE Society o f Autom otive Engineers (USA)
SST Special Service Tool
SUB-ASSY Sub-Assembly
T= Tightening Torque
U/S Undersize
OPERATIONAL TIPS
1. Safe operation
(1) Make sure that correct size wire is used when lifting heavy material.
(2) A fte r jacking up, always be sure to support with rigid rack or stand.
2. Availability o f SST and measuring tools

Have the SST's and measuring tools available before starting work.
3. Neatness and orderliness

(1) Keep the working place neat and orderly so as to make it easier to w ork on your job.
(2) Disassembly o f hydraulic equipment should always be done in clean place.
4. Genuine Toyota parts

Genuine Toyota parts should be used even in the replacement o f packings, gaskets, " 0 " rings, and
similar parts.
5. Repairs on electrical system

Before doing any repairs on the electrical system, disconnect the cables from the battery terminals.
Always disconnect the (—) cable first.
6. Tightening torque when installing

Be sure to observe the tightening torque given in this manual. If not specified, tighten to the torque
listed in "Tightening Torques fo r Standard Bolts".
- 15 -
RECOMMENDED LUBRICANT QUANTITY & KIND
0 -1 2
-
16
-
o
O
I-
O
ill
LU
LU
Q.
CC
c
o
c
c
‘o
>
u
>
>
’>
>
-X
“D
X
U
“O
D
O
O
O
“O
O
C
C
C
c
c
c
'c
©
_Q
_©
JC
©
o
o
c
o
i—
+ -*
D
+-<
_Q
ZD
CD
V—
CD
CD
CD
CD
CD
CD
CD
_o
_o
X)
L—
CD
CD
"o
O )
Q_
Q_
O )
Q.
“O
q.
CD
"O
O)
CO
1
£
“O
O
_Q
CD
CD
C/5
0
>
>
o
o
I
>
0
w
©
©
©
j' z
Q
C
r->
_C
o
o
o
CO
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CD
CD
• •
CN
CN
o
O
0 £
"O
O
d)
-E c
©
CO
OC
CD
CD
CD
CD
Q.
Q .
1 ©
<D O
JE
O
O
o
o
o
o
099 000 L
00
CO
CO
CO
CO
CM
00
Hours 170 340 500 1170 1340 1500
Item Operation
-
a
o
00
p t
CO
CO
CM
to
CM
Months
55
O
O
O
O
O
O
O
O
O
O
O
O
Oil and water leakage Check, retighten
O
O
O
O
O
o
o
o
o
o
Tire damage & unusual wear Check
O
O
O
O
O
O
o
o
o
o
o
Tire inflation Check, adjust
O
O
O
O
O
O
O
o
o
o
o
o
Rim, hub nuts loosening & damage Check, retighten
O
O
O
O
O
o
o
o
o
o
All lights Check
17-
O
O
O
O
O
O
O
O
O
O
O
O
Mirrors d ir ty , damage, reflective state Check, adjust, clean
•
•
o
o
o
o
o
o
o
o
o
o
Hydraulic oil amount & contamination Check, replace
•
o
o
o
o
o
o
o
o
Radiator coolant am ount Check, replace
•
•
•
•
•
•
•
•
•
•
•
•
Engine oil Check, replace
O
O
O
O
O
o
o
o
o
Engine exhaust color & unusual noise. Cheek
_____ I
O
O
O
O
O
O
O
O
O
O
Brake operation & effectiveness Check
O
o
o
o
o
o
Parking brake operation & effectiveness Check
O
O
O
o
o
o
Clutch operation (engage-disengage state) Check
O
O
O
O
O
O
O
O
Steering wheel operation (steering state) Check

O
O
O
O
O
O
O
Horn Check
O
O
O
O
O
Actuation of instruments Check

_____________________ '
0 -1 3
09 9
o
Hours 170
O
340 500 830 1000 1170
00
1340 1500 2 0 00
CO
CO
CO
0 -1 4
Item Operation
-
£
M onth
00
05
CM
LO
CO
CO
CM
o
o
o
o
o
o
o
Fan belt tension & damage
O
Check, adjust
O
O
O
O
Torque converter fluid
o
o
o
o
•
o
o
o
o
o
o
Check, replenish, replace
(Torque converter vehicles only)
o
o
o
o
o
o
o
o
o
Engine starting condition o
o
o
Check, adjust
0
o
o
o
o
o
o
O
Rotating state when idling Check, adjust
O
O
O
O
o
o
o
o
o
o
o
o
o
o
o
Rotating state when accelerating Check, adjust

O
o
o
o
o
o
Engine oil contamination & oil leakage Check
O
O
O
O
O
O
O
•
•
•
•
•
o
o
o
o
o
o
o
Engine oil cleaner clogging & dirtying Check, replace
o
o
o
o
o
o
o
o
o
o
o
Fuel leakage & fuel pipe line Check, retighten

O
•
•
-
o
o
o
o
o
o
o
o
o
o
Fuel filter element clogging Check, replace
o
o
o
o
o
o
o
o
o
Check, clean
18
O
Feed pump filter clogging (D )

O
O
-
o
o
o
o
o
o
O
O
O
Check
O
O
Carburetor linkage wear (G)

'
o
o
o
o
o
o
o
o
O
O
O
O
Radiator water leakage Check
o
o
o
o
o
o
o
o
o
o
o
O
Rubber hose deterioration Check

o
O
O
O
O
O
O
O
O
O
O
Radiator cap operation & installed state Check

o
o
o
o
o
O •o
o
o
o
o
o
o
Fan blade and holder wear Check
O
O
O
O
O
O
O
O
O
O
O
O
Fan mounting loose & rattle Check, retighten
O
O
O
O
O
O
O
O
O
O
O
O
Clutch pedal play & floor clearance Check, adjust

o
o
o
o
o
o
o
o
o
o
O
Clutch unusual noise & slippage Check O

O
O
O
O
O
O
O
O
O
Clutch booster function & oil leakage (2) Check

o
o
o
o
o
o
o
o
o
O
O
O
Transmission oil leakage Check, retighten

o
o
o
o
o
o
o
O
O
O
Transmission control function & loosening Check, adjust

O
o
o
o
o
o
o
00
00
00
CO
CM
Hours 170 34 0 500 1000 1170 1340 1500
CO
CO
CO
CO
Item Operation
-
g
r*
00
CO
CM
CM
Month
LO
CO
o>
o
o
o
o
o
o
o
o
o
o
o
o
Torque converter fluid leakage Check, retighten
Torque converter control function
0
o
o
o
o
O
O
O
O
O
O
Check, adjust O
& loosening
Torque converter control valve & clutch
o
o
o
o
o
o
o
o
O
O
O
O
Check
function
o
o
o
o
O
O
O
O
O
O
O
Torque converter inching valve function Check
Torque converter clutch and brake pedal
o
o
o
O
O
O
O
O
O
O
O
O
Check, adjust
and clearance
o
o
o
o
o
o
o
O
O
O
O
Differential oil leakage Check, retighten
O
O
O
O
O
O
O
O
O
O
O
O
Tire tread groove depth Check
O
O
O
O
O
O
O
O
O
O
O
O
Metal piece, stone & others lodged in tire Check
-
O
O
O
O
O
O
O
O
O
O
O
O
Hub bolts loosening & damage Check, retighten
19
o
o
o
o
o
O
O
O
O
O
O
O
Rim, side ring & disc wheel damage Check
-
O
O
O
O
O
O
O
O
O
O
O
O
Wheel bearing excessive clearance Check, adjust
O
O
O
O
O
O
O
O
O
O
O
O
Wheel bearing abnormal noise Check

O
O
O
O
O
O
O
O
O
O
Steering wheel play Check, adjust
o
o
o
o
o
O
O
O
O
O
Steering wheel axial & radial excessive play Check, adjust

■
o
o
o
o
o
o
O
O
O
O
O
Steering gear box mounting loose Check

O
O
O
O
O
O
O
O
O
O
O
Steering gear box oil leakage Check, retighten
-
Rod, arm, bell crank excessive play
o
o
o
o
o
O
O
O
O
Check, retighten
& loosening
o
o
o
o
o
O
O
O
O
O
O
O
Power steering oil leakage Check
Power steering mounting & connection

O
O
O
O
O
O
O
O
O
O
O
Check, retighten
loose -
o
o
o
O
O
O
O
O
O
O
Brake pedal play & floor clearance Check, adjust

O
O
O
O
O
O
O
O
Air in brake system Check, adjust

0 -1 5
099
o
o
O
O
O
O
00
Hours 170 340 500 1000 1170 1340 1500
CO
CD
CO
CO
CO
CM
0 -1 8
Item Operation
-
£
o
M onth
r**
00
CN
CO
LD
CO
CN
a>
Head guard & back rest-deformation,
o
o
o
o
o
o
o
o
o
o
o
o
Check
cracks, injury
Direction indicator & warnings—operation,
o
o
o
o
o
o
o
o
o
o
o
O
mounted state Check
Lighting devices & reverse warning
O
O
O
O
O
O
O
O
O
O
O
O
Check
device—operation, mounted state
O
O
O
O
O
O
O
O
O
O
O
O
Seat loosened or damage Check, retighten

o
O
O
O
O
Tappet clearance Check, adjust (new

vehicle)
O
O
O
O
Battery fluid specific gravity Check
o
o
o
o
Hydraulic pressure Check, adjust
O
O
Ignition timing (G) Check, adjust
-
o
o
Injection timing (D ) Check, adjust
22
-
O
Glow plugs (D) Check

o
O
Engine compression Measure

•
Torque converter oil filte r Replace

o
Torque converter oil strainer Check, clean

•
•
o
o
o
o
o
o
o
o
o
O
Gear oils (except steering gear box) Check, replenish, replace

•
•
o
o
o
o
o
o
o
o
o
Differential oil Check, clean
O
Hydraulic oil tank strainer Check, clean

O
Hydraulic oil tank Check

•
•
Hyraulic oil filte r Replace (new
vehicle).
O
Wheel bearing grease Check, clean, replace

•
o
o
o
o
PCV valve operation (G) Check, clean, replace

0 -1 9
o
o o o
o
CM
O •
O
CO
00
O
CD
CO
o
o
ID
O
CO
o
o
o
o
CO
CO
o
CO
CO
o
o
ID
o
CO
o
o
D
o
X
0
a
O o o o o
0
SI .c
0
-C
0 0
.c
0
o
.c
(J (J CJ CJ CJ CJ
C
o
V-* O) c
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° i ill 0
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0 NSj? ■Q
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T5
0
a
D E o 0
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0 T o 0
0 > a
0
0
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o ° z D JZ
h- o — CD CD
23 -
o
0 09
o
o
o
o
O
CO
O
00
CO
CO
Hours 170 340
CM
1000 1170 1340 1500
CO
CO
CO
CO
0 -2 0
Item Operation
-
05
O
LO
CM
*-
CO
r-*
00
M onth
CM
CO
o
Return spring weakend Check

O
Automatic adjuster operation Check

O
Brake drums-wear, damage Check

O
Backing brake—deformation, cracks Check

O
Backing brake mounting loose Check, retighten

O
Forks—deform ation Check, repair

O
Fork base part—cracks Check

O
Mast support metal—wear, damage Check

O
-
Relief pressure Check
Distributor cap high tension cord

O
Check
24
insertion (G)
-
O
Terminals at distributor burned (G) Check

Distributor cap enter term inal—wear,
O
Check
damage (G)
O
Plug cords-open (G) Check

O
Charger charging condition Check, adjust

o
Frame, cross members, etc.—damage,

cracks Check
# (2 ye ars)
Power steering hoses Replace
# (2 ye ars)
Power steering rubber parts Replace
# (2 ye ars)
Masterial handling equipment hoses Replace
0 -2 1
LUBRICATION CHARTS
Chain
Chain
Differential & Mast support cap
transmission case Front wheel bearing
Front wheel bearing
Brake master cylinder L ift cylinder support guide
(1.0 ~ 1.75 ton vehicles only)
Oil tank
Torque converter case
Rear axle beam (front)

Engine crankshaft
Rear wheel bearing
Rear wheel bearing Steering knuckle king pin
Steering knuckle king pin
Rear axle beam (rear)
Bell crank pin
0 : Check, lubricate
• : Replace
1 MP grease
2 M otor oil
3 Brake fluid
4 Hypoid gear oil SAE 90
5 Hydraulic oil 90
6 A u to fluid special
Fig. 0-8 Gasoline Vehicle Lubrication Chart
Chain Chain
Differential & Mast support cap
transmission case F ront wheel bearing
Front wheel bearing
Brake master cylinder L ift cylinder support guide
( 1-0 — 1.75 ton vehicles only)
Torque converter case Oil tank
Pneumatic governor
Rear axle beam (front)
Engine crankshaft
^ Rear wheel bearing
Rear wheel bearing A .
Bell crank pin Rear axle beam (rear)
0 : Check, lubricate
• : Replace
1 MP grease
2 Diesel engine oil
3 Diaphragm oil
4 Hypoid gear oil SAE 90
5 Hydraulic oil 90
6 A u to fluid special
7 Brake fluid
Fig. 0-9 Diesel Vehicle Lubrication Chart
- 25 -
ENGINE
Page
GENERAL ................................................................................................... 1- 2
ENGINE PERFORMANCE ....................................................................... 1 - 4
ENGINE REMOVAL (CLUTCH VEHICLE) 1- 5
ENGINE INSTALLATION (CLUTCH VEHICLE) 1 -1 0
ENGINE REMOVAL (TORQUE CONVERTER V E H IC L E S ) 1 -1 0
ENGINE IMPORTANT SPECIFICATIONS ........................................... 1 -1 2
ENGINE SPEED ADJUSTMENT ............................................................. 1 -1 4
AIR CLEANER ............................................................................................ 1 -1 7
MUFFLER .................................................................................................... 1 -1 8
RADIATOR .............. .................................................................... 1 -1 9
BATTERY .................... B H H ................. ........................... 1 -2 1
- 27 -
1 -2
GENERAL
Fig. 1-1 Engine Sectional V iew (4P)
Fig. 1-2 Engine Sectional V ie w (5R )
- 28 -
1 -3
Fig. 1-3 Engine Sectional V iew (5P)
Fig. 1-4 Engine Sectional V iew (2J)
- 29 -
1 -4
ENGINE PERFORMANCE
^ \lte m Displacement No-load Rated Output Maximum Torque

V e h ic ie \ ^ Engine
CC steady rpm ft-lb/rpm
PS/rpm HP/rpm kg-m/rpm
(SAE)
GROSS GROSS
4P 1493 2600 30/2400 9.5/1800
38/2600 77/2600
1 ton ~ GROSS GROSS

5R 1994 2600 41/2300 13.5/1800
50/2600 103/2200
1.75 ton
NET NET
2J 2481 2300 44/2200 14.5/2000
41/2200 100/2000
GROSS GROSS
4P 1493 3050 35/2800 10/1800
44/3000 77/2600
GROSS GROSS
5R 1994 2600 41/2300 13.5/1800
50/2600 103/2200
2 ton ~ 2.5 ton
GROSS GROSS
5P 2771 2300 54/2100 18.5/1400
60/2300 138/2000
2J NET NET
2481 2300 44/2200 14.5/2000
41/2200 100/2000
GROSS GROSS
5P 2771 2300 54/2100 18.5/1400
60/2300 138/2000
2.75 ton, 3 ton
NET NET
2J 2481 2600 50/2500 14.5/2200
47/2500 100/2200
- 30 -
1 -5
ENGINE REMOVAL
(CLUTCH VEHICLE)
1. Remove the rear toeboard.

(1) Set bolts
(2) Rear toeboard
Fig. 1-5 Removing Toeboard
2. Remove the engine hood.

(1) Engine hood stay cotter pins
(2) Radiator cover set bolts
(3) Engine hood
Fig. 1-6 Removing Engine Hood
3. Remove the air cleaner case.

(1) Hose clip
(2) Set bolts
(3) A ir cleaner case
Fig. 1 -7 Removing A ir Cleaner Case
4. Remove the battery

(1) Battery cables
(2) Battery cap
(3) Battery
(4) Set bolts
(5) Battery cape
Caution:
When disconnecting the battery cables, always
disconnect the minus terminal cable first.
Fig. 1-8 Removing Battery
- 31 -
1 -6
5. Disconnect the wiring.

(1) Wiring to alternator
(2) Wiring to distributor ignition coil
(3) Wiring to starter
(4) Engine ground wire
Caution:
In case of diesel engine, disconnect the wiring
to glow plugs.
Fig. 1-9 Disconnecting Wiring
6. Disconnect the piping and wires.

(1) Fuel piping
(2) Accelerator wire
(3) Choke wire or engine stop wire
7. Remove the balanceweight.

(1) Suspend the weight w ith wire rope
(2) Set bolt Fig. 1-10 Disconnecting Wires
(3) Balanceweight
Weights
1.0 ton Vehicle:
Approx. 540 kg (1191 lb)
1.35 ton Vehicle:
1.5 ton Vehicle:
1.75 ton Vehicle:
2.0 ton Vehicle:
Approx. 1260 kg (2778 lb) Fig. 1-11 Removing Balanceweight
2.25 ton Vehicle:
2.5 ton Vehicle:
2.75 ton Vehicle:
3.0 ton Vehicle:
8. Remove the m uffler.

(1) Exhaust pipe connector
(2) M uffler set bolts
(3) M uffler
Fig. 1-12 Removing M uffler
- 32 -
1 -7
9. Drain out the coolant.

(1) Drain out the radiator
(2) Drain out the engine
Fig. 1-13 Draining O ut Coolant
10. Remove the radiator.

(1) Hose clamps
(2) Radiator set bolts
(3) Radiator fan shroud
Fig. 1-14 Removing Radiator
11. Disconnect the oil pump.

(1) Loosen the alternator set bolt
(2) Remove the fan belt from pulley
(3) Oil pipes
(4) Oil pump set bolts
(5) Disconnect the oil pump
Caution:
Just disconnect the oil pump from the engine.
There is no need of disconnecting the piping.
Fig. 1-15 Disconnecting O il Pump
12. Remove the starter motor.

(1) Starter m otor wiring
(2) Set nut
(3) Starter m otor
Fig. 1-16 Removing Starter M otor
33
1 -8
13. Remove the clutch disc, clutch cover, and

flywheel.
Note:
For procedures on removing the clutch disc,
clutch cover, and flyw heel, refer to par. 2 —6 .
(1) Clutch housing cover

(2) Main drive shaft
UseSST 09210-20170-71
(3) Disconnect clutch rod
(4) Clutch cover
(5) Clutch disc Fig. 1-17 Removing Flywheel
(6) Flywheel
14. Lightly suspend the engine.

(1) Pass wire rope on the engine hooks
and lightly suspend the engine.
SST used:
09010-20110-71 when hoist is used.
09020-20110-71 when lift is used.
Caution:
The SST is considerably heavy so exercise
sufficient care.
Make sure that the wire rope is securely hooked.
It w ould be preferable to use a shackle. P '9 -1-18 Engine Lightly Suspended
15. Remove the engine mounting set nuts.
16. L ift up the engine w/transmission until the

mounting bolts pull out from the bracket.
■js
Caution:
Do not lift up too high since the clutch housing
and engine are still attached together.
Fig. 1-19 Removing Engine M ounting Set Nut
17. Insert wooden block under the transmission.
Fig. 1-20 Transmission Blocked
34 -
1 -9
18. Separate the clutch housing from the engine.

(1) Set bolts
Fig. 1 -21 Separating Engine
19. L ift up the engine and remove it from the

vehicle.
Caution:
Use care not to damage the oil pump.
Make sure that all wiring and piping have
been disconnected.
Fig. 1-22 Removing Engine

1 -1 0
ENGINE INSTALLATION (CLUTCH VEHICLE)
Install by performing the disassembly in reverse order.
Caution:
o The im portant point in assembling the engine to clutch housing is to f it in the dowel pins.
First insert the upper or lower dowel pin and then f it on the engine by slightly raisingor lowering it.
° Have the wooden block under the engine removed before starting to install the engine set nuts.
° Position the oil pump in an easy-to-assemble position before bolting down the engine.
If during assembly, the oil pump splines fail to mesh in w ith those at the engine, slightly turn the engine
crankshaft.
o Check the electrical wiring to see that there are no wrong connections before connecting the battery minus
term inal.
o Check the coolant and engine oil, and replenish if low before starting to tune up the engine,
o Tighten the flyw heel bolts to the following torque.
T = 5.8 ~ 6.6 kg-m (41.9 ~ 47.7 ft-lb) (4P, 5R)

T = 10 ~ 11 kg-m (72.2 ~ 79.4 ft-ib) (5P, 2J)
ENGINE REMOVAL
(TORQUE CONVERTER VEHICLES)
Note:
The procedures fo r removing the gasoline
vehicle engine up to the end o f operation 15,
engine mounting set nuts, are the same for
removing the torque converter vehicle engine
so th at they should be utilized.
The follow ing are the procedures from sepa
rating the engine fro m the torque converter.
16. Disconnect the forward and reverse shift

Fig. 1-23 Disconnecting S h ift and Inching Rods
rods and the inching rod.
17. L ift up the engine w/torque converter

assembly until the mounting bolts are
pulled out from the bracket.
Caution:
Do not lift up to o much as the torque con
verter and engine are still connected together.
Fig. 1-24 Removing Engine w /T o rq ue Converter Set Nut
- 36 -
1-11
18. Insert a wooden block under the trans

mission.
Fig. 1-25 Transmission Underside Blocked
19. Separate the torque converter from the

drive plate.
(1) Set bolts (6).
Important:
To turn the drive plate, turn it by hooking a
box wrench or open-end wrench on the crank
pulley bolt.
Fig. 1-26 Removing Drive Plate Bolt
20. Separate the torque converter from the

engine.
(1) Housing set bolts
Fig. 1-27 Separating Torque Converter fro m Engine
21. L ift up the engine and remove it from the

vehicle.
Caution:
Use care not to damage the oil pump.
Make sure that all wiring and piping have
been disconnected.
Fig. 1-28 Engine Removal
37
1 -1 2
ENGINE IMPORTANT SPECIFICATIONS (GASOLINE)
Engine Type 4P
1 Ton 2 Ton 5R 5P
Item Series Series
Total displacement cc 1493 (91 cu-in) 1994 (122 cu-in) 2771 (169 cu-in)
Bore x stroke 76.6 x 81.0 88.0 x 82.0 93.0 x 102.0

mm (3.01 x 3.18 in) (3.46 x 3.22 in) (3.66 x 4.01 in)
Compression ratio 8.5 8.2 8.3
kg/cm2 11.0 (250) 11.0 (250) 11.0 (250)

Compression pressure (rpm) (156.4 psi) (250) (156.4psi) (250) (156.4 psi) (250)
3 0 /2 4 0 0 3 5 /2 8 0 0 41/2300 54/2100
PS/rpn?UtPUt ^ AE Gross HP/rpm) (3 8 /2 6 0 0 ) (4 4 /3 0 0 0 ) (50/2600) (60/2300)
9 .5 /1 8 0 0 1 0 .0 /1 8 0 0 13.5/1800 18.5/1400
kg^m/rpm116 ^ A E Gross ft-lb/rpm ) (7 7 /2 6 0 0 ) (7 7 /2 6 0 0 ) (103/2200) (138/2000)
Full load max. fuel
g/PS-h/rpm 215/2600 220/1800 230/2300
consumption
62 2x 53 0x6 41 695x540x625 671x587x660
Engine dimensions mm (2 4 .5 x 2 0 .9 x 2 5 .2 in) (2 7 .4 x 2 1 .3 x 2 4 .6 in) (2 6 .4 x 2 3 .1 x 2 6 .0 in)
138 163 230

Service weight kg (304 lb) (359 lb) (507 lb)
Ignition tim ing BTDC/rpm 8°/550 10°/550 5°/700
Firing order 1- 3 - 4 -2 1 —3 —4 — 2 1_ 2 - 4 - 3
7.0 8.7 10.6

Total coolant £ (1.85 US gal) (2.30 US gal) (2.77 US gal)
3.9 4.8 7.0
Total engine oil (1.03 US gal) (1.27 US gal) (1.85 US gal)
No-load governed speed rpm 2 6 0 0 ± 50 3050 ± 5 0 2600 ± 50 2300 ± 50
+50 500 5 ° 700 ± 50

Idling speed rpm 500 - 0
- 38 -
1 -1 3
ENGINE IMPORTANT SPECIFICATIONS (DIESEL)
Engine Type 2J
Item 1 ton ~ 2.5 ton 2.75 ton & 3 ton
Total displacement cc 2481 (151 cu-in)
88.0 x 102.0
Bore x stroke mm (3 .46 x4 .01 in)
Compression ratio 21.0
27.0 (260)
Compression pressure kg/cm 2 (rpm) (383.9 psi) (260)
44/2200 50/2500
Rated output PS/rpm (SAE Net HP/rpm)
(41/2200) (47/2500)
14.5/2000 14.5/2200
Max. torque kg-m/rpm (SAE Net ft-lb/rpm ) (100/2200)
(100/2000)
Full-load max. fuel consumption g/PS-h/rpm 190/1600
713x 565x689
Engine dimensions mm (28.1 x 2 2 .2 x 27.1 in)
242
Service weight kg (534 lb)
Injection pump type Bosch
Injection timing 13° stopped
Injection order 1- 2 - 4 -3
Total coolant 8 10 (2.64 US gal)
Total engine oil 8 7.0 (1.85 US gal)
No-load governed speed rpm 2300 ± 25 2600 ± 25
Idling speed rpm 650 ± 25
- 39 -
1 -1 4
ENGINE SPEED ADJUSTMENT

(GASOLINE VEHICLES)
1. Idling speed adjustment.

(1) Warm up the engine
(Coolant temperature 75° ~ 85°C,
167° ~ 185°F)
(2) M ount the engine tachometer
(3) Turn the adjusting screw and adjust
the specified idling speed.
Clockwise
Raises idling speed Fig. 1-29 Adjusting Idling Speed
Counterclockwise
Lowers idling speed
Engine Idling Speed
4P 550 + § ° rpm
5R 550 rpm
5P 700 ± 50 rpm
2. No-load governed maximum speed adjust

ment (4P and 5R engines)
(1) Warm up the engine Fig. 1-30 Measuring Engine rpm at Full Relief
(Coolant temperature 75° ~ 85°C,
167° ~ 1 8 5 °F )
(2) M ount the engine tachometer and
measure the speed when the accel
erator is fu lly depressed.
'No-load governed
Engine max.speed
4P (1 ~ 1.75 ton) 2600 ± 50 rpm
4P (2 ~ 2.5 ton) 3050 ± 50 rpm
5R 2600 ± 50 rpm
Fig. 1 -31 No-load Governed Maxim um Speed Adjustment

(3) Operate the cargo handling lever, and
while at full relief, measure the engine
speed.
(4) Adjust the no-load maximum speed
by turning the adjusting nut and
screw in the air gevernor until the
speed stabilizes at the value shown
above. A t the same time, adjust such
that the engine speed drop w ill be
at minimum when at fu ll relief.
A: Adjusting nut
B: Adjusting screw
Speed drop at fu ll relief

w ith in 300 rpm
- 40 -
1 -1 5
Important:
o Turning the adjusting nut clockwise w ill cause the engine speed to rise. (A fter turning the adjusting nut, tap
it lightly toward the body side so as to fix it.)
o Turning the screw clockwise will cause the engine speed to rise.
o If the engine speed drop is large at full relief, turn the adjusting nut clockwise and the screw counterclockwise.
Keep adjusting in this manner until the engine tends to develop hunting. Stop adjusting just before coming
to this point.
o If the engine speed is not stable at maximum speed (hunting), turn the adjusting nut counterclockwise and
the screw clockwise. If turned too far, the engine speed drop at full relief will become large, and in this
case, hunting could also develop,
o The engine speed drop at full relief is around 20 0 rpm when the vehicle is new. If the speed drop becomes
larger than 3 0 0 rpm, the engine, carburetor, and governor should be adjusted,
o The governor should be sealed after adjusting.
(5P engine)
( 1) Adjust the length o f governor con
necting rod (with engine stopped).
Adjust the length o f governor con
necting rod so as to have the governor
levers No.1 and No.2 come in intimate
contact at " A " when the accelerator
lever is fu lly open.
Governor connecting rod

No.2 governor lever
No.1 governor lever
Nut
Spring tension
Governor main spring
(2) Warm up the engine.

(Coolant temperature 75° 85° C,
167° ~ 185°F)
(3) Mount the engine tachometer
(4) Adjust the no-load governed max
imum speed by means o f the me
chanical governor adjust screw.
Adjust nut
No.1 governor lever
Governor main spring
Spring tension
Lead ball
No-load governed maximum speed

5P engine 2300 ± 50 rpm
- 41 -
ENGINE SPEED ADJUSTMENT
(DIESEL VEHICLE)
1. Adjust the idling speed.

(1) Warm up the engine
(Coolant temperature 75 ~ 85 C,
167° ~ 185°F)
(2) M ount the engine tachometer
to the specified idling speed.
Engine Fig. 1-35 Adjusting Idling

Idling Speed
2J 650 ± 25 rpm
Fig. 1-36 Measuring Engine Speed (Diesel)
2. Adjust the no-load governed maximum

speed.
(1) Fully depress the accelerator pedal.
to the specified no-load governed
maximum speed
No-load governed
Engine maximum speed
2J (1 — 2.5-ton) 2300 ± 25 rpm

Fig. 1-37 Adjusting No-load Governed Maxim um Speed
2J (2.75 ~ 3-ton) 2600 ± 25 rpm
(3) Operate the cargo handling lever, and

measure the engine speed at full
relief.
Speed drop at full relief

w ith in 300 rpm
If above 300 rpm, adjust the engine

and injection pump.
Fig. 1-38 Measuring Engine Speed a Speed at Full Relief
- 42 -
1 -1 7
AIR CLEANER
A ir cleaner hose
A ir cleaner connector
Gasket
A ir cleaner assy
Fig. 1-39 A ir Cleaner Component Parts (4P & 5R )
LIST OF AIR CLEANER COMMON PARTS
^ Case Hose Connector Element
4FG10, 15 Series, 3FG20

4P engine equipped vehicle o o o o
Series
40-4FG10, 15, 40-3FG20
5R engine equipped vehicle t t t t Series
5P engine equipped vehicle o o o o 2FG30 Series
o 3FD10, 1 5 & 3 F D 2 0 , 30
2J engine equipped vehicle t t t
Series
Note: O Exclusive part t Common part
INSPECTION AND CLEANING
1. Open the engine hood.
2. Loosen the air cleaner case wing nut, and

take o ff the case cover.
3. Take out the element.
4. Clean the element by blowing w ith com

pressed air.
Fig. 1-40 Inspecting A ir Cleaner
- 43 -
1 -1 8
MUFFLER
LIST OF MUFFLER COMMON PARTS

M uffler Exhaust Pipe U-bolt Gasket
4P engine equipped vehicle o o o o
5R engine equipped vehicle t t t t

5P engine equipped vehicle t o o t
2J engine equipped vehicle t t t t
MUFFLER REMOVAL & INSTALLATION
1. Remove the counterweight.

(1) Set bolts
(2) Counterweight
2. Remove the m uffler.

(1) Set nuts
(2) Set bolts
(3) Remove the m uffler assy, using care
not to damage the radiator.
Fig. 1-42 Removing m uffler
- 44 -
1 -1 9
RADIATOR
Radiator assy
Cap sub-assy
Fan shroud
Fan
Reverse tank assy
Reverse tank bracket sub-assy
Fig. 1-44 Radiator Component Parts (2J Torque Converter Vehicle)
- 45 -
1 -2 0
COOLANT CAPACITIES AND LONG-LIFE COOLANT QUANTITIES

25 % L L 30 % LL. 50 % LL.
Radiator Coolant
Coolant Coolant Coolant
Capacity Quantity
—12°C —15°C —35°C
3.8 8 7 8 1.8 8 2.1 8 3.5 8
4P engine equipped
(1.00 US gal) (1.85 US gal) (0.48 US gal) (0.55 US gal) (0.92 US gal)
4.7 8 8.7 8 2.2 8 2.6 8 4.4 8
5R engine equipped vehicle
4.7 8 10.6 8 2.7 8 3.2 8 5.3 8
5P engine equipped vehicle
4.7 8 10 8 2.5 8 3 8 5 8
2J engine equipped vehicle
RADIATOR REMOVAL &

INSTALLATION
Fig. 1-45 Engine Hood Removed
2. Drain out the coolant from both the engine

and radiator.
3. Loosen the hose clamps and pull out the

No.1 and No.2 hoses.
4. Remove the radiator set bolts.
5. Remove the radiator together w ith fan

shroud.
Caution:
Fig. 1-46 Coolant Drain Holes
o When removing the radiator, use care not
to damage the fins.
o Pull o u t the radiator hoses by turning the
fan.
Im portant:
o Tighten the radiator mounting bolts until
the cushion rubbers are compressed to
around 4 ~ 5 m m (0.16 7 ~ 0 .1 9 7 in)
thickness.
o T he specified am ount o f coolant cannot
be filled at one tim e. Fill in and after
starting the engine, fill in the remainder.
Fig. 1-47 Removing Radiator
- 46 -
1-21
BATTERY
Fig. 1-49 Battery Component Parts (BP)
- 47 -
1 -2 2
Battery earth cable

Battery connector cable
Battery starter cable
Battery cap sub-assy
Battery
Battery case
Bolt
Fig. 1-50 Battery Component Parts <2J)
LIST OF BATTERY COMMON PARTS

(—) terminal (+) terminal Between
Battery Battery
Battery to ground to starter battery
Cap Case
harness harness harness
4P Engine vehicle o o o o o —
5R Engine vehicle t t t t t —
5P Engine vehicle o t o t t —
2J Engine vehicle t t o o o o
INSPECTION
1. Battery flu id level.
2. Battery flu id specific gravity

1.260 (Fully charge, 20°C ,68°F)
3. D irty battery terminals.
4. Loose harness connection.
Fig. 1-51 Inspecting Battery
- 48 -
CLUTCH
Page
GENERAL ................................................................................................... 2 - 2
SPECIFICATIONS & SERVICE STANDARDS 2- 3
COMPONENT PARTS ................................................................................ 2 - 4
REMOVAL ................................................................................................... 2- 5
DISASSEMBLY ............................................................................................ 2 - 7
INSPECTION ................................................................................................. 2 - 9
ASSEMBLY .................................................................................................. 2 -1 2
INSTALLATION .......................................................................................... 2 -1 3
CLUTCH BOOSTER - GENERAL ....................................................... 2 -1 4
CLUTCH BOOSTER REMOVAL ................................................. 2 -1 6
CLUTCH BOOSTER DISASSEMBLY .................................................... 2 -1 7
CLUTCH BOOSTER INSPECTION ........................................................ 2 -2 0
CLUTCH BOOSTER ASSEMBLY .......................................................... 2 -2 2
CLUTCH BOOSTER INSTALLATION ................................ 2 -2 3
CLUTCH ADJUSTMENT ( 1 - 1 . 7 5 ton) ................................................ 2 - 2 4
CLUTCH ADJUSTMENT ( 2 - 3 ton) ..................................................... 2 -2 5
RELEASE FORK SHAFT ......................................................................... 2 -2 6
- 49 -
2 -2
GENERAL
(4P Engine)
Fig. 2-1 Clutch
- 50 -
2 -3
SPECIFICATIONS & SERVICE STANDARDS
CLUTCH PEDAL
1.0 — 1.75 ton 2.0 ~ 3.0 ton
Clutch Pedal Type Pendant Type Treadle Type
Clutch Pedal Height (to toeboard) 129 mm (5.08 in) 128 mm (5.04 in)
15 ~ 20 mm 2 ~ 3 mm (0.079 ~ 0.118 in)

Clutch Pedal Play at pedal tip
(0.59 ~ 0.79 in)
Release Lever Tip Play 5 mm (0.197 in)
CLUTCH COVER
Type Coil spring (Chordal strap)
Number 6 (4P),9 (5R, 5P,2J)
62.0 mm (4P) 58.8 mm (5R, 5P, 2J)

Free Height
(2.44 in) (2.31 in)
Springs Installed Height 37.7 mm (1.48 in)
45.4 kg (4P) 39.5 kg (5R, 5P, 2J)

Installed Load
(100.1 lb) (87.1 lb)
Squareness (at free height) 2.5 mm max. (0.098 in)
Non-uniformity at Release Lever Tips 0.35 mm max. (0.014 in)
CLUTCH DISC
Type Dry, single-plate
Outside Diameter 275 mm (10.83 in)
Inside Diameter 175 mm (6.89 in)
Thickness 8.6 mm ' (0.338 in)
Material A50
Rivet Depth Lim it 0.3 mm (0.012 in)
Runout L im it 1.5 mm (0.059 in)
- 51 -
2 -4
COMPONENT PARTS
2 3 4 5 6 7 8 9 10
18 19
Tightening torque unit: kg-m (ft-lb)
1. Clutch housing cover 11. Spring

2. Flywheel 12. Bearing hub
3. Release fo rk shaft 13. Release bearing
4. Eye bolt 14. Release fo rk
5. Plate pin 15. Pilot bearing
6. Release lever 16. Clutch housing
7. Adjust nut 17. Needle bearing
8. Torsion spring 18. Clutch disc
9. Pressure plate 19. Compression spring
10. Clutch cover 20. S tru t plate
Fig. 2-2 Clutch Com ponent Parts
- 52 -
2 -5
REMOVAL
1. Remove the toeboard.

(1) Open the engine hood.
(2) Rear toeboard.
(3) Pull out the ignition coil cord.
(On gasoline engine vehicle).
(4) Pull the stop button all the way out.
(On diesel engine vehicle).
2. Remove the clutch housing cover.
3. Disconnect the push rod.

(1) Dust cover.
(2) Clevis pin.
(3) Push rod
Fig. 2-4 Disconnecting Push Rod
4. Pull out the main drive shaft.

(1) Front plug
(2) Main drive shaft
Use SST 09210-20170-71
Caution:
o Make sure th at end of SST is properly
screwed in.
o Main drive shaft cannot be pulled outside
the fro n t axle housing.
Fig. 2-5 Pull o u t Main Drive Shaft
5. Install the service bolts in the clutch cover.

Service bolt M8 x 40 (P = 1.25)
Fig. 2-6 Installing Service Bolt
- 53 -
2 -6
6. Remove the clutch cover set bolts.
Caution:
o Use crankshaft pulley set bolt to turn the
flyw heel to position th at w ill allow easy
removal of the clutch cover set bolts.
o Never turn the fan by hand as means of
turning the flyw heel.
Fig. 2-7 Removing Set Bolts
7. Remove the clutch disc.

(1) S hift the clutch cover fu lly over to
the release bearing side.
Caution:
o Use care not to get oil or grease on the
clutch disc facings.
o If only the clutch disc is to be removed,
the 7 operations up to now w ill be
sufficient.
Fig. 2-8 Removing Clutch Disc
8. Remove the clutch cover.
9. Remove the release bearing hub.

(1) Tension spring
(2) Bearing hub
ft
C autio n :
Remove only in the case where there is
evidence o f defect in the release bearing
ro tatio n, surface contacting on the fo rk , and
sliding condition w ith release bearing guide.
Fig. 2-9 Removing Clutch Cover
10. Remove the flyw heel.

(1) Set bolts
(2) Flywheel
Caution:
Check the clutch disc contacting surface,
starter gear, and p ilo t bearing, and remove
only in case any defect is observed.
Fig. 2 -1 0 Removing Flywheel
54 -
2 -7
DISASSEMBLY
Caution:
Before disassembling, check fo r defects in
pressure plate contacting surface, and for
cracks in cover, wear in release lever, and
other troubles.
1. Punch aligning marks (match marks).

(1) Clutch cover
(2) Pressure plate
Important: Fig. 2-11 Punching Aligning Marks

The clutch cover has been balanced in
assembled state so that it should be reassem-
I bled to the same initial position.
2. Remove the straps.

(1) Set bolts
(2) Straps
Fig. 2-12 Removing Straps
3. Remove the adjusting nuts.

(1) Screws
(2) Nut lock springs
(3) Nut lock plates
Fig. 2-13 Removing N u t Lock Springs
(4) Adjusting nuts
Catuion:
Position the wooden blocks so that they are
not contacting on the release levers, adjusting
nuts, or service bolts, and w ill also allow easy
removal of the nuts.
Fig. 2-14 Removing Adjusting Nuts
55
2 -8
4. Remove the clutch cover.

(1) Service bolts
#
Fig. 2-15 Removing Service Bolts
(2) Clutch cover
Fig. 2-16 Removing Clutch Cover
(3) Compression springs
Caution:
o Place matching marks at the place where
the compression springs are to be installed,
o It should be noted th at the number of
springs d iffe r w ith vehicle types.
Fig. 2-17 Removing Springs
5. Remove the release levers.

(1) Clutch pressure plate pins
(2) Clutch release lever pins
(3) Clutch torsion springs
(4) Clutch release levers
Caution:
Remove only when there is evidence o f defect
in the release levers, torsion springs, o r clutch
pressure plate.
56 -
2 -9
INSPECTION
Caution:
Inspect the parts and repair or replace any
part found defective.
1. Pressure plate.
(1) Wear or damage in clutch disc
contacting surface.
(2) Damage in compression spring
contacting surfaces.
13) Wear in eye bolt contacting surfaces.
(4) Wear in release lever contacting Fig. 2-19 Inspecting Pressure Plate
surfaces.
2. Clutch cover
(1) Warping, cracks, deformation, or
wear in clutch cover.
Caution:
Always replace if found defective. Do not
attem pt to repair or weld.
Fig. 2-20 Inspecting Clutch Cover
3. Compression springs
(1) Deformation, loss o f tension, or
breakage
(2) Free height (A), squareness (B)
Compression Spring Specifications
4P Engine 5 R ,2J,5 P Fig. 2-21 Inspecting Compression Springs

Vehicles Engine Vehicles
No. o f springs 6 9
62.0 mm 58.8 mm
Free height
(2.44 in) (2.31 in)
37.7 mm 37.7 mm
Installed height
(1.48 in) (1.48 in)
45.4 kg 39.5 kg
Installed load
(100.1 lb) (87.1 lb)
below below
Squareness lim it 2.5 mm 2.5 mm
(0.098 in) (0.098 in)
Discrimination Pink Green
Fig. 2-22 Compression Spring Inspection
- 57 -
2 -1 0
4. Release levers and stops

(1) Wear, damage, or deformation in
release levers.
(2) Looseness in release levers (when
installed)
(3) Deformation or damage in strap.
Fig. 2-23 Release Lever Inspection
5. Flywheel
(1) Wear or damage in clutch disc
contacting surface.
6. Pilot bearing
(1) Defective bearing rotation
Fig. 2-25 Inspecting Pilot Bearing
(2) Bearing replacement
Caution:
Replace p ilo t bearing only if found defective.
Fig. 2-26 Removing Pilot Bearing
58
2 -1 1
7. Release bearing
(1) Defective bearing rotation, wear in
contacting surface, or noise
Fig. 2-27 Inspecting Release Bearing
(2) Bearing replacement

SST used: 09950-20012
Tool used: Hand press
Caution:
Never wash the release bearing as it is grease-
sealed type (oilless typ e). Replace if found
defective.
Bearing hub
(1) Wear in release fork contacting
surface.
Fig. 2-28 Replacing Release Bearing
(2) Wear in release guide sliding surface
or sticking.
Clutch disc
(1) Wear, cracks, or loose rivets in facing.
Wear lim it (rivet depth) 0.3 mm
(0.012 in)
(2) Disc runout
Runout lim it 1.5 mm (0.059 in)
(3) Hardened (glazed) facing or oil or
grease on surface.
(4) Weakened or broken torsion springs.
(5) Worn or damaged splines.
Fig. 2-29 Inspecting Clutch Disc Wear
Caution:
o Always replace the clutch disc if found
defective.
P Care should take on repairing or conti
nuing usage as this w ill lead to poor
disengaging, slipping, or chattering.
Fig. 2-30 Inspecting Clutch Disc
59 -
2 -1 2
ASSEMBLY
1. Assemble the release levers.

(1) Release levers
(2) Eye bolts
Caution:
o Caution should be taken on assembling the
release lever and eyebolt in correct
direction.
o A pply molybdenum disulfide grease on
the release lever fulcrum parts.
Fig. 2-31 Assembling Release Levers
Fig. 2-32 Greasing Points
2. Assemble the compression springs.

(1) Compression springs.
(2) Clutch cover
Caution:
o If the clutch cover and pressure plate are
to be reused, make sure to align their
matching marks.
o Do not forget to assemble the torsion
springs on the clutch cover.
Fig. 2-33 Assembling Clutch Cover
Install three service bolts.

Service bolt M8 x 40 (P = 1.25)
Fig. 2-34 Installing Service Bolts
- 60 -
2 -1 3
4. Install the strap plates.

T = 1.5 ~ 2.8 kg-m (10.8 ~ 20.2 ft-lb)
Fig. 2-35 Installing Strap Plates
5. Adjust the clutch release lever heights.

(1) Use the three service bolts and set
the pressure plate to the following
distance from the clutch cover
mounting surface.
Set height: 8.3 mm (0.327 in)
Fig. 2-36 Adjusting Pressure Plate Height
(2) Install the eye bolts nuts and adjust

the release lever heights to following
value.
From clutch cover mounting surface:
56 mm (2.20 in)
6. Assemble the eyebolt nut lock plates
Caution:
Upon completing the assembly, set the press
on the release lever ends and operate the press
up and down 2 or 3 times to check the lever
operation. Fig. 2-37 Adjusting Release Lever Heights
INSTALLATION
Install by performing the removal in reverse

order.
Im portant:
o A p p ly m olybdenum disulfide grease lightly to the main drive shaft splines and release bearing,
o Position the clutch disc w ith the longer boss pointed toward the transmission,
o Polish the pressure plate frictional surface w ith sandpaper (about # 1 8 0 ).
o It is recommended that long nose plier be used in inserting the clutch disc on to the main drive shaft,
o A fte r installing the clutch cover, do not forget to remove the service bolts.
- 61 -
2 -1 4
CLUTCH BOOSTER - GENERAL
Fig. 2-38 Clutch Booster Sectional View
COMPONENT PARTS
Boot 14. " O " ring

Snap ring 15. Seal ring
Rod guide 16. " 0 " ring
" 0 " ring 17. Power piston assy
Cylinder cup 18. " 0 " ring
Cup retainer 19. Seal ring
Snap ring 20. Check valve
O utput rod 21. Cylinder cup
Piston return spring 22. Cylinder cup
Pin 23. Reaction piston
Spring retainer 24. Snap ring
Compression spring 25. Boot
Control valve sheet 26. Push rod
Fig. 2 -3 9 Clutch Booster Component Parts
- 62 -
2 -1 5
TROUBLE SHOOTING
Symptom Possible Cause Remedy
Pedal heavy Push rod binding due to improper installation Adjust installation.
o f clutch booster.
Valve seal defective. Replace valve seat,

reaction piston.
Seat defective Replace
Flow divider orifice clogged. Clean

(In case pedal is normal when depressed
slowly but defective when depressed suddenly.)
Pedal returned violently Seal in check valve sub-assy is defective or Clean or replace.
when engine stalls. clogged
Valve seal defective. Replace valve seat,

reaction piston.
Seal defective Replace
- 63 -
2 -1 6
CLUTCH BOOSTER REMOVAL
Caution:
° Be sure to have the engine stopped,
o Since oil w ill run out, have waste ready on
hand.
1. Rear toeboard
(1) Set bolts
(2) Rear toeboard
Fig. 2-40 Removing Rear Toeboard
2. Disconnect the fro n t and rear push rods

(1) Dust cover
(2) Clevis pins
Fig. 2-41 Disconnecting Push Rods
Disconnect the piping.
Fig. 2-42 Disconnecting Piping
4. Remove the clutch booster.

(1) Set bolts
(2) Clutch booster
Fig. 2-43 Removing Clutch Booster
- 64 -
2 -1 7
CLUTCH BOOSTER DISASSEMBLY
1. Remove the boot and push rod.
Fig. 2-44 Removing Push Rod
2. Remove the rod guide

(1) Snap ring
(2) Rod guide
Caution:
Be careful of the rod guide jumping out.
Fig. 2-45 Removing Rod Guide
3. Remove the cup retainer and cylinder cup

from the rod guide.
(1) Snap ring
Fig. 2-46 Removing Snap Ring
(2) Cup retainer

(3) Cylinder cup
Fig. 2-47 Removing Cylinder Cup
- 65 -
2 -1 8
4. Take out the output rod, reaction piston, 1 W > iB

and power piston together.
( 1 ) Piston return spring
Fig. 2-48 Removing Return Spring
(2) Reaction piston snap ring
(3) O utput rod, reaction piston, power mgf jj| ip iji

piston it
Caution:
Pull o u t by pushing o u t from the reaction
piston end.
Fig. 2 -5 0 Removing Piston
5. Disconnect the output rod from the

reaction piston.
(1) Spring retainer
Caution:
Loosen the tw o staked parts w ith screwdriver,
using care not to break.
Fig. 2-51 Removing Spring Retainer
66 -
2 -1 9
(2) Pin
Fig. 2-52 Removing Pin
(3) O utput piston

(4) Compression spring
Fig. 2-53 Removing Piston and Spring
6. Disconnect the reaction piston from the

power piston.
Fig. 2-54 Disconnecting Pistons
7. Remove the check valve.
Fig. 2-55 Removing Check Valve
- 67 -
2 -2 0
CLUTCH BOOSTER INSPECTION
Caution:
Inspect all parts after washing them w ith fresh
hydraulic flu id , and replace any part found
defective.
1. Inspect the booster body.

(1) Damage or binding in " 0 " ring.
(2) Wear or damage in body inside
surface.
Fig. 2-56 Inspecting Booster Body
2. Inspect the reaction cylinder.

(1) Deformation in snap ring.
(2) Damage or degradation in cylinder
cup.
(3) Fitting parts wear lim it
wear lim it: 0.16 mm (0.0063 in)
(Diameter clearance)
Fig. 2-57 Reaction Cylinder Inspection
3. Inspect the booster power piston.

(1) Damage or binding in " 0 " ring
(2) Damage or binding in seal ring.
Fig. 2-58 Booster Power Piston Inspection
Inspect the output rod.

(1) O utput rod sliding surface.
a. Extreme damage
b. Worn out-of-round
c. Corroded
(2) Breakage or weakening at spring
retainer staked parts.
(3) F it between rod and rod guide
Wear lim it: 0.13 mm (0.0051 in)
Fig. 2-59 O utp u t Rod Inspection
- 68 -
2 -2 1
5. Inspect the springs

(1) Breakage or loss-of-tension in
■1 * . ■ '- ''■ - 7 ; . : * ' -
compression spring.
Free length: 21 mm (0.827 in) ■I;;
a
(2) Breakage or loss-of-tension in piston
return spring.
Free length: 56 mm (2.20 in)
■■ , SS
Fig. 2-60 Spring Inspection
6. I nspect the check valve. jg r ^ H

(1) Check ball movement, spring action. • " - .J b Ifc * ■
(2) Extreme damage, wear, or rusting in
valve seat contacting surface.
[ l ^s t i —
mm
1X ~22HHHBKfcH*«uXL"H3Hwitw«Bl
Fig. 2-61 Check Valve Inspection
Inspect the rod guide, retainer cup, and

cylinder cup.
(1) Damage or degradation in cup
retainer.
(2) Damage or degradation in cylinder
cup.
OPOQ
:=-:
Fig. 2-62 Rod Guide Inspection
69
2 -2 2
CLUTCH BOOSTER ASSEMBLY
Caution:
A pply hydraulic fluid on all parts and assemble
them such th at there w ill be no binding.
1. Assemble the reaction piston to the power

piston.
2. Assemble the output rod.

(2) O utput rod
Fig. 2-64 Assembling O utp u t Rod
3. Connect the output rod to reaction piston

w ith pin.
(1) Pin
(2) Spring retainer
Caution:
A fte r assembling the spring retainer, be sure
to stake it.
Fig. 2 -6 5 Assembling Spring Retainer
4. Assemble the pistons into booster body.

(1) O utput rod, power piston, reaction
piston
(2) Piston return spring
Fig. 2-66 Assembling Pistons
70 -
2 -2 3
5. Assemble the cup to the rod guide.

(1) Cylinder cup
(2) Cup retainer
(3) Snap ring
6. Assemble the rod guide into booster body.
Fig. 2-67 Assembling Cup
7. Assemble the snap rings.

(1) Snap ring at rod guide side
(2) Snap ring at reaction piston
Fig. 2-68 Assembling Snap Rings
Install the check valve.

T = 6 ~ 9.6 kg-m (43.3 ~ 69.3 ft-lb)
Fig. 2-69 Installing Check Valve
9. Assemble the push rod and bushing.
CLUTCH BOOSTER INSTALLATION

order.
Fig. 2-70 Assembling Push Rod
71
2 -2 4
CLUTCH ADJUSTMENT ( 1 - 1 .7 5 ton)
1. Clutch pedal height adjustment

Adjust the distance from the pedal pad
upper surface to the rear toeboard floor
surface to the specified height by means of
the adjust bolt on the pedal bracket.
Pedal height: 129 mm (5.08 in)
Im portant:
Clutch pedal height should be made the same
as the brake pedal height. The brake pedal
height should always be set before setting the
clutch pedal height.
2. Clutch pedal play adjustment

(1) Remove the clutch housing cover,
and measure the clearance between
the clutch release lever and the
clutch release bearing.
(2) Disconnect the tension spring, and
w ith the release lever contacting on
the bearing, measure the clearance
between the release fo rk and hub.
Standard clearance:
2.4 - 3.0 mm (0.094 - 0.118 in)
Fig. 2-72 Measuring Clutch Pedal Height
(3) If not to the standard value, make

the adjustment w ith the turn buckle
on the pedal push rod. A fte r
adjusting, depress the clutch pedal
several times and check that pedal
play is up to the standard value.
Standard play: 15 — 20 mm
( 0 .5 9 - 0 .7 9 in)
Fig. 2-73 Adjusting Pedal
- 72 -
2 -2 5
CLUTCH ADJUSTMENT (2.0 ~ 3.0 ton)
1. Adjust the length of stopper bolt (1) so

as to make the pedal height 128 mm
(5.04 in).
Caution:
Stopper bolt length (Reference only):
19 mm (0.748in )
Adjust the length of push rod (2) so as to

provide 2 ~ 3 mm (0.079 ~ 0.118 in) at
the pedal tip.
3. Adjust the length o f stopper bolt (3) so as

to have the release lever move 27 mm
(1.06 in) when the clutch pedal is
depressed.
Reference:
Stopper bolt length (Reference only):
22 mm (0 .8 6 €| in)
The purpose is to prevent the pedal tip from
striking the toeboard when the pedal is
depressed.
4. Adjust the length of push rod (4) so as to

provide 5 mm (0.197 in) play in the release
lever.
- 73 -
2 -2 6 _________________
RELEASE FORK SHAFT
REMOVAL
Caution:
Perform after removing the transmission
assembly.
1. Remove the release fork shaft.

(1) Release fork
(2 ) Release fork shaft
Fig. 2-78 Removing Release Fork Shaft
2. Remove the needle bearings.

(1) Needle bearings
SST used 09601-30011
Fig. 2-79 Removing Needle Bearings
U . I I " ■ ' W W I l
INSPECTION
1. Release fo rk and fork shaft

(1) Damage or wear on hub contacting
surfaces.
(2) Wear or bending in shaft sliding
parts.
2. Needle bearings
(1) Wear or damage
Fig. 2 -8 0 Release Fork Shaft Inspection
INSTALLATIO N
Perform the removal in reverse order.
Caution:
o A p p ly MP grease on the needle bearings.
o A p p ly m olybdenum disulfide grease on the contacting surfaces between release fo rk and bearing hub.
- 74 -
TORQUE CONVERTER
Page
GENERAL ...................................................................... ............................. 3 - 2
HYDRAULIC CIRCUIT DIAGRAM ..................................................... 3 - 2
SPECIFICATIONS 3- 3
TROUBLE SHOOTING .............................................................................. 3 - 4
COMPONENT PARTS ............................................................................... 3 -1 1
SERVICE STANDARDS ............................................................................. 3 -1 5
UNDER COVER REMOVAL 3 -1 7
LEVERS ........................................................................................................ 3 -1 8
OIL CONTROL VALVE ........................................................................... 3 -2 2
TORQUE CONVERTER 3 -2 7
OIL PUMP .................................................................................................... 3 -3 9
TRANSMISSION ASSY ............................................................................. 3 -4 6
MEASUREMENTS & TESTS .................................................................. 3 -6 7
INCHING PEDAL ADJUSTMENT ........................................................ 3 -6 9
- 75 -
3 -2
GENERAL
Fig. 3-1 Sectional V iew of Torque Converter
HYDRAULIC CIRCUIT DIAGRAM
IN C H IN G V A L V E
D=0=
SELECTOR M IC R O F IL T E R
VALVE iw r n
SUM P T A N K
TO RQ UE CO NVERTER
REVERSE CLUTCH FO R W A RD CLUTCH
Fig. 3-2 Hydraulic Circuit Diagram
- 76 -
SPECIFICATIONS
/
/
/
>
02-4FG 10 42-4FG 10 02-3F D 10
•-
©
©
Vo®
02 -3F G 20 42-3FG 20 62-3FG 20 02-3FD 20
/
02-4FG 14 42-4 FG 14 02-3FD 14 02-FG 28 02-FD 28
/
/
/02-FG23 \ 42-FG 23 62-FG 23 02-FD 23
/
/
02-4FG 15 42-4FG 15 02-3F D 15 02-2FG 30 02-3FD30
//
/
E
®
\0 2 -3 F G 2 5 / 42-3FG 25 62-3FG 25 02-3FD 25
02-FG 18 42-FG 18 02-FD 18
3-element, 3-element, 3-element, 3-element, 3-element, 3-element, 3-element, 3-element, 3-element,

Type single stage single stage single stage single stage single stage single stage single stage single stage single stage
2-phase 2-phase 2-phase 2-phase 2-phase 2-phase 2-phase 2-phase 2-phase
N IS IV N IS IV N IS IV
Designation A IS IN A IS IN A IS IN A IS IN A IS IN A IS IN
00
Stall torque ratio 3.7 8 3.75 3 .7 5 3.78 3.75 2.6 3.75 2.6
o
o
o
o
o
o
o
LO
00
00
1950 1700
00
Stall speed (rpm) 1700
00
1850 1950
Forward 2.453 2.453 2.453 2.9 14 2.914 2.453 2.914 2.914 2.914
(4.239)
Speed gear ratio
2.9 52
Reverse 2.458 2.458 2.458 2.952 2.458 2.952 2.952 2.952
<4.188)
Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic [ Hydraulic Hydraulic Hydraulic
-
Speed selection system
pressure pressure pressure pressure pressure pressure pressure pressure pressure
1.5 ~ 1.5 ~ 1.5 ~ 1.5 ~ 1.5 ~ 1.5 ~
77
1.5 ~ ' 1.5 ~ 1 .5 -
-
6 kg/cm 6 kg/cm 2 6 kg/cm 2 6 kg/cm 2 6 kg/cm 2 6 kg/cm 2 6 kg/cm 6 kg/cm2 6 kg/cm 2
(idling) (idling) (idling) (idling) (idling) (idling) (idling) (idling) (idling)
(21.3 — (21.3 — (21.3 — (21.3 — (21.3 ~ (21.3 ~ (21.3 — (21.3 — (21.3 —
Clutch actuating pressure 85.3 psi) 85.3 psi) 85.3 psi) 85.3 psi) 85.3 psi) 85.3 psi) 85.3 psi) 85.3 psi) 85.3 psi)
(Main pressure) 8.5 ~ 8.5 — 8.5 — 8.5 — 8.5 — 8.5 — 8.5 - 8.5 — 8.5 ~
13 kg/cm2 13 kg/cm2 13 kg/cm2 13 kg/cm2 13 kg/cm2 13 kg/cm2 13 kg/cm2 13 kg/cm2 13 kg/cm2
(2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm)
(111 — (111 — (111 — (111 ~ (111 ~ (111 ~ (111 — (111 — (111 ~
185 psi) 185 psi) 185 psi) 185 psi) 185 psi) 185 psi) 185 psi) 185 psi) 185 psi)
1.0 - 1.0 ~ 1.0 ~ 1.0 ~ 1.0 ~ 1.0 ~ 1.0 ~ 1.0 ~ 1.0 ~

Converter internal pressure 1.6 kg/cm2 1.6 kg/cm2 1.6 kg/cm2 1.6 kg/cm2 1.6 kg/cm 1.6 kg/cm
1.6 kg/cm 2 1.6 kg/cm2 1.6 kg/cm2
(Outlet pressure) (2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm)
(2000 rpm) (2000 rpm) (2000 rpm) (2000 rpm)
(1 4 .2 - (14.2 ~ (14.2 — (14.2 — (14.2 — (14.2 ~ (14.2 — (14.2 — (14.2 —
22.8 psi) 22.8 psi) 22.8 psi) 22.8 psi) 22.8 psi) 22.8 psi) 22.8 psi) 22.8 psi) 22.8 psi)
13.2 £ 13.2 £ 13.2 £ 13.2 £ 13.2 £ 13.2 £ 13.2 £

C* 3
C* 3
o[in
Oil capacity
C/5
©
co co
(3.5 US gal)
cn in
(3.5 US gal) (3.5 US gal) (3.5 US gal)
o>
CO
(3.5 US gal) (3.5 US gal)
00 co
(3.5 US gal)
O)
Operating fluid Auto fluid Auto fluid Auto fluid Auto fluid Auto fluid Auto fluid Auto fluid Auto fluid Auto fluid
in
5.833
CO
CO
5.143 5.143
00
Speed reduction ratio 5.833 5.833 5.143 5.143 5.143
o
No-load governed maximum
o
2300 2300 2600
CO
2600 2300 3050 2600 2300
CM
speed (rpm)
in
in
3
Q_
CL
cc
5P
CM
—>
4P
CM
Coupled engine 5R
CM
3 -3
3 -4
TROUBLE SHOOTING
Symptom Inspection Method Probable Cause & Remedy
1- Vehicle tota lly 1.1 Check main hydraulic pressure. o Check fluid amount.
inoperative or oper <• Idling 2 ~ 6 kg/cm 2 -* Check w ith level gage.
ates extremely Std { (28.4 ~ 85.3 psi)
sluggishly. 12000 rpm 9 ~ 13 kg/cm 2
[Due to clutch (128 ~ 185 psi)
not transmitting Check while shifting to forward
power] and reverse, and also to neutral.
1.1a Pressure at neutral much o Regulator valve sticking.

lower than std. pressure. -¥ Check fo r clogging.
Clean.
o Regulator valve spring broken or
weakened Replace
o Oil pump malfunction.
1) Oil pump defect -*■ Replace
2) Extension spring broken
-*• Replace
o Suction system defective
1) Suction filte r clogged
-* Clean or replace
2) A ir drawn in Check jo in t
" 0 " rings, gaskets
o Oil passage from pump to control
valve clogged or fluid leakage -*■
check passage -*■ replace " 0 ” ring,
gaskets.
1.1b Pressure abnormally high. o Regulator valve orifice clogged

-*■ check and wash valves.
1.1c Pressure far lower than std. o Inching spool sticking -> Check for
at both forward and reverse. clogging, wash.
(Normal at neutral) o Inching lever defective sliding r*
Repair, replace
o Inching rod defective return
-*■ Check rod link, replace
o Modulator valve sticking -*■ Check
fo r clogging, wash.
o Orifice valve clogged Wash.
- 78 -
3 -5
1.1 d Pressure far lower than std. .-*• Continued on 1.2

at either forward or reverse only.
1.2 Check clutch pressure

1.5 ~ 6 kg/cm 2
(2 1 .3 -8 5 .3 psi)
Std at idling
8 .5 — 13 kg/cm 2
(111 - 185 psi)
at 2 0 0 0 rpm
Clutch pressure appears
slightly lower than main pressure.
1,2a Pressure far lower than std. o Hydraulic oil leaking between
at either forward or reverse only. selector valve and servo collar
Check oil passage-> Replace.
o Seal ring (servo collar) worn or
broken =* Replace
o Main shaft oil passage plug fell
out-*- Repair, replace
o Clutch piston damaged, piston ring
broken, piston loosened, etc. -*•
Overhaul clutch
1.3 Main pressure and clutch o Clogging in oil passage between

both normal. selector valve and clutch piston
(forward side oil passage clogged
if no forward advance) -*■ Check
o Clutch piston stuck.
1.3a Mechanical trouble in

transmission or differential.
Such cases are usually accom
panied by rapid rise in torque
converter oil and noise.
2. Lack o f hill 2.1 Check engine no-load governed

climbing and maximum speed and maximum
tractive perform speed when laden.
ance.
(Insufficent 2.1a Check sngine no-load a. Tune-up engine if rpm is not at
governed maximum speed. standard value.
power)
1 2600 rpm Note: Refer to engine tune-up section.
[Due to torque 4 P 13050 rpm
converter not
Standard 5R 2600 rpm
developing
torque] 5P 2300 rpm
| 2300 rpm
L2J 12600 rpm
- 79 -
3 -6
2 . 1 b Check engine maximum speed b. If speed drop is larger than

when laden. standard (Engine power
A fte r checking maximum speed insufficient)
in 2 . 1 a, set the t ilt lever forward
o Readjust air governor.
or backward, and at relief state
and accelerator full depressed, Note: Refer to air governor adjustment
measure the maximum speed. section.
In case o f gasoline engine: o Check carburetor th ro ttle to see
about 150 — 2 0 0 rpm down if it opens fu lly when accelerator
from no-load maximum pedal is fu lly depressed.
governed speed.
o Power tends to drop easier with
In case of diesel engine:
LPG than gasoline so that closer
about 1 0 0 rpm down from
adjustment o f governor and
no-load governed maximum regulator w ill be required when
speed.
using LPG.
c. When engine rpm and output are
normal. Cont'd in 2.2 I
2.2 Check main pressure and o When main or clutch pressure is

clutch pressure. abnormal 4 Check in accordance
Standard pressures: w ith 1.1 or 1 .2 .
2 ~ 6 kg/cm 2
( 2 8 .4 - 8 5 .3 psi)
Main . at idling
press. 9 - 1 3 kg/cm 2
( 1 2 8 - 185 psi)
at 2 0 0 0 rpm
■ 1.5 — 6 kg/cm 2
(2 1 .3 - 8 5 .3 psi)
Clutch. a tid lin 9
press. 8 . 5 - 1 3 kg/cm 2
(111 - 1 8 5 psi)
at 2 0 0 0 rpm
2.3 Check stall rpm. Checking the stall speed enables

o Perform the stall test and determining whether the converter
measure the engine speed at or clutch is at fault.
that time.
Note: Before checking stall rpm,
always check engine output (full
load maximum rpm) and main and
clutch pressures to confirm that
engine system is in normal state.
- 80 -
3 -7
Stall speeds (Standard) a. Stall speed too low

(Drops more than 300 rpm)
Max. rpm Stall rpm
o Stator one-way clutch is slipping.
2600 1600
~4P -*■ Dissasemble, inspect, replace
3050 1600
stator.
5R 2600 1700
b. Stall speed too high
5P 2300 1700
o Clutch slipping badly.
2300 1750 -*• Disassemble, inspect, replace
I 2600 1800 clutch.
Caution: Stall speed could vary
about 1 0 0 rpm from the above
values due to slight differences in
engine and torque converter
inherent performances. Thus, the
above values should only be used
as guide to determine troubles.
3. Large time lag 3.1 Depress accelerator pedal

when starting together w ith shifting to
determine delay in starting.
It would be desirable if
comparison could be made w ith
normal vehicle.
3.2 Check main and clutch pres a. Main or clutch pressure abnormal.
sures. A t same time, check Refer to 1.1 or 1.2
clutch pressure rise charac b. Clutch pressure rise up character
teristics. istic abnormal.
Standard pressures:
o Modulator valve spring weak or
2 — 6 kg/cm 2
broken -*■ Disassemble, inspect,
(28.4 ~ 85.3 psi)
at idling replace.
Main
press. 9 — 13 kg/cm 2 o Orifice valve clogged -*■ Disassemble,
(128- 185 psi) inspect, clean.
at 2 0 0 0 rpm
o Inching spool defective return ->
1.5 ~ 6 kg/cm 2 Foreign object lodged, spring
(2 1 .3 - 8 5 .3 psi) weakj broken flush out, replace.
Clutch at idling
o Inching lever sliding defective
press. 8.5 — 13 kg/cm 2
-* lever repair, replace.
(111 - 185 psi)
at 2 0 0 0 rpm o Inching rod return defective
-+ Rod link inspect, replace.
3.3 Check oil Oil insufficent, suction filte r

clogged, air drawn in -*■ Replenish,
disassemble, wash.
- 81 -
3 -8
4. Inching defective, 4.1 Check inching rod operation. a. Inching rod malfunction
jerking (shock)
o Inching spring defective -* Replace.
develops
-*■ A pply grease, replace
o Inching spool return defective
* * Foreign object lodged, spring
weak, broken •* flush out replace.
4.2 Check main and clutch pres a. If clutch rise up pressure is

sures. Operate inching valve abnormal:
and check variation in clutch o Inching spool sticking Foreign
pressure. object lodged -*• wash
Standard pressures:
2 ~ 6 kg/cm 2
-*■ apply grease, replace.
( 2 8 .4 - 8 5 .3 psi)
... at idling o Inching lever sliding defective |
press. 9 - 1 3 kg/cm 2 A pply grease, replace
(128 — 185 psi) o Inching rod defective return -*■
at 2 0 0 0 rpm
Return spring defective -*■ Replace
■1.5 — 6 kg/cm 2
o Orifice valve clogged -> Wash
(2 1 .3 - 8 5 .3 psi)
at.idling
ClUtCh 0 c 10 i / 2 b. If clutch pressure rise-up charac
8 .5 — 13 kg/crrr
press. a teristic is normal.
( 1 1 1 - 1 8 5 psi)
(Check clutch parts)
at 2 0 0 0 rpm
o Clutch return spring broken, weak
-*• Disassemble, replace
o Clutch piston malfunction -*•
Disassemble, check, replace
o Clutch plate abnormal wear-»-
5. Entry o f d iffe r 5.1 Check by smelling torque a. If hypoid gear oil smell is detected.
ential oil converter oil fo r entry of o Pinion oil seal installed position
hypoid gear oil. defective, lip turned up -*■
o Pinion " O " ring defective
o Retainer b olt seal defective
-» Repair, retighten
o A ir breather clogged -*■ Replace
- 82 -
3 -9
6 . Overheating 6 .1 Check torque converter a. Torque converter oil amount

oil amount and quality. insufficient, quality defective
o Check if excessive or insufficient
and correct to proper level.
o A ir drawn in -*■ Check and replace
"O ” ring at joining surface.
o Water mixed in oil -*■ Replace oil
6.2 Check main press., clutch a. Main and clutch pressures below
press., converter press, standard.
(outlet press.) o Stator shaft orifice clogged
Standard pressures: ~ t Disassemble, check, wash
2 — 6 kg/cm 2
o Large resistance in internal oil
( 2 8 .4 - 8 5 .3 psi)
passages and piping -*• Check
Main at idling
internal oil passages, wash
press. 9 — 13 kg/cm 2
( 1 2 8 - 185 psi) o Suction filte r clogged -* Disassemble,
at 2 0 0 0 rpm wash, replace.
1.5 — 6 kg/cm 2
( 2 1 .3 - 8 5 .3 psi)
Clutch at id lin 9
p ress. 8 . 5 - 1 3 kg/cm 2
(111 - 185 psi)
at 2 0 0 0 rpm
<•1 .0 — 1 .6 kg/cm 2
Conv. J ( 1 4 .2 -2 2 .8 psi)
press. l at 2 0 0 0 rpm
6.3 Check clutch parts a. Moves ahead or backward when

Check if vehicle runs when at neutral.
at neutral. o Clutch plates seized by burning,
clutch pack damaged
-*■ Disassemble, check, replace
6.4 Check torque converter parts. a. Converter parts defective.

o Stator sticking -*■ Disassemble
stator, check, replace
o Impeller contacting * Determine
through oil filter. Replace if
defective.
o Decrease in oil circulation
•* Stator shaft orifice clogged
-»• Disassemble, check, wash.
- 83 -
3 -1 0
6.5 Check transmission parts a. Transmission parts defective.

o Clutch dragging
-*■ Disassemble, check, replace
o Bearing worn, burned and seized
-> Disassemble, check, replace
6 .6 Check user's operating a. Check driver's operating methods,

condition using conditions, and place used.
o Check if pushing in operation is
done while inching.
o Check if excessive switch back
is being done.
7. Noise develops 7.1 Check torque converter o Drive plate damaged -*■ Replace
o Bearing damaged *¥ Replace
o Impeller contacting# Check by
oil and oil filte r-► Repair or replace.
o Bolts loosened -*■ Retighten
o Gear pump damaged -*■ Repair or
replace.
7.2 Check transmission parts o Dragging noise due to seized

clutch j * Check, replace
o Bearing worn or damaged
-*■ Check, replace
o Gears damaged -*■ Replace
o Splines worn -*■ Replace
7.3 Check differential parts o Pinion and ring gear tooth contact
or backlash defective
Adjust, replace
o Bearings or gears damaged
-*■ Check, replace
8 . Oil leakage 8.1 Check oil seals o Check all seals for wear or damage
at lips and on their contacting parts
surfaces, and replace any part found
defective.
8.2 Check case joints o Retighten bolts, replace " 0 " rings
and packings.
8.3 Check for blowholes and o Repair or replace

cracks.
8.4 Oil blowing out from air o Overheating Refer to 6 above,

breather o Excessive oil
- 84 -
3 -1 1
COMPONENT PARTS
1. Drive plate rear spacer

2. Flywheel
3. Flywheel housing
Fig. 3-3 Flywheel Housing
1. Torque converter housing

2. Transmission housing
3. Filter
Fig. 3-4 Torque Converter Housing
- 85 -
3 -1 2
1. Center piece 11 . Pump impeller extension

2. Pilot bearing 12 . Oil seal
3. Turbine fro n t washer 13. Oil pump body
4. Pump impeller disk 14. Oil pump driven gear
5. Turbine runner 15. Oil pum p drive gear
6. Turbine runner hub 16. Stator shaft
7. Stator wheel rear collar 17. Inp u t shaft
8. Stator 18. Seal ring
9. Pump impeller 19. Bearing
10. Bearing
Fig. 3-6 Torque Converter
- 86 -
3 -1 3
1. Wave washer 10 . Seal ring

2. Forward gear collar 11. Clutch drum
3. Forward gear 12. Main shaft
4. Forward gear thrust washer 13. Reverse gear thrust
5. Clutch backing plate 14. Reverse gear
6. Clutch driven plate 15. Reverse gear thrust
7. Clutch drive plate No. 1 16. Bearing
8. Clutch return spring 17. Main shaft collar
9. Clutch piston 18. Main shaft cap
Fig. 3-7 Torque Converter Clutch

T = 9 ~ 12 (65 .0 ~ 8 6 .6 )
12 (65 .0 ~ 8 6 .6 )
T = 35 ~ 40
(252.7 ~ 28 8.8)
1. Thrust washer 9. Bearing spacer

2. Needle bearing 10 . Oil seal
3. Idle shaft 11. Bearing retainer
4. Idle shaft spacer 12 . Shim
5. Idle gear 13.f,t Bearing
6. O utput gear 14. Drive pinion
7. Bearing 15. Pilot bearing
8. Shim
Fig. 3-8 Torque Converter Gears
- 87 -
3 -1 4
mmm
1. Selector valve 7. Orifice valve body

2. Change valve stopper 8. Regulator valve
3. Change valve 9. Spring holder
4. Control valve body 10. Separator plate
5. M odulator valve 11. Inching valve
6. O rifice valve
Fig. 3-9 Oil Control Valve
- 88 -
3 -1 5
SERVICE STANDARDS
Item Standards Value
Shift lever stopper to shift lever clearance lim it below 0.5 mm (0 .0 2 0 in)
Shift lever actuating force 4 - 8 kg ( 9 - 1 8 lb)
Free length 70 mm (2.760 in)

Inching valve spring
Lim it 60 mm (2.362 in)

Regulator valve spring
Lim it 8 6 mm (3.386 in)

iv io a u ia io r va ive spring jo m a iw
Lim it 73 mm (2.874 in)
Free length 84.5 mm (3.327 in)

iv io a u ia io r va ive spring vi_argtp
Lim it 81.5 mm (3.209 in)

Orifice valve spring
Lim it 25 mm (0.984 in)
Driven gear to pump body clearance lim it 0.4 mm (0.016 in)
Driven gear to crescent clearance lim it 0.3 mm (0 .0 1 2 in)
Drive gear to crescent clearance lim it 0.3 mm (0 .0 1 2 in)
Pump body to gears clearance lim it 0 .2 mm (0.008 in)
Pump drive gear bushing to stator shaft clearance lim it 0.15 mm (0.006 in)
Forward gear bushing bore wear lim it 40.36 mm (1.589 in)

Forward gear thrust washer thickness wear lim it 2 .8 mm (0 .1 1 0 in)
Reverse gear bushing bore wear lim it 34.36 mm (1.353 in)

Reverse gear thrust washer thickness wear lim it 2 .8 mm (0 .1 1 0 in)
Main shaft to main shaft seal ring clearance lim it 0 .2 mm (0.008 in)
Standard 1 .8 mm (0.071 in)
Drive plate thickness
Lim it 1 .6 mm (0.063 in)
Standard 2.9 mm (0.114 in)

Driven plate thickness
L im it 2 .6 mm (0 .1 0 2 in)
Free length 113 mm (4 .4 4 9 in)
Free length lim it 103 mm (4.055 in)

Clutch return spring 150 mm
clutch Installed load 70 kg (154 lb) [Ins.Igth 43 mm
(1.693 in)]
Squareness 2 max.
- 89 -
3 -1 6
Item Standards Value
Clutch piston to piston seal ring clearance lim it 0.15 mm (0.006 in)
Reverse idler gear thrust washer thickness wear lim it 1.9 mm (0.075 in)
Reverse idler gear thrust clearance 0.2 ~ 0.7 mm (0.008 ~ 0.028 in)
- 90 -
3 -1 7
UPPER COVER REMOVAL
REMOVAL
1. Remove the toeboard.

(1) Reartoeboard
(2 ) Front toeboard
2. Remove the upper cover.

(1) Disconnect inching rod.
Fig. 3-11 Disconnecting Inching Rod
(2) Disconnect shifting rod.
Fig.3-12 Disconnecting Shifting Rod
(3) Remove upper cover.
Fig. 3-13 Removing Upper Cover
- 91 -
3 -1 8
LEVERS
DISASSEMBLY
1. Remove the shifting lever.

(1) Set bolt
(2) Screw on service nut to bolt threads
and drive out w ith hammer.
(3) Shifting lever
(4) Plate
Fig. 3-14 Removing Shifting Lever
2. Remove the inching valve lever.

(1) Set bolt
(2) Screw on service nut to bolt threads
and drive out w ith hammer.
(3) Inching valve lever
(4) Plate
Fig. 3-15 Removing Inching Valve Lever
3. Remove the oil control valve.

(1) Separator plate
a. Set bolt
b. Separator plate
Caution:
Valve set bolt is located at separator plate
lower part.
(2) Control valve

a. Set b olt
b. Oil control valve
Fig. 3-16 Removing Control Valve
4. Remove the cam lever.

(1) Cam lever
(2) Plate
Caution:
Remove oil seal only when found necessary
to do so.
Fig. 3-17 Removing Cam Lever
- 92 -
3 -1 9
5. Remove the inching cam lever.

(1) Inching cam lever
(2) Plate
Caution:
Remove oil seal only when found necessary to
do so.
Fig. 3-18 Removing Inching Cam Lever
INSPECTION
1. Wear, damage, or deformation in shifting

lever, cam lever, inching valve lever, and
inching cam lever.
Fig. 3-19 Lever Inspection
ASSEMBLY
1. Assemble the oil seal.

SST used 09620-30010
Essential:
o Apply grease to oil seal outer side and lip.
o Drive in the oil seal until its surface is
flush w ith the cover.
Fig. 3-20 Assembling Oil Seal
2. Assemble the inching cam lever.

(1) A pply grease to upper cover interior.
(2) Washer
(3) Inching cam lever
Fig. 3-21 Assembling Cam Lever
93
3. Assemble the cam lever.
(1) A pply grease to upper cover interior.
(2) Plate
(3) Cam lever
Fig. 3-22 Assembling Cam Lever
4. Install the oil control valve.

(1) Packing
(2) Oil control valve
(3) Set bolt
Caution:
Assemble w ith the inching spool and inching
cam lever, and the inching spool and cam
lever fitted together.
Fig. 3-23 Assembling Oil Control Valve
5. Assemble the inching valve lever.

(1) Plate
(2 ) Inching valve lever
(3) Set bolt and nut
A
Caution:
Assemble the inching valve lever by aligning
it w ith the inching cam lever groove position.
Fig. 3-24 Assembling Inching Valve Lever
6. Assemble the shifting lever.

(1) Plate
(2) Shifting lever
(3) Set bolt
Caution:
Assemble the shifting lever by aligning it w ith
the inching cam lever groove position.
Fig. 3-25 Assembling Shifting Lever

3 -2 1
7. Adjust the shifting lever stopper.

With the steel ball properly fittin g into the
selector valve groove, adjust the stopper
position so as to provide a clearance of
w ithin 0.5 mm (0.020 in) between the shift
lever stopper and shift lever.
A : Below 0 .5 mm (0.02 in.)
Fig. 3-26 Adjusting Stopper
- 95 -
3 -2 2
OIL CONTROL VALVE
Fig. 3-27 Sectional V iew of Oil Control Valve
DISASSEMBLY

(1) Sparator plate
a. Set bolt
b. Separator pilate
Caution:
Valve set bolt is located at lower part of sepa
rator plate.

a. Set bolt Fig. 3-28 Removing Control Valve
b. Oil control valve
2. Remove the valves

(1) Set bolt
(2) Spring holder
(3) Spring (Inching valve)
(4) Spring, regulator valve
(5) M odulator valve, etc.
Fig. 3-29 Removing Valves
- 96 -
3 -2 3
3. Remove the orifice valve.

(1) Snap ring
(2) Piston
(3) Spring
Fig. 3-30 Removing O rifice Valve
4. Remove the steel ball.

(1) Adjust screw
(2) Spring
(3) Steel ball
Fig. 3-31 Removing Steel Ball
5. Remove the selector valve.
Fig. 3-32 Removing Selector Valve
6. Remove the inching valve.

(1) Spring pin
(2) Inching valve
Fig. 3-33 Removing Inching Valve
- 97 -
3 -2 4
7. Remove the change valve.

(1) Spring pin
(2) Change valve stopper
Caution:
Before disassembling, check the change valve
fo r free drop action. If normal, there is no
need to disassemble the change valve.
Fig. 3-34 Removing Change Valve
INSPECTION
Caution:
Before starting inspection, wash all parts
thoroughly in solvent.
1. A ll valves and spools

(1) Damage
2. Body
(2) Damage
Fig. 3-35 Inspection of Valves and Body
mm mm
3. Clogged orifices in orifice valve, regulator
valve and m odulator valve. ' I S a il
A : O rifice
Fig. 3-36 Checking Clogged Orifices
4. Sliding action between the valve spools and

valve body.
Essential:
A p p ly torque converter oil to the valve body
and spool. W ith the body positioned upright,
insert the spool into the body. The spool
should slide down sm oothly by its own
weight.
Fig. 3-37 Checking Sliding Action
98 -
3 -2 5
5. Springs
(1) Loss-of-tension, breakage
Free Length Lim it

Spring
mm (in) mm (in)
Inching valve 70 (2.760) 6 6 (2.362)
Regulator valve 91 (3.583) 8 6 (3.386)
Modulator valve (Large) 84.5 (3.327) 81.5 (3.209)
Modulator valve (Small) 76 (2.992) 73 (2.874)
Orifice valve 27 (1.063) 25 (0.984)
Fig. 3-38 Inspecting Spring
ASSEMBLY
Perform the disassembly in reverse order.
Caution:
o Wash all parts once more before assembl
ing, and assemble w ith the parts liberally
coated w ith torque converter fluid.
o Orifice valve
A fte r assembling, push the valve to its stop
position and then release to make sure
that it returns properly.
o Change valve
Spring pin is driven in the direction shown
in sketch. Drive in until the pin end is
flush w ith the body surface.
Fig. 3-40 Assembling Change Valve
o Inching valve
Spring pin is driven in the direction shown
in sketch. Drive in until pin end is flush
w ith body surface.
Fig. 3-41 Assembling Inching Valve
99
When installing the oil control valve to
the upper cover, use care to see th at the
inching cam lever and cam lever are
correctly positioned.
Selector valve
H ook on a spring scale to the shifting lever
hole and adjust the shift load to 4 ~ 8 kg
19 ~ 18 lb) by means of the adjusting
b o lt.
3 -2 7
TORQUE CONVERTER REMOVAL
1. Remove the drive plate set bolts

(1) Cover set bolts
(2) Cover
(3) Set bolts (6 )
I>
Caution:
When turning the flyw heel, do it by means
of the crankshaft pulley set bolts.
Fig. 3-43 Torque Converter Sectional View
2. Remove the engine.
Reference:
For engine removal, refer to Engine Removal 09020-20110171
section.
Fig. 3-45 Removing Engine
101 -
3 -2 8
3. Remove the torque converter.

(1) Set bolt
(2) Center piece
Fig. 3-46 Removing Center Piece
(3) Snap ring
(4) Torque converter assy.
Caution:
o Use care when pulling out the torque
converter assy from the stator shaft so as
not to damage the lugs on the pump
impeller extension,
o Handle the torque converter carefully
when removing as there is still oil con
tained in the interior.
Fig. 3-48 Removing Torque Converter Assy
DISASSEMBLY
1. Punch aligning marks on the pump impeller

disc and pump impeller.
Fig. 3-49 Punching Aligning Marks
- 102 -
3 -2 9
Remove the pump impeller disc.

(1) Set bolts
(2) Mount the center piece w ith four
bolts. (Positioned 90° apart).
Fig. 3-50 Mounting Center Piece
(3) Use a suitable round bar and lightly

tap the center piece from the pump
impeller extension lug end, and
remove the center piece and pump
impeller.
(4) Remove the center piece.
(5) Pilot bearing
Fig. 3-51 Removing Pump Im peller Disc
3. Remove the turbine runner sub-assy.
Fig. 3-52 Removing Turbine Runner Sub-assy
4. Disassemble the stator.

(1) Snap ring
(2) Stator thrust washer, one-way clutch
inner race thrust plates.
Fig. 3-53 Disassembling Stator (1)
103 -
3 -3 0
(3) One-way clutch inner race, rollers,

one-way clutch roller springs, spring
caps.
Fig. 3-54 Disassembling Stator (2)
5. Remove pump impeller extension.

(1) Set bolts
(2) Pump impeller extension.
SST used 09608-35010
Fig. 3-55 Removing Extension
6. Remove the bearing.

(1) Snap ring
(2) Bearing
SST used 09620-30010
Fig. 3-56 Removing Bearing
- 104-
3 -3 1
INSPECTION
Caution:
Wash all parts thoroughly w ith cleaning
solvent before inspection.
1. Pump impeller disc

(1) Cracks, damages
Fig. 3-57 Pump Impeller Disc Inspection
2. Pump impeller
(1) Cracks, damages
-S
I IS®!
Fig. 3-58 Pump Impeller Inspection
3. Pump impeller extension *' ''//wwk

(1) Cracks, damages
: • ■
I P ■. i n 1
■ m w b w b m m m b i■
Fig. 3-59 Pump Im peller Extension Inspection
4. Turbine runner sub-assy.

(1) Cracks or damage in turbine runner
(2) Loosening in the f it between turbine
runner and turbine runner hub.
(3) Damage in turbine runner hub.
Fig. 3-60 Turbine Runner Sub-assy Inspection
- 105 -
3 -3 2
5. Center piece
(1) Cracks, damages
Fig. 3-61 Center Piece Inspection
Bearings
(1) Rotating condition
(2) Wear, damage
111
Fig. 3-62 Bearing Inspection
7. Stator wheel rear collar, turbine fro n t

washer.
(1) Damage
Fig. 3-63 Collar and Washer Inspection
8. Stator
(1) Stator wheel
a. Cracks, damage
(2) One-way clutch inner race, outer race
(3)
a. Cracks, damage
Stator thrust washer, one-way clutch
CM g
inner race thrust washer.
a. Damage
Fig. 3-64 Stator Inspection (1)
- 106 -
3 -3 3
(4) Rollers, springs, caps,

a. Damages
Fig. 3-65 Stator Inspection (2)
ASSEMBLY
1. Assemble the bearing to the pump impeller

extension.
(1) Bearing
SST used 09608-30011
Caution:
Take care not to damge the tension lugs.
Fig. 3-66 Installing Bearing
(2) Snap ring
Fig. 3-67 Installing Snap Ring
2. Assemble the pump impeller extension.

(1) Pump impeller.
(2) Pump impeller extension
SST used 09370-10410-71
Caution:
A pply grease on the " O " ring before installing.
(3) Set bolts
Fig. 3-68 Assembling Extension
- 107 -
3 -3 4
3. Assemble the stator.
One w ay clutch inner race
Fig 3 -6 9 Assembling Stator (1) Fig. 3-70 Assembling Stator (2)
Caution:
A p p ly torque converter fluid thoroughly on all parts before assembling.
(1) Assemble the stator thrust washer on

pump impeller side.
a. Thrust washer
b. Snap ring
Vi
Fig. 3-71 Assembling Thrust Washer
(2) Assemble the one-way clutch inner

race.
a. One-way clutch inner race thrust
plates.
b. One-way clutch inner race
Essential:
The inner race has directivity. When assembl
ing, make sure to position it so that the w ider
shoulder side is directed toward the pump
im peller side and narrower shoulder side
tow ard the turbine runner.
Fig. 3-72 Assembling Inner Thrust
- 108 -
3 -3 5
(3) Use tweezers and assemble the spring

caps, springs, and rollers.
Fig. 3-73 Assembling Rollers
(4) Check the stator turning condition.
Essential:
A fte r assembling' the rollers, hold the inner
race stationary and check the stator rotation.
When pressure is applied toward the curved
vane outer side, the stator wheel should turn
(in clockwise direction). When pressure is
applied toward the curved vane inner side, the
stator wheel should not turn. (Should not
turn in counterclockwise direction).
A : Turn
B: No turn
C: Settle Fig. 3-74 Checking Stator Rotation
(5) Assemble the one-way clutch inner

race thrust plate.
(6 ) Assemble the startor thrust washer.
(7) Install the snap ring.
Fig. 3-75 Assembling Plate & Washer
(8 ) Install the stator on the stator shaft,

and rotate by hand to check that it
turns and locks.
A: Rotates
B : Does not rotate
Essential:
I f it is possible to turn the stator in lock
direction by hand, replace the stator assy.
A : Turn
B: No turn
Fig. 3-76 Checking Stator Assy Action
- 109 -
3 -3 6
4. Assemble the stator wheel rear collar and

stator assy to the pump bearing sub-assy.
(1) Set the pump impeller so that its
inner side faces upward.
(2 ) Stator wheel rear collar.
A : Oil grooves
Caution:
Have the grooved side facing the stator
(upward).
Fig. 3-77 Assembling Rear Collar
A : Pumps impeller side

B: Turbine runner side
(3) Stator assy.

Fig. 3-78 Stator Directivity
Caution:
o Stator has directivity so make sure to
position it correctly,
o A fte r assembling the stator, rotate the
stator to make sure that there is no
interference.
Fig. 3-79 Assembling Stator
5. Assemble the turbine runner sub-assy.
Caution:
If turbine runner or turbine runner hub had
been replaced, hub should be installed on the
hub by riveting.
Fig. 3-80 Assembling Turbine Runner
110 -
3 -3 7
SELECTION OF TURBINE FRONT WASHER
6. Assemble the turbine fro nt washer.

(1) Install SST 09230-30150-71 on
turbine runner.
Fig. 3-81 Installing SST
(2) Install the pump impeller disc on the

impeller, and w ith thickness gage,
measure the clearance A at 3 places
on the circumference.
Caution:
Have the " O " ring on pump impeller disc and
p ilo t bearing removed.
(3) Select the fro n t washer from the

following table to conform w ith the
measured results o f A clearance.
Front Washer Thickness Clearance A

Part No. mm mm
32291-12010-71 2 .8 0.6 — 0.9
32292-12010-71 3.1 0 .3 -0 .5
32293-12010-71 3.4 0.1 - 0 .2
32294-12010-71 3.7 0
Example: If clearance A is 0.5 mm, use 3.1 mm

fro n t washer.
Fig. 3-83 Measuring A Dimension
7. Install the fro n t washer.
8. Assemble the pump impeller disc.

T = 1 . 5 - 2 .0 kg-m
( 1 0 .8 - 14.4 ft-lb)
Caution:
o Apply grease on " O " ring before installing,
o Make sure to align the aligning marks
before assembling,
o A fte r assembling the converter assy,
rotate the pump inpeller by fingers to
make sure that there is no interference.
Fig. 3-84 Assembling Pump Im peller Disc
- 111 -
3 -3 8
INSTALLATION
1. Install the torque converter.

(1) Install the torque converter assy to
the stator shaft.
(2) Pilot bearing
SST used 09620-30010
(3) Snap ring
(4) Center piece
Caution:
A pply grease on " O " ring before installing.
Fig. 3-85 Installing Converter Assy
Essential:
Check the torque converter to see that it
rotates smoothly as the converter assy shifts
slightly forw ard or backward after installation.
2. Install the engine.
Reference:
For installation procedure, refer to section on
engine installation.
Fig. 3-87 Installing Engine
112 -
3 -3 9
OIL PUMP REMOVAL
Reference:
The oil pump is removed after removing the
torque converter. For procedures on removing
the torque converter, refer to section on
torque converter removal.
1. Remove the transmission housing.

(1) Set nuts
(2) Transmission housing.
Caution:
Be careful not to injure the stud bolts.
Fig. 3-88 Oil Pump Sectional View
Fig. 3-89 Removing Housing
- 113 -
3 -4 0
DESASSEMBLY
1. Remove the oil pump.

(1) Set bolts
(2) Oil pump assy
SST used 09310-10160-71
Fig. 3-90 Removing Oil Pump
(3) Gears
■■Mi
Fig. 3-91 Removing Geras
(4) Oil seal
Caution:
Remove the oil seal only when found neces
sary.
Fig. 3-92 Removing O il Seal
2. Remove the input shaft.

(1) Snap ring
(2) Input shaft
Fig. 3-93 Removing Inp u t Shaft
- 114 -
3 -4 1
(3) Remove the bearing.

a. Snap ring
b. Bearing
Caution:
Use SST if bearing is tight fit.
SST used 0 9 9 5 0-20 01 2
3. Remove the stator shaft.

SST used 09608-30011
Fig. 3-95 Removing Stator Shaft
INSPECTION
Caution:
Thoroughly wash all parts w ith solvent before
starting inspection.
1i Oil pump body, oil pump gears

(1) Cracks and damages in oil pump body
(2) Damage in drive and driven gears
(3) Assemble the drive gear and driven

gear into the oil pump body and
measure the clearances at the various
parts.
a. Drive gear to pump body clearance
L im it 0.4 mm (0.016 in)
Fig. 3-97 Oil Pump Inspection (2)
- 115 -
3 -4 2
b. Driven gear to crescent clearance

L im it 0.3 mm (0.012 in)
Fig. 3 -9 8 Oil Pump Inspection (3)
c. Drive gear to crescent clearance

L im it 0.3 mm (0.012 in)
Fig. 3-99 Oil Pump Inspection (4)
d. Clearance between pump body

surface and gears
L im it 0.2 mm (0.008 in)
Fig. 3-1 00 Oil Pump Inspection (5)
(4) Measure the clearance between the

pump drive gear bushing and stator
shaft.
L im it 0.15 mm (0.006 in)
Fig. 3-101 Measuring Bushing Bore & Shaft Diameter
116 -
3 -4 3
2. Stator shaft
(1) Wear and damages in splines
(2) Clogged orifices
(3) Wear and damages in surface sliding
against oil pump gears
Fig. 3-1 02 Stator Shaft Inspection
3. Input shaft
(1) Wear and damages in splines
(2) Clogged orifices
(3) Wear and damages in seal ring
Fig. 3-103 Input Shaft Inspection
4. Bearing
(1) Wear and rotating condition
Fig. 3-1 04 Bearing Inspection
- 117 -
3 -4 4
ASSEMBLY
1. Assemble the stator shaft and oil pump to

the transmission housing.
(1) Stator shaft
Caution:
Assemble w ith the oil holes and bolt holes
properly aligned.
(2) Assemble the pump gears into the oil

pump body, and install as one unit.
Caution:
o A pply torque converter fluid to body and
gears before assembling,
o Set bolts are not equally spaced so make
sure to align all holes before installing.
(3) Set bolts.
Caution:
Install w ith the seal washers positioned such
Fig. 3-1 06 Assembling Pump Body & Gears
th at their rubber or coated sides are faced
toward the pum p body.
2. Install the input shaft.

(1) Bearing
Fig. 3-1 07 Installing Bearing
(2) Snap ring

(3) Seal ring
Caution:
o Carefully insert the seal ring into the input
shaft groove, using care not to break it.
Close the ring open ends,
o A p p ly grease to the ring and groove.
Fig. 3-1 08 Installing Snap Ring
118 -
3 -4 5
(4) Input shaft

(5) Snap ring
Caution:
o Drive in the seal ring little by little, using
care not to break it.
o A fte r assembling, fill torque converter
fluid into the bearings and rotate the input
shaft 5 or 6 times.
I
Fig. 3-109 Installing Input Shaft
INSTALLATION
Essential:
o Apply grease on all " O " rings before
installing.
o For procedures on installing the torque
converter and engine, refer to the respective
sections.
- 119 -
3 -4 6
TRANSMISSION ASSY
REMOVAL
1. Remove the engine, radiator, etc.
Reference:
For procedures on removing the engine,
radiator, and related parts, refer to the section
on engine removal.
2. Drain out the differential oil.

(1) Drain plug Fig. 3-1 10 Draining Differential Oil
Differential oil 5 £ (1.32 US gal)
3. Remove the steering wheel.

SST used 09609-20010
Fig. 3-111 Removing Steering Wheel
4. Remove the fro n t toeboard.
Fig. 3-1 12 Removing Front Toeboard
5. Disconnect the inching rod.
Fig. 3-1 1 3 Disconnecting Inching Rod
- 120 -
_____________________ 3 -4 7
6. Disconnect shaft lever connecting rod.
Fig. 3-114 Disconnecting Shift Lever Connecting Rod
7. Pull out the axle shaft.
(In case o f 1.5 and 1.75 ton vehicles)

(1) Jack up the vehicle and remove the
fro n t tire.
Fig. 3-1 15 Removing Tire ( 1 .5 ,1 .75-ton)
(2) Front axle shaft
Fig. 3-1 16 Removing Axle Shaft
(In case o f % 1.35, 2, 2.25, 2.5, 2.75,

3 ton vehicles)
Fig. 3-1 17 Removing Axle Shaft
- 121 -
3 -4 8
8. Remove the differential housing set bolts.
Essential:
Do not remove all set bolts. Leave 1 or 2 of
the easy removable bolts fo r safety.
Fig. 3-118 Removing Differential Set Bolts
9. Remove the engine and transmission assy.
(1) SST used 09010-20120-71
(2) SST used 09010-20110-71

(when using hoist)
SST used 09020-20110-71
(when using lift)
(3) To make removal and installation

easier, slightly lift up the torque
converter and transmission, and
Fig. 3-119 Mounting SST
slightly t ilt the differential housing.
Caution:
Be careful to overlift.
(4) Remove the remaining differential

housing set bolts.
(5) Engine and transmission assy

Fig. 3-1 20 Removing Engine & Torque Converter
Caution:
o Have the parking brake cable clamp on
transmission underside removed before
hand.
o Carefully pass through the oil pum p,
o When removing, be very careful not to
strike against any object in the vicinity.
10. Drain o ut the torque converter oil.

(1) Drain plug
Oil capacity
13.2 8
(3.5 US gal)
Fig. 3-121 Draining O ut Oil
- 122
3 -4 9
11. Remove the drive plate set bolts.

(1) Cover
(2) Drive plate set bolts (6 ea)
Caution:
Turn the flywheel by rotating the clutch shaft
pulley set bolts.
12. Separate the engine from the torque con

verter.
(1) Set nuts
(2) Separation
Fig. 3-123 Engine and Torque Converter Separation
13. Remove the torque converter upper cover.

(1) Set bolts
(2) Upper cover
Fig. 3-1 24 Removing Upper Cover
14. Separate the transmission housing from the

transmission case.
(1) Set bolts
(2) Separation
Fig. 3-1 25 Separation
- 123 -
3 -5 0
DISASSEMBLY
m m
Fig. 3-1 26 Transmission Sectional V iew
1. Remove the suction filter.

(1) Filter lock set bolt
(2) F ilter lock
(3) Suction filte r
(4) " 0 ” ring
Fig. 3-1 27 Removing Suction Filter
- 124 -
3 -5 1
2. Remove the idler gear.

( 1 ) Shaft lock set bolt
(2 ) Shaft lock
(3) Idler gear shaft
(4) Idler gear, washer, idler gear spacer,
needle bearing, shaft spacer.
Fig. 3-128 Removing Idler Gear
3. Remove the clutch assy.

(1) Snap ring
(2) Main shaft cap
SST used 09810-20170-71
Fig. 3-129 Removing Cap
(3) From the differential side, strike the

main shaft w ith a brass rod so as to
drive the clutch assy into the trans
mission case.
Caution:
o When driving out the clutch assy, use care
not to damage the main shaft collar and
main shaft ring.
o When taking out the clutch assy, be careful
not to drop the clutch assy.
Fig. 3-1 3 0 Removing Clutch Assy
Fig. 3-131 Removing Clutch Assy
- 125 -
3 -5 2
4. Remove the main shaft collar.

SST used 09620-30010
Caution:
There is no necessity of removing the main
shaft collar except replacement.
Fig. 3-132 Removing Main Shaft Collar
5. Remove the main shaft and gears.

(1) Wave washer
(2) Snap ring
(3) Use plastic hammer and drive out the
main shaft from forward gear side.
Fig. 3-1 33 Driving O u t Main Shaft
(4) Reverse gear

(5) Reverse gear thrust washer
(6 ) Forward gear
(7) Forward gear thrust washer
Fig. 3-1 34 Removing Gears
(8 ) Forward gear collar
Caution:
There is no necessity o f removing the reverse
gear bushing except replacement.
- 126 -
3 -5 3
(3) Drive plates and driven plates
Essential:
There are tw o kinds of drive plates, No.1 and
No.2. These should be clearly differentiated
and stored.
Fig. 3-137 Removing Plates
(4) Remove the clutch return spring.

a. Mount the SST.
SST used 09220-30200-71 © 9220-30200-71
b. Snap ring
c. Plate and spring
Fig. 3-1 38 Removing Snap Ring
Fig. 3-1 39 Removing Spring
- 127 -
3 -5 4
(5) Pistion sub-assy
Fig. 3-1 40 Removing Piston Assy
(6 ) Seal ring
Caution:
For drive pinion, ring gear, and other parts
related to the differential, refer to Trans
mission and Differential section.
Fig. 3-141 Removing Seal Ring
INSPECTION
1. Idler gear and related parts

(1) Cracks and damages in gears
(2) Damage in needle bearings
(3) Damage in idler shaft
(4) Wear in thrust washer
Wear lim it 1.9 mm (0.075 in)
Fig. 3-1 42 Idler Gear Inspection
Fig. 3-143 Inspecting Thrust Washer
128 -
3 -5 5
2. Suction filte r
(1) Clogging
(2) Damages in wire mesh
Fig. 3-144 Suction Filter Inspection
3. Forward gear and related parts

(1) Forward gear
a. Cracks, damages
b. Clogged orifice
c. Wear in forward gear bushing
Bore lim it 40.36 mm
(1.589 in)
(2) Forward gear collar
a. Wear, damage
Fig. 3-1 45 Forward Gear Inspection
(3) Thrust washer

a. Wear, damage
Fig. 3-1 4 6 Inspecting Thrust Washer
4. Reverse gear and related parts

(1) Reverse gear
a. Cracks, damages
b. Wear in reverse gear bushing
Bore lim it 34.36 mm
(1.353 in)
Fig. 3-147 Reverse Gear Inspection
- 129 -
3 -5 6
(2) Reverse gear thrust washer

a. Wear, damages
Fig. 3-1 4 8 Inspecting Thrust Washer
5. Main shaft ■
(1) Cracks and damage in main shaft
(2) Damage in splines
(3) Clogged oil passages
M B M IW W W W
Fig. 3*149 Main Shaft Inspection
(4) Measure seal ring side clearance

Clearance lim it 0.2 mm (0.008 in)
Fig. 3 -1 5 0 Inspecting Clearance
6. Main shaft collar

(1) Interior damage or clogging
Fig. 3-151 Main Shaft Collar Inspection
- 130 -
3 -5 7
7. Clutch drum assy.

(1) Pressure, drive, driven plates
Caution:
If the plates have been badly discolored by
overheating, replace the drive and driven
plates w ith new set o f plates.
Fig. 3-1 52 Clutch Plate Inspection
(2) Wear and damages in clutch backing

plate
4.0 mm (0.157 in)
4.5 mm (0.177 in)
(use by selection)
Fig. 3-153 Inspecting Pressure Plate
(3) Wear, damages, burning, distortion,

discoloring in drive plates
Standard thickness
1.8 mm (0.071 in)
Service lim it
1.6 mm (0.063 in)
Fig. 3-1 5 4 Inspecting Drive Plate
(4) Wear, damages, burning, distortion,

discoloring in driven plates
Standard thickness
2.9 mm (0.114 in)
Service lim it
2 .6 mm (0 .1 0 2 in)
Fig. 3-1 55 Inspecting Driven Plate
- 131 -
3 -5 8
>5) Cracks, loss-of-tension in clutch

return spring
150 mm
Clutch
113 mm
Free length (4 .4 4 9 in )
Installed length 43 mm
(1.693 in)
Squareness 2 ° max.
Fig. 3-1 56 Inspecting Spring (1)
70 kg
Installed load
(154 lb)
103 mm
Free length lim it
(4.055 in)
Fig. 3-157 Inspecting Spring (2)
(6 ) Cracks, damage in clutch drum, and

wear, damage in splines
Fig. 3-1 5 8 Clutch Drum Inspection
(7) Clutch piston sub-assy

a. Cracks, damage in piston
Fig. 3-1 59 Piston Inspection (1)
- 132 -
3 -5 9
(2) Steel ball movement in piston

A : Steel ball
Essential:
Move the piston and inspect the steel ball
check valve mechanism. Action is satisfactory
if steel ball shifts.
(3) Damage in seal ring and ring side

clearance with piston
Side clearance lim it
0.15 mm (0.006 in)
Fig. 3-161 Inspecting Clearance
- 133 -
3 -6 0
ASSEMBLY
1. Assemble the clutch drum assy.
Caution:
Thoroughly wash all parts in torque coverter
fluid before assembling.
Fig. 3-1 62 Assembling Seal Ring
(1) Assemble the seal ring to the piston.
Caution:
Assemble w ith side punched w ith letter " R "
faced toward the pressure side. Drop con
verter flu id in the seal ring groove and turn
the seal ring 2 or 3 times.
A : Oil Pressure side
Fig. 3-163 Piston
(2) Assemble the clutch piston sub-assy

to the drum.
a. Set the clutch piston, spring, spring
retainer, and snap ring in the drum.
b. Mount SST-09220-30200-71 and
tighten the bolt slightly so as to
apply pressure on the srping.
Fig. 3-1 64 Setting S.S.T
c. Use a screwdriver, and while

pressing the seal ring, f it in the
piston.
Fig. 3-1 6 5 Assembling Piston (1)
- 134 -
3 -6 1
d. Tighten the SST bolt further so as

to compress the spring to the
snap ring position, and then install
the snap ring.
Fig. 3-1 66 Assembling Plate (2)
(3) Assemble the drive and driven plates,

a. Assemble in the sequence o f drive
plate, driven plate, drive plate, etc.
Drive plate thickness

Std: 1.8 mm (0.071 in)
Lim it: 1 .6 mm (0.063 in)
Driven plate thickness
Std: 2.9 mm (0.114 in)
Lim it: 2.6 mm (0.102 in)
(4) Adjust the clearance C between the

clutch backing plate and driven plate
by selecting proper thickness clutch
backing plate.
a. Put a straightedge on the clutch
drum upper side, and measure
dimension A and dimension B
w ith a vernier caliper.
b. Calculate dimension C by the
following equation.
C= A -B
c. Assemble the clutch backing plate
after selcting proper one by
dimension C.
[150 mm dia. clutch]

Size C mm (in) Clutch Backing Plate Used Thickness
For 1.0 ~ 1.5

32437-12050-71 4.0 mm (0.157 in)
(0.039 ~ 0.059)
For 1,5 ~ 2.0
32438-12050-71 4.5 mm (0.177 in)
(0.059 ~ 0.079)
1.0 — 1.5 mm
Std. clearance
(0.039 ~ 0.059 in)
- 135 -
3 -6 2
Reference:
° The tw o kinds of pressure plates shown at
right are available.
o If dimension C is not to standard value, /

the follow ing are the possible causes. L
When below 0 .9 5 mm (0.03 7 i n ) .....

Drive plates warped
When above 2.0 5 mm (0.081 i n ) .....
Drive and driven plates worn r
r— '
Fig. 3-1 69 Kinds of Pressure Plates
(5) Assemble the Clutch backing plate

a. Clutch backing plate
b. Snap ring
Fig. 3-1 70 Assembling Pressure Plate
2. Assemble the main shaft.

(1) Assemble the seal ring oh the main
shaft and f it together the ends.
Caution: Fig. 3-171 Assembling Seal Ring

o Assemble the seal ring carefully so as not
to damage it.
o A fte r assembling, apply torque converter F W .. ;— -■ si
flu id liberally to the seal ring and groove,
and turn the ring 2 or 3 times.
(2) Assemble the main shaft from the

clutch drum reverse gear side.
Caution:
Assemble by fittin g together the clutch drum
splined part w ith o u t valleys to the main shaft
splined part w ith o u t teeth.
A : Reverse gear side Fig. 3-1 7 2 Assembling Main Shaft

B: Forward gear side C: Spline
136
3 -6 3
Fig. 3-1 73 Gear Directivity
(1) Assemble the forward gear.

a. Forward gear thrust washer.
Caution:
Assemble w ith oil groove surface faced toward
gear.
b. Forward gear
c. Collar
Caution:
Assemble by fittin g together the main shaft
splined part w ith o u t teeth and the collar
Fig. 3-1 74 Assembling Forward Gear & Collar
splined part w ith one valley missing.
d. Snap ring
e. Wave washer
A : Oil groove
Fig. 3-1 7 5 Assembling Snap Ring
(2) Assemble the reverse gear

a. Reverse gear thrust washer
Caution:
Assemble w ith oil groove surface faced toward
gear.
A : Oil groove
Fig. 3-1 76 Assembling Thust Washer
- 137 -
3 -6 4
b. Reverse gear
c. Thrust washer
Fig. 3-177 Assembling Reverse Gear & Washer
4. Drive in the main shaft collar into trans

mission case.
SST used 09620-30010
09 6 2 0 -3 0 0 1 0
Caution:
A pply torque converter fluid on the main
shaft collar.
Fig. 3-1 78 Driving in Main Shaft Collar
5. Assemble the main shaft cap.

(1) Main shaft cap
SST used 09620-30010
Caution:
Use new " O " ring and be sure to grease it
before installing.
Fig. 3-1 79 Assembling Main Shaft Cap
(2) Snap ring
Fig. 3-1 8 0 Installing Snap Ring
- 138
3 -6 5
Assemble the clutch assy to case.

(1) Apply grease on the seal ring
(2) Clutch assy
Fig. 3-181 Assembling Clutch Assy
7. Assemble the idler gear into case.

(1) Grease the thrust washer and stick it
on so that the stopper comes on the
case side groove.
(2) Apply grease on the needle bearings.
(3) Needle bearing
(4) Spacer
(5) Needle bearing
(6 ) idler gear
(7) Idler gear shaft
Caution:
o Apply grease on the " O " rings Fig. 3-182 Installing Idler Gear
o Be sure to position shaft lock groove in
correct direction. ■BS
8. (8 ) Measure the idler gear thrust clearance.
Place Measure Thrust Clearance
Transmission case & 0.2 ~ 0.7 mm

washer (0.008 ~ 0.028 in)
Caution:
If thrust clearance is too large, use new thrust
washer. Fig. 3-183 Measuring Thrust Clearance
9. Install the shaft lock.

(1) Shaft lock
(2) Set bolt
Fpgfe 3-1 84 Installing Shaft Lock
- 139 -
3 -6 6
10. Install the suction filter.

( 1 ) " 0 " ring (apply grease)
(2) Filter
(3) Filter lock
(4) Set bolt
H i
Fig. 3-1 85 Installing Filter
11. Install the transmission case.

(1) Transmission housing
(2) Set nuts
Fig. 3-1 86 Installing Housing
12. Install the upper cover.

(1) Gasket
Essential:
A pply liquid seal.
(2) Upper cover

(3) Set bolts
Fig. 3-187 Installing Upper Cover
TORQUE CONVERTER & TRANSMISSION

INSTALLATIO N

order.
Caution:
o Connect the battery (—) term inal only
after checking the electrical wiring to see
th at there is no error,
o Fill in the differential and torque converter
oils, and check to see th at the proper
amounts have been filled in.
Fig. 3-1 88 Installing Torque Converter & Transmission
o Check the coolant and engine oil quantities,
and replenish if found insufficient.
140 -
3 -6 7
MEASUREMENTS & TESTS
Determination o f the measurement and test

results and their disposition should be made in
accordance w ith Trouble Shooting procedures.
1. Measure oil quantity.
(1) Maintain the vehicle level, shift lever
in neutral, and engine idling.
(2) A fte r warming up, keep the engine
idling and measure the oil level with
oil level gage. Level should be between
F ■*—*■ L lines. Fig. 3-1 89 Measuring Oil Q uantity
Torque converter oil quantity
Approx. 13.2 8 (3.5 US gal)
2. Measure hydraulic pressure

(1) Warm up the engine and measure the
idling speed and no-load governed
maximum speed.
Reference:
If engine speed is found defective, adjust by
referring to section Engine Speed Adjustment
under E N G IN E . Fig. 3-1 90 Measuring Engine RPM
^ \ V e h i c l e Type 4P Engine 5R Engine 5P Engine 2J Engine
1—1.75ton 2—2.5 ton 1 —2 .5 ton 2—3 ton 1—2.5 ton 2.75 & 3 ton
Item
Vehicle Vehicle Vehicle Vehicle Vehicle Vehicle
Idling speed 550 rpm 550 rpm 550 rpm 700 rpm 650 rpm 650 rpm
No-load maximum
2600 rpm 3050 rpm 2600 rpm 2300 rpm 2300 rpm 2600 rpm
governed speed
(2) A fte r finishing speed adjustments,

shut o ff the engine
(3) Jack up the fro n t axle so as to float
the tires, (both wheels)
(4) Remove the rear toeboard and mount
the pressure gage. If three gages are
used, the main pressure, clutch pres
sure and torque converter pressure
can all be measured at the same time.
(5) Start the engine, set the shift lever to
neutral, and measure the main pres
sure and outlet pressure.
(6 ) Set the shift lever to forward and
reverse, and measure the clutch
actuating pressure.
A : Clutch pressure B: Main pressure
measurement point measurement point
C: O utlet pressure Fig. 3-191 Mounting Pressure Gage

measurement point
- 141 -
3 -6 8
Caution:
° Use 20 kg/cm 2 (284 psi) oil pressure gages. For torque converter pressure (outlet pressure), about a 5 kg/
cm (71 psi) oil pressure gage would be more preferable.
° Do not operate the inching or brake pedal while measuring the hydraulic pressures. (Operating the inching
valve could cause the main pressure to rise about 15 to 20 kg/cm 2 (213 to 284 psi)).
~~~~^^/ehicle Type
A ll Vehicle
Item -— .___
Idling 2~ 6 kg/cm 2 (28.4 ~ 85.3 psi)

Main pressure
2 0 0 0 rpm 9 — 13 kg/cm 2 ( 128 — 185 psi)
Idling 1.5 ~ 6 kg/cm 2 (21.3 ~ 85.3 psi)

Clutch pressure
2 0 0 0 rpm 8 .5 ~ 13 kg/cm 2 ( 1 1 1 ~ 185 psi)
O utlet pressure 2 0 0 0 rpm 1.0 ~ 1 .6 kg/cm 2 (14.2 ~ 2 2 .8 psi)
Main and clutch pressure lim its 9 kg/cm 2 (128 psi) at 2000 rpm
3. Stall test.
(1) Securely block the fro n t and rear
wheels. Load to nearly permissible
lim it and fu lly apply the parking
brake.
Caution:
Maintain the vehicle in perfectly immovable
state.
(2) Warm up the engine and measure the

idling speed and no-load governed
maximum speed.
Fig. 3-192 Stall Test
Reference:
For rpm , refer to table in par. 2 above.
(3) Check the engine o utput by means o f engine no-load maximum rpm.
(Method)
A fte r adjusting no-load governed maximum speed, set the t ilt lever forward or backward so as
to create full relief condition. Then w ith the accelerator wide open, measure the maximum rpm.
(Criteria)
Gasoline engine vehicle About 150 to 200 rpm down from no-load max. rpm.
Diesel engine vehicle A bout 100 rpm down from no-load max. rpm.
LPG vehicle shown slightly larger drop then shown above.
(Disposition)
If engine rpm drops considerably, this is an indication that engine is still out-of-adjustment.
Adjust the air governor and other engine parts. (Refer to engine adjustment).
- 142 -
3 -6 9
(4) Start the engine and set the shift (5) For a vehicle equipped w ith power
lever to forward or reverse. Race the brake, stall speed must not be
engine and measure the speed (stall measured w ith the brake pedal
speed) when the speed becomes pressed.
constant.
^ '- '\ V e h ic le Type 4P Engine 5R Engine 5P Engine 2J Engine
1—1.75 ton 2 —2 .5 ton 1—2.5 ton 2—3 ton 1 —2 .5 ton 2.75 & 3 ton
Item
Vehicle Vehicle Vehicle Vehicle Vehicle Vehicle
Stall speed 1800± 100 1800± 100 1850+ 100 1850± 100 1950± 100 1800± 1 0 0
rpm rpm rpm rpm rpm rpm
No-load maximum '2300 rpm 2600 rpm
2600 rpm 3050 rpm 2600 rpm 2300 rpm
governed speed
4. Measure time lag

(1) Warm up the engine and have it
idling. Do not operate the inching
pedal at this time.
(2) Move the shift lever to forward or
reverse speed and at the same time
press the stop watch ON.
(3) A small shock w ill be fe lt at the
instant the clutch engages. Press the
stop watch OFF at this instant and
read the time.
(4) Make the measurment several times
in both forward and reverse directions
and take the average o f the readings
taken.
INCHING PEDAL ADJUSTMENT
- 143
3 -7 0
1 . 0 - 1 . 7 5 TON TORQUE CONVERTER TYPE VEHICLES
(1) Separating inching lever A and inching rod B.

(2) Using the pedal height adjustment bolt C, adjust the inching pedal and brake pedal height.
Pedal height 130 mm (5.12")
(3) Adjust the inching rod length and fasten to the inching lever. A t this time confirm that the inching
lever completely returns w ith o u t moving the inching lever as it is fastened.
(4) While looking at the inching lever movement step on the inching pedal the inching lever A as
illustrated below move to a right angle to the torque converter upper cover position D in order for
the adjust bolt E to contact the brake pedal adjust the E bolt length.
(Until the adjust b olt is contacted the pedal stroke is about 35 mm — 40 mm (1.38" — 1.57").
C a u tio n :
When the inching rod and the inching lever are joined in this way absolutely avoid adjusting the pedal height.
When the inching lever location is in poor condition it w ill cause the burn damage and overheating of the
clutch.
2 . 0 - 3 . 0 TON TORQUE CONVERTER TYPE VEHICLES
2.0 — 3.0 ton vehicles w ith the inching rod adjust the pedal height to 128 mm.
In this way the inching lever position can normally be clinched at construction.
- 144 -
4 -1
TRANSMISSION & DIFFERENTIAL
Page
G E N E R A L ..................................................................................................... 4 -2
SPE C IFIC A TIO N S ........................................................................................ 4 -4
SERVICE STANDARDS ........................................................................... 4- 5
COMPONENT PARTS .................. ......................................................... 4- 8
REMOVAL ............................. . . . . . .............................. 4 -1 2
DISASSEMBLY ............ . . ........................... 4 -1 6
INSPECTION ............. ......................................... ......................................... 4 -2 9
ASSEMBLY & ADJUSTMENT ........ ............... ......................................... 4 -3 7
IN S T A L L A T IO N .............................................................. ............... 4 -5 7
- 145 -
4 -2
GENERAL
Fig. 4-1 Transmission Sectional V iew (1 ~ 1.75 ton)
- 146 -
Fig. 4-2 Transmission Sectional V iew (2 ~ 3 ton)
Fig. 4-3 Differential Sectional V iew

SPECIFICATIONS
4 -4
-
148
-
4 -5
SERVICE STANDARDS
Measuring Location Standard
0.05 ~ 0.13 mm
Low speed gear x speed shaft (0.0020 ~ 0.0051 in.)
0.05 ~ 0 .1 3 mm
High speed gear x speed shaft
(0.0020 ~ 0.0051 in.)
0.05 ~ 0.13 mm
Forward gear x reverse idler gear
(0.0020 ~ 0.0051 in.)
0.05 ~ 0.13 mm
Reverse gear x reverse idler gear
(0.0020 ~ 0.0051 in.)
Backlash
0.05 ~ 0.13 mm
Forward gear x output gear
(0.0020 ~ 0.0051 in.)
0.05 ~ 0.13 mm
Reverse idler gear x output gear
(0.0020 ~ 0.0051 in.)
0.2 ~ 0.3 mm
Drive Pinion x ring gear
(0.008 ~ 0.012 in.)
0.1 ~ 0.25 mm
Differential side gear x differential pinion
(0.0039 ~ 0.0098 in.)
Gear shift lever operating force 3 ~ 4 kg (6.6 ~ 8.8 lb)
Gear shift lever side play 3 ~ 7 mm (0.12 ~ 0.28 in.)
.. .. 8.8 mm
Gear shift lever groove Width lim it (Q 346 jfl )
... .. ... 7.5 mm

Gear shift lever pin Wear lim it (0.295 in.)
Transmission
.... 1.0 mm
Gear shift Clearance between gear shift lever and pin
L,m it (0.039 in.)
lever
system . 13.0 mm
Standard |Q 512
Gear shift lever end
... .. .. 12.5 mm
Wear hm it 4g2
r- . .. 27 mm
Free length (1 0 6 ir U
S hift lever spring
Free length lim it fo ^ 4 in.)
. . .* 1.0 mm
S hift fork to clutch hub sleeve clearance Lim t 1 r\ rton • \
(0.039 in.)
, 13.0 mm
Std. bore (0.512 in.)
Gear shift lever insertion part
■• 13.6 mm
Gear shift L im it irt r o r ■ \
(0.535 in.)
fo rk
system Outer diameter 15.0 mm
standard (0.591 in.)
Gear shift fork shaft
, • .. 14.9 mm
L im it in c z o - i- \
(0.587 in.)
D j 0.1 mm
Main drive shaft Bend lim it ln r u w n . ,
(0.0039 in.
- 149 -
4 -6
Std.bore ™ '
(1.575 in.)
High and low speed gear
Bore lim it '
(1.579 in.)
Std.bore
(1.575 in.)
Forward and reverse gear
Bore lim it ^ .
(1.579 in.)
Standard 1 -10 ~ 1-90 mm

(0 .0 4 3 3 ~ 0.0748 in.)
Synchronizer ring to gear clearance
, • ... 0 .8 mm
L im it Ir. n01 . .
(0 .0 3 1 in.)
Outer diameter 45.0 mm
Bushing
Counter
lim it (1.760 in.)
shaft
system ct . . 0.10 ~ 0.25 mm
sianaaro (0 0 0 3 9 ~ 0.0098 in.)
Forward gear and clutch hub thrust
clearance . . .. 0.5 mm
L im it (Q 02Q jn j
0.10 ~ 0.25 mm
Reverse gear and clutch hub thrust Standard (o.0039 ~ 0.0098 in.)
clearance • ... 0.5 mm
L |m|t (Q 02Q jn j
Transmission
Qt h h 0.10 ~ 0.25 mm
btanaara (0 0 0 3 9 ^ 0.0098 in.)
High speed gear to bushing thrust
clearance . • 0.5 mm
L |m|t (Q 02Q jn j
c+ h h 0.10 ~ 0.25 mm
btanaara (0 0 0 3 9 J 0.0098 in.)
Low speed gear to bushing thrust
clearance , . .. 0.5 mm
L im it (Q 0 2 0 jn j
Outer diameter 3 5.0 mm

standard (1.37 8 in .)
Reverse idler shaft
Outer diameter 3 4.9 mm
lim it (1.3 7 4 in .)
Length 3 7,0 mm
Reverse idler gear collar
iLength
4-u i- •*
hm it 36.7
,1 mm. .
a (1.445 in.)
Reverse
idler shaft Thickness 2.95 ~ 3 .05 mm
std. (0.116 ~ 0 .1 2 0 in.)
Thrust washer
Thickness 2.65 mm
lim it (0.104 in.)
c , , 0.05 ~ 0.55 mm
btanaara (q .0 0 2 0 ~ 0.0217 in.)
Reverse idler gear thrust clearance
0 .8 mm
L im ,t (0 .0 3 1 in.)
- 150 -
4 -7

Thickness 1.6 mm
Std. (0.063 in.)
Side gear thrust washer
Thickness 1.3 mm
lim it (0.051 in.)
standard (0 .8 6 6 in.)
Spider
lim it (0.856 in.)
Thickness std. \
(0.063 in.)
Pinion thrust washer
Thickness 1.0 mm
lim it (0.039 in.)
Differential
D 2 2 .1 2 mm
B°re std. (0 8?1 jn )
Differential pinion
D .... 2 2 .2 2 mm
Bore lim it (0.875 in.)
-ru- i 13.0 mm
Thickness std. mem- \
(U .blz in.)
Thrust screw cap
Thickness 12.2 mm
lim it (0.480 in.)
Drive pinion bearing pre-load Starting force: 12.7 ~ 15.6 kg
(measured w ith the output gear) (28.0 ~ 34.4 lb)
Differential side bearing pre-load Starting force: above figure + 2 kg
(measured w ith the output gear) (4.4 lb)
Clutch vehicle 112 (2.9 US gal)
1 ~ 1.75-ton vehicle
Converter vehicle 52 (1.32 US gal)
Differential and transmission oil quantity
Clutch vehicle 122 (3.2 US gal)
2 ~ 3-ton vehicle
Converter vehicle 52 (1.32 US gal)
- 151 -
4 -8
COMPONENT PARTS
TRANSMISSION CASE
T .6 ft-lb)
1. Transmission case sub-assy

2. Gasket
3. Transmission case upper cover
4. Gasket
5. Transmission case rear cover
6. Bearing cap
Fig. 4-4 Transmission Component Parts (1)

4 -9
TRANSMISSION GEARS
1. Stop plate spring 22. Transmission clutch hub

2. Stop plate 23. Transmission hub sleeve
3. Countershaft (1 — 1 .7 5 ton) 24. Low speed gear
4. Stopper 25. Bearing plate
5. Main drive shaft 26. Lock plate
6. Speed shaft 27. Thrust washer
7. Oil seal 2 8. Needle bearing
8. Synchromesh shifting key 2 9. Reverse idler gear
9. Plate washer 3 0. Reverse idler gear spacer
10. Counter shaft (2 — 3 ton) 3 1. Reverse idler gear shaft
11. Spacer 32. " O " ring
12. Reverse gear bushing 33. Lock plate
13. Reverse gear 34. Spacer set bolt
14. High & Low clutch hub 35. Differential drive pinion
15. Transmission hub sleeve 36. Bearing spacer
16. Forward gear bushing 37. Bearing preload adjust shim
17. Forward gear 38. D iff. drive pinion adjust shim
18. Speed gear bushing 3 9. Bearing retainer
19. High speed gear 40. O utput gear
20. Synchronizer ring 41. Lock nut
21. Synchromesh shifting key spring
Fig. 4-5 Transmission Component Parts (2)
- 153 -
4 -1 1
DIFFERENTIAL
Tightening torque unit; kg-m (ft-lb)
1. Side bearing 7. Differential ring gear & pinion set

2. Differential side gear thrust washer 8. Ring gear thrust screw cap
3. Differential side gear g. Differential ring gear thrust screw
4. Differential spider 10. Differential housing
5. Differential pinion 11 . Adjust lock nut
6. Differential pinion thrust washer 12. Adjust nut
Fig. 4-7 Differential Component Parts
- 155 -
4 -1 2
REMOVAL
Caution:
o The transmission assembly cannot be either removed or installed apart from the engine. The installation or
removal of the transmission assembly must be done together w ith the engine.
For details on the procedure for removing the engine, refer to the section on "Engine Removal".
° The upper case and shift lever parts on the transmission case can be disassembled aboard the vehicle. De
pending on the nature of the trouble encountered, you can decide on the proper action to be taken.
TRANSMISSION CASE UPPER COVER
1. Remove the rear toeboard.

3. Remove the shift lever.
Use SST 09130-10170-71
4. Remove the transmission case upper cover.

Caution:
Be careful not to damage the shift forks when
removing the cover.
Fig. 4-9 Removing Upper Cover
5. Disassemble the upper cover.
Caution:
In order to prevent erroneous assembly o f the
components, mark w ith magic ink the installa
tion positions on the shift forks and shift fork
shafts.
(1) Spring pins

Use SST 09700 -30200-71.
Fig. 4 -1 0 Removing Spring Pins
- 156 -
4 -1 3
(2 ) Cotter pins
(3) Straight screw plugs
(4) Springs
(5) Steel balls
(6 ) Fork shafts, shift forks 8 8 B M
Fig. 4-11 Removing Screw Plug
TRANSMISSION WITH DIFFERENTIAL
1. Drain the differential oil.

Oil capacity:
11 liters (2.9 US gal)
2 ~ 3-ton vehicle
12 liters (3.2 US gal)
Fig. 4-12 Draining Differential Oil

(1) Horn button
(2) Set bolts
(3) Steering wheel
Use SST 09609-20010

(1) Clevis pins (Clutch and brake pedals)
(2) Accelerator bracket
Fig. 4 -1 4 Removing Front Toeboard
- 157 -
4 -1 4
4. Disconnect the clutch pedal No. 2 rod.

(1 1.75 ton vehicles)
Fig. 4-15 Disconnecting Rod
5. Remove the clutch booster.

(2 ~ 3 ton vehicles)
(1) Spring
(2 ) Cotter pin
(3) Push rod clevis pin
(4) Set bolts
(5) Clutch booster
(6 ) Clutch booster return pipe
Caution:
Be careful not to bend the pipes when you re
move them.
Fig. 4-16 Removing Clutch Booster
Remove the differential housing set bolts.
Fig. 4-17 Removing Differential Housing Set Bolts
7. Remove the fro n t axle shaft.

(For 1.5 and 1.75 ton vehicles)
(1) Jack up the vehicle, and remove
the fro n t tires.
(2) A xle shafts.
(For T, 1.35, 2, 2.25, 2.75, 3 ton
vehicles)
(1) A xle shafts
Fig. 4-18 Removing Axle Shaft
- 158 -
4 -1 5
8. Remove the engine w ith transmission.

(1) Cylinder head rear plate.
(2) I nstal I SST 09010-20120-71.
Fig. 4-19 Installing SST
(3) Engine w ith transmission.

Use SST 09010-20110-71 (For hoist)
Use SST 09020-20110-71 (For lift)
Fig. 4-20 Removing Engine w ith Transmission
9. Remove the main drive shaft.

Use SST 09210-20170-71.
Fig. 4-21 Removing Main Drive Shaft
10. Remove the engine from the transmission.

(1) Clutch upper cover.
(2) Clutch release bearing tension spring
(3) Set bolts
Fig. 4-22 Removing Engine from Transmission
- 159 -
4 -1 8
5. Remove the counter shaft fro n t bearing

plate.
Fig. 4-29 Removing Bearing Plate
6. Remove the counter shaft, forward & re

verse gears, high & low speed gears.
(For 1 ~ 1.75-ton vehicles)
(1) Mount SST 09810-20170-71 to the
counter shaft.
(2) Drive out the counter shaft and gear
assembly until the low speed gear
comes into contact with the trans
mission case.
Fig. 4-30 Driving O ut Counter Shaft
(3) Insert the handle of a hammer be

tween the reverse gear and trans
mission case to hold the gear assembly
stationary.
Fig. 4-31 Holding Gear Assembly Stationary
(4) Drive in the counter shaft w ith a

brass bar.
Fig. 4-32 Driving in Counter Shaft
- 162 -
4 -1 9
(5) Remove the stop plate.
Note:
The stop plate is split.
Fig. 4-33 Removing Stop Plate
(6 ) Mount the SST 09810-20170-71 to

the counter shaft again, and drive out
the counter shaft.
Caution:
Set the stop plate collar (A) to the same
height as that of the bushing, and drive out
the counter shaft carefully w hile checking the
position of the collar (A ). Otherwise, the stop
plate collar (A) would be stuck in the stop
plate groove.
Be careful: If the collar (A ) moves away
from the shaft center, the shaft cannot be re
moved. Fig. 4 -3 4 Driving O ut Counter Shaft (1)
Fig. 4-35 Driving O ut Counter Shaft (2)
Fig. 4 -3 6 Driving O ut Counter Shaft (3)
163 -
4 -2 0
(For 2 ~ 3-ton vehicles)

(1) Remove the cotter pins
(2) Remove the castle nuts
(3) Remove the collar
Fig. 4-37 D riving O u t Counter Shaft (1)

(2 ~ 3 ton Vehicle)
(4) Drive out the counter shaft w ith a

brass bar to remove it from the
differential side.
Fig. 4-38 Driving O u t Counter Shaft (2)

(2 ~ 3 ton Vehicle)
7. Remove the forward and reverse gear

assembly.
Fig. 4-39 Removing Forward & Reverse Gear Assembly
8. Remove the high and low speed gear

assembly.
Fig. 4 -4 0 Removing High and Low Speed Gear Assembly
164 -
4 -2 1
9. Remove the speed shaft.

(1) Drive out the speed shaft from the
differential side.
Use SST 09608-20011.
Fig. 4-41 Driving O ut Speed Shaft
(2) Snap ring

(3) Bearings
Use SST 09950-20012.
l099.50!
Fig. 4-42 Removing Bearings
(4) Speed shaft
Fig. 4 -4 3 Removing Speed Shaft
10. Remove the reverse idler gear and shaft.

(1) Set bolts
(2) Lock plate
Fig. 4 -4 4 Removing Lock Plate
- 165 -
4 -2 2
Fig. 4-45 Removing Reverse Idler Shaft
(4) Collar
(5) Reverse idler gear
Fig. 4 -4 6 Removing Collar and Reverse Idler Gear
(6 ) Thrust plate
Fig. 4-47 Removing Thrust Plate
11. Remove the o utput shaft cover.
I
Fig. 4 -4 8 Removing O utp u t Shaft Cover
- 166 -
4 -2 3
DIFFERENTIAL
12. Measure the runout at the ring gear back

surface.
Runout lim it: 0.1 mm (0.0039 in)
Essential:
Set a dial gauge perpendicular to the ring gear
back surface, and rotate the ring gear by tu rn
ing the output gear lock nut.
Fig. 4-49 Measuring Ring Gear Back Side Runout
13. Measure the backlash.

Standard backlash: 0.2 — 0.3 mm
(0 .0 0 8 -0 .0 2 1 in)
Fig. 4 -5 0 Measuring Backlash
14. Measure the side bearing pre-load.

(1) Wind a cord around the output gear
and measure the starting force w ith a
spring scale for the reference when
assembling.
Reference:
The value indicated by the spring scale
includes also the pinion bearing pre-load.
Fig. 4-51 Measuring Bearing Pre-load
15. Remove the thrust screw cap.

(1) Lock nut
(2) Thrust screw, cap
Fig. 4-52 Removing Thrust Screw
167 -
4 -2 4
16. Punch matching marks on the transmission

case and bearing caps.
Essential:
The transmission case and bearing caps
have been machined together. Thus, the
left and right sides are not interchange
able. Before removing the bearing caps,
punch matching marks to make it
possible to correctly re-install the parts
in their initial location.
Fig. 4-53 Punching Matching Marks
17. Remove the bearing caps.

(1) Lock wires
(2 ) Lock bolts
(3) Adjusting nut locks
(4) Set bolts
(5) Bearing caps
Essential:
The caps can be removed easily by lightly
tapping them w ith a plastic hammer.
Fig. 4 -5 4 Removing Bearing Caps
18. Remove the adjusting nuts.
Fig. 4 -5 5 Removing Adjusting Nuts
19. Remove the differential case assembly
Fig. 4-5 6 Removing Differential Case Assembly
168 -
4 -2 5
20. Measure the drive pinion bearing pre-load.

spring scale fo r the reference when
assembling.
Fig. 4-57 Measuring Bearing Pre-load
21. Remove the speed shaft bearing and

counter shaft bearing from the transmission
case by using a brass rod.
Fig. 4 -5 8 Removing Bearings
22. Remove the output gear and drive pinion

assembly.
( 1 ) Set bolts
Fig. 4-59 Removing Drive Pinion Assembly (1)
(2) Use a brass rod fo r removal.

(3) O utput gear and drive pinion as
sembly.
Fig. 4 -6 0 Removing Drive Pinion Assembly (2)
- 169 -
4 -2 6
23. Remove the output gear.

(1) Loosen the lock nut.
(2) Remove the lock nut.

(3) O utput gear.
Fig. 4-62 Removing O utput Gear (2)
24. Remove the drive pinion.

(1) Drive out the drive pinion.
(2) Bearing spacer.

(3) Shims
Caution:
Record the number and thickness of the
bearing pre-load adjusting shims used.
Fig. 4 -6 4 Removing Shims
- 170 -
4 -2 7
25. Remove the tapered roller bearing inner

race.
0 9 9 5 0-20 01 2
Use SST 09950-20012.
Caution:
Remove the bearing inner race only when the
bearing is found defective.
Fig. 4 -6 5 Removing Bearing Inner Race
26. Remove the pilot bearing.

(1) Loosen the caulked end of the drive
pinion.
(2) Pilot bearing
Use SST 09950-20012.
Caution:
Inspect bearing, and remove only when a
defect is detected.
Fig. 4 -6 6 Removing Pilot Bearing
27. Remove the tapered roller bearing outer

race from the retainer.
Caution:
Inspect the retainer and bearing, and remove
only when a defect is detected.
Fig. 4-67 Removing O uter Race
28. Remove the differential side bearings.

Use SST 09950-20012.
Caution:
Remove the bearings only when they are
found defective.
Fig. 4-68 Removing Differential Side Bearing
171 -
4 -2 8
29. Remove the differential upper case.

(1) Check the match marks on the upper
and lower cases.
Fig. 4-69 Checking Match Marks
(2) Lock plates

(3) Set bolts
(4) Upper case
Fig. 4 -7 0 Removing Upper Case
30. Remove the side gears and differential

pinion gears.
(1) Side gear, thrust washer.
(2) Differential spider, differential
pinion gears, thrust washer.
(3) Side gear, thrust washer.
Reference:
Tw o differential pinion gears are installed in
vehicles equipped w ith 4P engines. Four
pinion gears are installed in other vehicles.
Fig. 4-71 Removing Side & Pinion Gears
31. Remove the differential ring gear.

(1) Loosen the caulked set bolts.
(2) Set bolts
(3) Ring gear
Caution:
Remove the ring gear, drive pinion, and d if
ferential case only when they are found
defective.
Fig. 4-72 Removing Ring Gear
- 172 -
4 -2 9
INSPECTION
Caution:
Wash all disassembled parts and inspect them
in accordance w ith the following items.
Repair or replace any part found defective.
1. Gear shift lever parts

(1) Bending, cracks in gear shift levers,
wear, damage on lever ends.
Lever end standard: 13.0 mm
(0.512 in)
Lever end wear lim it: 12.5 mm Fig. 4-73 Inspecting Gear Shift Lever
(0.492 in)
(2) Wear on the fittin g part o f the shift
lever retainer.
Shift lever groove width lim it:
8 .8 mm (0.346 in)
S hift lever pin wear lim it:
7.5 mm (0.295 in)
Fig. 4 -7 4 Inspecting Gear Shift Lever Pin
(3) Weak or broken shift lever spring.

Free length standard: 27 mm
(1.06 in)
Free length lim it: 25 mm
(0.984 in)
Fig. 4-75 Inspecting Shift Lever Spring
2. Gear shift forks mm m

(1) Wear, damage o f the gear shift lever
insertion part.
Inner diameter standard: 13.0 mm
(0.512 in)
Inner diameter lim it: 13.6 mm
(0.535 in)
Fig. 4-76 Inspecting Gear Shift Fork (1)
- 173 -
4 -3 0
(2) Wear, damage o f the shift fork and

hub sleeve.
Clearance lim it: 1.0 mm (0.039 in)
Fig. 4-77 Inspecting Gear Shift Fork
3. Gear shift fork shafts.

(1) Wear on the shaft sliding surface. ti
t
Outer diameter standard: 1
’’..y :I|y2
15.0 mm (0.591 in)
Outer diameter lim it:
14.9 mm (0.587 in)
(2) Damage, bending o f shift fork shaft,
wear in ball stopper grooves.
t
(3) Damage o f the lock ball springs.
(4) Wear, damage o f the lock balls. I
a MM m m
Fig. 4-78 Inspecting Gear S h ift Fork Shaft
4. Main drive shaft.

(1) Damage, wear on shaft ends.
(2) Damage, stepped wear on the splines. • ■ - - 4 W H I
(3) Bending o f the shaft.
Bend lim it: 0.1 mm (0.0039 in)
KHPvs ::M;
■ K - -
i': . . V'v
__ im m .. . n z m n ~ ........... ........... —
£ x <
Fig. 4-79 Inspecting Main Drive Shaft
5. Countershaft.
(1) Wear, damage o f the splines.
(2)' Damage of the stop plate.
(3) Damage, breakage o f the stop plate
9
set ring.
IB M # 4
Fig. 4-80 Counter Shaft Inspection
- 174 -
4 -3 1
6. Reverse idler shaft, collar.

Shaft outer diameter standard:
35.0 mm (1.378 in)
Shaft outer diameter lim it:
34.9 mm (1.374 in)
Collar length standard: 37.0 mm (1.457 in)
Collar length lim it: 36.7 mm (1.445 in)
Fig. 4-81 Inspecting Reverse Idler Shaft, Collar
7. Bearings.
Wear, damage, abnormal noise and rotation
condition of the bearings.
(1) Ballbearings
Turn the balls by applying pressure
onto them and check to see whether
they rotate smoothly w ithout ab
normal noise.
(2) Tapered roller bearings
Inspect to see if the rollers are pitted
or worn, and if the bearing holder
and outer race are damaged. Check
the rotating condition o f the rollers. Fig. 4-82 Inspecting Bearings
8. High and low speed gears.

(1) Damage, wear o f the cones.
(2) Damage, wear o f the splines.
(3) Damage o f the gears.
(4) Damage, wear o f the gear ends.
(5) Damage, wear of the gear inner
surface.
Gear inner diameter standard:
40.0 mm (1.575 in)
Gear inner diameter lim it:
40.1 mm (1.579 in)
Fig. 4-83 High and Low Speed Gear Inspection
9. Forward & reverse gears. I

;-T:1
(1) Damage, wear of the splines.

(2) Damage, wear of the gears.
(3) Damage, wear of the gear ends.
(4) Damage, wear o f the gear inner
surface.
Gear inner diameter standard:
40.0 mm (1.575 in)
Gear inner diameter lim it:
40.1 mm (1.579 in)
Fig. 4 -8 4 Forward and Reverse Gear Inspection
- 175 -
4 -3 2
10. Speed shaft.

(1) Gear damage, wear
(2) Wear and damage of the internal
splines.
Fig. 4 -8 5 Speed Shaft Inspection
11. Reverse idler gear

( 1 ) Gear damage, wear
(2) Damage, wear o f the gear ends
(3) Damage, wear on the sliding surface
o f the needle bearing.
Fig. 4 -8 6 Reverse Idler Gear
12. 1 s t/ 2 nd speeds clutch hub and sleeve. R P iM i

■
(1) Damage and wear o f the external
splines.
(2) Damage and wear o f the shifting key
fittin g part.
(3) Damage and wear o f the surface of
the hub in contact w ith the gear.
(4) Damage and wear o f the internal
splines.
(5) Damage and wear o f the shift fork
contact groove. Fork to hub sleeve
clearance lim it: 1.0 mm (0.039 in)
Fig. 4-87 1st/2nd Speeds Clutch Hub Sleeve
Caution:
When fittin g the hub to the sleeve, slide
smoothly.
13. Shifting key, key spring.

(1) Damage and wear o f the key center
protrusion.
(2) Damage of the spring, wear o f the
contact part between the key and
spring.
Fig. 4 -8 8 Inspecting Key and Spring
- 176 -
4 -3 3
14. Synchronizer rings.

( 1) Damage and wear o f the splines.
( 2) Damage and wear o f the tapered
part.
(3) Gear braking action.
Fig. 4-89 Synchronizer Ring Inspection (1)
(4) Gear to ring clearance.

Standard: 1.10 ~ 1.90 mm
(0.0433 ~ 0.0748 in)
L im it: 0.8 mm
(0.031 in)
Fig. 4 -9 0 Synchronizer Ring Inspection (2)
15. Forward & reverse clutch hub and sleeve.

(1) Damage, wear o f the external splines.
(2) Damage and wear of the hub surface
in contact w ith the gear.
(3) Damage and wear o f the internal
splines.
(4) Damage and wear o f the shift fork
contact groove.
Fork to hub sleeve clearance:
1.0 mm (0.039 in)
Caution:
When fitting the hub to the sleeve, slide
Fig. 4-91 Inspecting Forward & Reverse Clutch Hub and
smoothly.
Sleeve I
'v ■■■
16. Bushing.
(1) Damage and wear o f the sliding sur
I
■
face.
!«, ■«. v t ,
Hi
■
(I
Fig. 4-92 Bushing Inspection (1)
177
4 -3 4
Outer diameter standard: ■

45.0 mm (1.772 in)
Outer diameter lim it:
44.7 mm (1.760 in)
Fig. 4-93 Bushing Inspection (2)
17. Thrust washer.

(1) Damage and wear o f the thrust sur
faces.
Thickness standard:
2.95 ~ 3 .0 5 mm
(0.116 ~ 0 .1 2 0 in)
Thickness lim it:
2.65 mm
(0.104 in)
Fig. 4 -9 4 Inspecting Thrust Washer
18. Transmission case rear cover.

(1) Damage and wear o f the oil seal lip.
(2) Damage and wear o f the release bear
ing hub sliding part.
(3) Damage and cracks in the cover.
Fig. 4-95 Inspecting Transmission Case Rear Cover
19. Transmission case.

(1) Damage, cracks in the transmission
case and upper cover.
(2) Damage o f the transmission carrier
cap.
Fig. 4 -9 6 Inspecting Transmission Case
- 178 -
4 -3 5
20. Thrust screw cap.

(1) Damage of the threaded part.
(2) Damage, wear o f the cap.
Standard:
13.0 mm (0.512 in)
Wear lim it:
12.2 mm (0.480 in)
Fig. 4-97 Inspecting Thrust Screw, Cap
21. Side bearings.

(1) Cracks, damage and wear in the
rollers.
(2) Damage of the bearing holders.
(3) Damage, wear o f the bearing outer
race.
Fig. 4-98 Inspecting Side Bearing
22. Drive pinion and ring gear.

(1) Damage and wear in the teeth sur
faces.
(2) Damage, cracks in the p ilo t bearing.
(3) Damage of the pinion splines.
(4) Damage o f the pinion threaded part.
Caution:
If either the drive pinion or ring gear is
defective, both of them must be replaced as a
set.
Fig. 4-99 Pinion and Ring Gear Inspection
23. Side gears, differential pinions, spider, and

thrust washers.
Check them fo r damage and wear.
(1) Differential pinion
Bore standard:
22.12 mm (0.871 in)
Bore wear lim it:
22.22 mm (0.875 in)
Fig. 4-1 0 0 Differential Gear and Side Gear Inspection
179 -
4 -3 6
(2) Thrust washer (differential pinion)

Thickness standard:
1.6 mm (0.063 in)
Wear lim it:
1.0 mm (0.039 in)
(3) Thrust washer (side gear)

Thickness standard:
1.6 mm (0.063 in)
Wear lim it:
1.3 mm (0.051 in)
Fig. 4-101 Inspecting Thrust Washer
(4) Spider
Outer diameter standard:
2 2 .0 0 mm (0 .8 6 6 in)
Outer diameter wear lim it:
21.75 mm (0.856 in)
- ■ ■ .I.".........'
■ ■ B lliiliB M M lM
mm
Fig. 4-102 Inspecting Spider
24. Differential case.

(1) Cracks, damage in the case.
Fig. 4-1 03 Inspecting Differential Case
25. Adjusting nuts.

(1) Damage in the nut threaded p a rt.
Fig. 4-1 0 4 Inspection o f Adjusting N u t
- 180 -
4 -3 7
ASSEMBLY AND ADJUSTMENT

DIFFERENTIAL
1. Assemble the ring gear.
(1) Differential lower case
(2) Ring gear
(3) Set bolts
T = 13 ~ 18 kg-m
( 9 3 .9 - 130 ft-lb)
Essential:
o Use new set bolts fo r assembly, and coat
their threads w ith a locking compound.
o Tighten each pair of bolts opposite to each Fig. 4-1 05 Assembling Ring Gear
other, and finally tighten the bolts to the
specified torque successively in a circular
sequence.
2. Caulk the set bolts.

(1) Caulk the set bolt ends in cross forms.
Fig. 4-1 0 6 Caulking Set Bolts
3. Assemble the side gears.

(1) Thrust washer
Caution:
Assembly must be performed w ith the oil
groove side on the gear side.
(2) Side gear
Fig. 4-107 Assembling Side Gear
4. Assemble/the spider pinion set.

(1) Spider 1
(2) Pinions I Must be assembled as
(3) Thrust washers j a set
Fig. 4-1 08 Assembling Spider Pinion
- 181 -
4 -3 8
5. Assemble the side gear and thrust washer.

(1) Side gear
(2) Thrust washer
Caution:
Assembly must be performed w ith the oil
groove side on the gear side.
Fig. 4-109 Assembling Side Gear
6. Assemble the differential upper case.

( 1) Differential upper case
Caution:
D uly align the match marks.
Fig. 4-1 10 Aligning Match Marks
(2) Lock plate

(3) Set bolts
T = 4.4 ~ 5.5 kg-m
(31.8 ~ 39.7 ft-lb)
Fig. 4-111 Tightening Set Bolts
(4) Caulk the lock plate.
Fig. 4-1 1 2 Caulking Lock Plate
182 -
4 -3 9
7. Install the side bearings.

Use SST 09370-10410-71
Caution:
Be careful not to install the bearing in the
reverse direction.
Fig. 4-1 13 Installing Side Bearing
8. Assemble the bearing outer race.

(1) Bearing retainer
(2) Drive in the oil seal from the torque
converter side (in the case o f the
converter vehicle only).
Use SST 09608-30011
Fig. 4-1 1 4 Installing Oil Seal (F o r Converter Vehicle)
(3) Bearing outer race.

Use SST 09130-30200-71
Fig. 4-1 1 5 Installing Bearing O uter Race
9. Install the pilo t bearing.

(1) Drive pinion
(2) Pilot bearing
Use SST 09608-30011 [Q9608jS§!
Fig. 4-1 1 6 Installing Pilot Bearing
- 183 -
4 -4 0
(3) Caulk the drive pinion end at 3

points.
Fig. 4-117 Caulking Drive Pinion
10. Install the drive pinion fro n t bearing inner

race.
(1) Drive pinion.
(2) Front side inner race.
Use SST 09370-20270-71
Caution:
Be careful not to install the bearing in the
reverse direction.
Fig. 4-1 18 Installing Bearing Inner Race
11. Assemble the drive pinion.

(1) Bearing retainer.
(2) Drive pinion.
(3) Bearing spacer.
(4) Shim
12. Install the drive pinion rear bearing inner

race.
Use SST 09370-20270-71
Fig. 4-1 2 0 Installing Bearing Inner Race
- 184 -
4 -4 1
13. Assemble the output gear.

(1) O utput gear
Fig. 4-121 Assembling O utp u t Gear
(2) Lock n u t.
T = 35 — 45 kg-m
(253 - 289 ft-lb)
Caution:
o Use new lock nut.
o A fte r tightening the nut, tap the shaft
w ith a plastic hammer, and retighten the
nut to the specified torque.
o The lock nut is to be caulked after the pre
load o f the bearing is measured.
Fig. 4-1 22 Tightening Lock N ut (1)
14. Measure the drive pinion bearing pre-load.

(1) Hold the bearing retainer in a vise.
(2) Measure the starting force o f the out- Fig 4.123 Tightening Lock N u t (2)
put gear.
Starting force:
Transmission vehicle
12.7 ~ 15.6 kg (28.0 ~ 34.4 lb)
Converter vehicle
1 2 .7 - 1 5 .6 kg (28.0 - 34.4 lb)
Note:
W ind a cord around the output gear and
measure the starting force by pulling the
spring scale at a constant speed.
Fig. 4 -1 2 4 Measuring Bearing Pre-Load
- 185 -
4 -4 2
(3) If the starting force is outside the Transmission Vehicle Shims (1 ~ 3-ton)
above range, disassemble the output
gear, adjust the shim thickness, and Shim Thickness
mm (in)
tighten the lock nut to the specified
torque. Afterward, remeasure the 0 .1 0
No. 1 41216-20540-71
starting force. (0.0039)
No. 2 41217-20540-71 0.15

Essential: (0.0059)
If the starting force measured is below the 0.35
specified value, use less shims. Where the No. 3 41218-20540-71
(0.0138)
starting force is above the specified value, use
more shims. No. 4 41219-20540-71 0.45
(0.0177)
No. 5 41213-20540-71 0.03

(0 .0 0 1 2 )
Torque Converter Vehicle Shims (1 ~ 3-ton)
Shim Thickness
mm (in)
No. 1 0.08
41216-10510-71
(0.0032)
No. 2 0.1
41217-10510-71
(0.0039)
No. 3 41218-10510-71 0.3

(0 .0 1 2 )
No. 4 41219-10510-71 0.5

(0 .0 2 0 )
15. Caulk the lock nut.
Caution:
o D uly caulk the lock nut at 2 points,
o Parts " A " should be set in contact as
shown in the figure to the right.
Fig. 4-1 2 5 Caulking Lock N ut (1)
Fig. 4 -1 2 6 Caulking Lock N u t (2)
- 186 -
4 -4 3
DRIVE PINION PROTRUSION ADJUSTMENT

16. Adjust the drive pinion protrusion by
varying the shim thickness.
<Shim Thickness Calculation Method>

(1) Measure the dimension A to 1/100
mm, using a height gauge.
Fig. 4-128 Measuring Dimension A
(2) Read the dimension B punched on

the transmission case.
Note:
If 15 is punched on the case, the dimension is
0 .1 5 mm (0.0059 in).
Fig. 4-1 29 Dimension B Punched Location
(3) Read the dimension C marked on the

drive pinion rear end w ith an electric
pen.
Note:
ooo ± aa js marked. Regard it as + aa only.
Fig. 4-1 30 Dimension C Marked Location
- 187 -
4 -4 4
(4) Calculate the shim thickness by using Shims to be Used fo r Transmission Vehicle
the following equation
1) Transmission vehicle (1 ~ 1.75 Shim Thickness
mm (in)
ton)
t = (A—44) + B/100 + C/100 No. 1 33436-20540-71 0 .1 0
t: Shim thickness (0.0039)
No. 2 33437-20540-71 0.15

2) Transmission vehicle (2 ~ 3 (0.0059)
ton) 0.35
No. 3 33438-20540-71
t = (A -3 4 ) + B/100 + C/100 (0.0138)
t: Shim thickness 0.45
No. 4 33439-20540-71
(0.0177)
3) Converter vehicle (1 ~ 1.75
ton) Shims to be Used fo r Converter Vehicle
t = (A —39) + B/100 + C/100
t: Shim thickness Shim Thickness
mm (in)
4) Converter vehicle (2 ~ 3 ton) 0.1

No. 1 32566-10510-71
t = (A —29) + B/100 + C/100 (0.0039)
t: Shim thickness 0 .2
No. 2 32567-10510-71
(0.0079)
Example: 32568-10510-71 0.3
No. 3
2) 2 ~ 3 ton transmission vehicle (0.0118)
For dimension A:
Value actually measured: 34.14
For dimension B:
Value stamped on the case: 08
For dimension C:
Value marked on the pinion: 00
t = (3 4 .1 4 -3 4) + 8/100 + 0/100
= 0.22
Use either tw o 0.10-mm shims or one
0.1-mm shim and one 0.15-mm shim.
rmm•
Fig. 4-131 Installing Drive Pinion Assembly (1)
17. Install the drive pinion assembly.

(1) Shims
(2) Set bolts
T = 9 ~ 12 kg-m
(65.0 ~ 8 6 .6 ft-lb)
Essential:
A p p ly a locking compound to the set bolt
threads before installing.
Fig. 4-1 32 Installing Drive Pinion Assembly (2)
- 188 -
4 -4 5
18. Install the differential case assembly.

(1) Side bearing outer race.
(2) Differential case assembly.
Caution:
Assembly must be performed in such a way
that the ring gear meshes w ith the drive
pinion.
Fig. 4-1 33 Installing Differential Case Assembly
19. Install the bearing caps.

(1) Adjusting nuts.
Fig. 4-1 34 Installing Adjusting N ut
(2) Bearing caps.
Caution:
Check the match marks when installing.
(3) Tighten the set bolts temporarily.

T = 2 kg-m (14.44 ft-lb)
RING GEAR BACKLASH & SIDE BEARING

PRE-LOAD ADJUSTMENT
20. Tighten the adjusting nuts.
(1) Set a dial gauge perpendicular to the
ring gear back surface. Fig. 4-1 3 5 Tightening Set Bolts Tem porarily
(2) Tighten the left and right adjusting

nuts alternately.
Use SST 09330-30010
(3) Measure the thrust clearance, and
tighten the nuts until the thrust
clearance is reduced to zero.
(4) Tighten the left and right adjusting
nuts by one notch each.
Fig. 4-1 3 6 Tightening Adjusting N ut
- 189 -
4 -4 6
21. Measure the ring gear backlash.

(1) Set a dial gauge perpendicular to the
ring gear teeth surface.
(2) Turn the ring gear to the left and
right, and measure the backlash.
Standard backlash:
0.2 ~ 0.3 mm (0.0079 ~ 0.0118 in)
Fig. 4-137 Measuring Backlash
22. If the backlash measured is outside the

above-mentioned range, adjust the ring
gear backlash in the following way:
(1) If the value measured is larger than
the standard backlash:
A fte r loosening the adjusting nut on
the ring gear teeth side, tighten the
adjusting nut on the ring gear back
side to bring the ring gear closer to
the drive pinion.
(2) If the value measured is smaller than
the standard backlash:
... , .. .. . Fig. 4-1 38 Adjusting Backlash (1)
A fte r loosening the adjusting nut on
the ring gear back side, tighten the
adjusting nut on the ring gear teeth
side to move the ring gear away from
the drive pinion.
Essential:
To adjust the backlash, loosen the adjusting
nut on one side by one notch and tighten the ( B ill!
adjusting nut on the other side by one notch
to gradually shift the differential case, while
watching the dial indicator.
Fig. 4-1 39 Adjusting Backlash (2)
23. Measure the differential side bearing pre

load.
spring scale.
Starting force = Starting force speci
fied in 14 (2) + 2 kg (4.4 lb)
Fig. 4-1 4 0 Measuring Differential Side Bearing Pre-Load
- 190 -
4 -4 7
Caution:
The value indicated by the spring scale also
includes the pinion bearing starting force.
(2 ) If the starting force measured is out

side the abovementioned standard
range, adjust the starting force in the
following way:
1) In case the pre-load is to be
increased:
Tighten the left and right
adjusting nuts by the same
amount. Fig. 4-141 Adjusting Pre-load
2) In case the pre-load is to be
decreased:
Loosen' the left and right
adjusting nuts by the same
amount.
Caution:
A fte r adjusting the pre-load, remeasure the
backlash and check that the backlash
measured is w ith in the standard range.
24. Tighten the bearing cap set bolts to the

specified torque. I
T = 6 ~ 8 kg-m (43.3 ~ 57.6 ft-lb) Fig. 4-1 42 Tightening Set Bolts
CHECKING GEAR TEETH CONTACT

25. Check the teeth contact between the ring
gear and drive pinion.
A pply uniform ly a light coat o f red lead on
both faces o f 7 to 8 gear teeth, and turn
the ring gear forward and backward several
times. Then check the teeth contact be
tween the ring gear and drive pinion by
observing the pattern formed on the gear
teeth. If the ring gear and drive pinion are
not in good contact, carry out the "D rive
Pinion Protrusion Adjustm ent" and "R ing
Fig. 4-1 43 Turning Ring Gear
Gear Backlash and Side Bearing Pre-Load
Adjustm ent" procedures.
(1) Good teeth contact.
The ring gear and drive pinion are in
proper contact w ith each other if the
above-mentioned pattern is roughly
on the centerline o f each tooth
surface and has an appropriate width.
Fig. 4 -1 4 4 Correct Teeth Contact
- 191 -
4 -4 8
(2) Heel contact.

Increase the pinion protrusion by de
creasing the drive pinion adjusting
shim thickness. Then move the ring
gear away from the pinion to adjust
the backlash.
Fig. 4-1 45 Heel Contact
(3) Toe contact.

Decrease the pinion protrusion by
increasing the drive pinion adjusting
gear closer to the pinion to adjust the
backlash.
Fig. 4-1 46 Toe Contact
(4) Flank contact.

Decrease the pinion protrusion by
increasing the drive pinion adjusting
gear away from the pinion to adjust
the backlash.
Fig. 4-1 47 Flank Contact
(5) Face contact.

Increase the pinion protrusion by
decreasing the drive pinion adjusting
gear closer to the pinion to adjust the
backlash.
Fig. 4-1 4 8 Face Contact
- 192 -
4 -4 9
26. Lock the bearing cap set bolts with a wire.

(1) Adjusting nut lock.
Caution:
When aligning the positions o f the adjusting
nut lock, align the nuts by turning them in
the direction for tightening.
(2) Wire lock.
Fig. 4-1 49 Wire Lock
27. Install the ring gear thrust screw and cap.

(1) Thrust screw and cap.
Caution:
Apply a liquid seal to the thrust screw before
installing it.
(2) Thrust screw cap clearance adjust

ment.
Clearance: 0.2 ~ 0.3 mm
Essential:
Fully tighten the thrust screw and loosen it Fig. 4-1 5 0 Thrust Screw Adjustm ent (1)
by 1/8 turn (45 degrees).
(3) Thrust screw lock nut.

T = 10.5 ~ 13 kg-m
(7 5 .8 -9 3 .9 ft-lb)
Fig. 4-151 Thrust Screw Adjustm ent (2)
TRANSMISSION
28. Install the bearings to the transmission
case.
(1) Counter shaft bearing.
Use SST 09608-30011
Fig. 4-1 52 Bearing Installation
- 193 -
4 -5 0
(2) Speed shaft bearing.

Use SST 09608-30011
096Q8S'QQ7IHi
Fig. 4-153 Bearing Installation
29. Install the reverse idler gear.

(1) Reverse idler gear.
(2) Needle bearing.
(3) Thrust washer.
Essential:
A pply a small am ount of grease to the thrust
washer when fixing the washer.
(4) Idler shaft.

(5) Collar.
Caution' 4-1'54 Reverse Idler Gear Installation (1)

Position the collar stop groove toward the
stopper bolt.
(6 ) Stopper plate.
(7) Stopper bolt.
Fig. 4-1 5 5 Reverse Idler Gear Installation (2)
Fig. 4-1 5 6 Reverse Idler Gear Installation (3)
194 -
4 -5 1
30. Install the speed shaft.

(1) Insert the speed shaft into the case
and tap the shaft w ith a copper
hammer.
Fig. 4-157 Installing Speed Shaft
(2) Drive in the bearing by tapping it.

Use SST 09370-20270-71
(3) Snap ring
r0'93;7M 2d270M f
Fig. 4-1 58 Tapping Bearing
31. Install the high & low speed gear assembly.
liO C M )
oO O io W m m
rjsSflf 1E l - j* ,
Fig. 4-159 Installing High & Low Gear Assembly
(1) Install the clutch hub.

a. Hub sleeve
b. Shifting key
c. Key spring
Caution:
o When installing the key spring, be careful
not to set the fittin g parts of the spring in
the same direction,
o Check th at the hub and hub sleeve slide
smoothly.
Fig. 4-1 6 0 Clutch Hub Installation
- 195 -
4 -5 2
(2) Assemble the high and low speed

gear.
a. Bushing
b. Low speed gear
c. Synchronizer ring
d. Clutch hub
Caution:
F it the clutch hub keys into the synchronizer
ring key ways.
e. Synchronizer ring
f. High speed gear Fig. 4-161 Assembling High & Low Speed Gear (1)
g. Bushing
iBIllllllfif Bfci
H H H
Fig. 4-1 62 Assembling High & Low Speed Gear (2)
(3) Install the high & low speed gear

assembly, and f it the counter shaft to
the assembly.
Fig. 4-1 63 Installing High & Low Speed Gear Assembly
32. Assemble the forward & reverse gear :D ifferen tial

assembly.
Install the forward gear (1) on the engine
side.
F it the reverse gear (2) on the differential
Engine
side.
Fig. 4-1 6 4 Assembling Forward & Reverse Gear
- 196 -
4 -5 3
[1) Direction fo r assembling the clutch

hub and sleeve.
Differential
a. Clutch hub
Its narrow splines must be on the
differential side.
b. Sleeve
Its wide splines must be on the
differential side.
Engine
Wide
Fig. 4-1 6 5 Assembling Clutch Hub and Sleeve
(2) Direction fo r assembling the for

ward gear bushing
Fig. 4-1 6 6 Assembling Forward Gear Bushing
(3) Install the forward & reverse gear

assembly.
(4) Stop plate collar (for 1~ 1.75-ton
vehicle), collar (for 2 ~ 3-ton
vehicle)
Fig. 4-167 Installing Forward & Reverse Gear Assembly
33. Drive in the counter shaft by tapping it

w ith a brass hammer.
Fig. 4-1 6 8 Driving in Counter Shaft
- 197 -
4 -5 4
34. Bring the high & low speed, forward &

reverse gear assembly to the engine side,
and install, the stop plate (on 1 ~ 1.75-
ton vehicle).
Caution:
A fte r installing the stop plate and spring,
turn the spring to the position where both
separating parts are not on the same line.
Fig. 4-169 Installing Stop Plate
35. Tap the bearing onto the counter shaft.

(1) Snap ring
(2) Bearing
Use SST 09602-30010
Fig. 4-1 7 0 Tapping Bearing
36. Install the collar, castle nut.

(1) Collar
(2) Castle nut
(3) Cotter pin
(on 2 ~ 3-ton vehicle only)
Fig. 4-171 Installing Collar and Castle Nut

(2 — 3 ton vehicle)
37. Install the counter shaft fro n t bearing

plate.
(1) Front bearing plate
(2) Lock plate
(3) Set bolts
T = 1.5 ~ 2.2 kg-m
( 1 0 .8 - 1 5 .9 ft-lb)
Fig. 4-1 72 Installing Bearing Plate
- 198 -
4 -5 5
38. Install the transmission case rear cover.

( 1) Install the oil seal to the rear cover.
(2) Apply grease to the oil seal.
(3) Gasket
(4) Set bolts
Caution:
Apply liquid seal to the gasket and set bolts.
Fig. 4-1 73 Installing Rear Cover
39. Install the clutch release bearing, tension

spring.
(1) Release bearing
(2) Tension spring
Fig. 4-1 74 Installing Tension Spring
40. Install the shift forks.

( 1 ) S hift fork shafts
(2 ) Gear shift forks
(3) Spring pins
(4) Lock balls, compression springs,
straight screw plugs
Caution:
Make sure that the shift forks and shafts are
positioned in the correct directions.
Fig. 4-1 75 Installing Shift Fork
41. Install the shift levers.

(1) S hift lever
(2 ) Pins
(3) Spring and spring seat
UseSST 09130-10170-71 i09.l 3dflSBffifi»gga
(4) Lever cap and cap cover

(5) Lock nut, knob
Fig. 4-1 7 6 Installing Shift Lever
- 199 -
4 -5 6
SHIFT LEVER OPERATING FORCE

ADJUSTMENT
38. Adjust the shift lever operating force.
(1) Hook on a spring scale to the shift
lever end and pull in the perpen
dicular direction.
S hift lever operating force:
3 ~ 4 kg (6 .6 ~ 8 .8 lb)
(2) Adjust the operating force by varying
the amount the straight screw plug is
screwed.
(3) Cotter pin
Fig. 4-177 Measuring Shift Lever Operating Force
39. Install the transmission case upper cover.

(1) Gasket
(2) Upper cover
Essential:
o Install w ith the gear and shift lever set in
the forward and high speed positions,
respectively.
o Install while making sure that the shift
forks are properly inserted in the clutch
hub sleeve.
Fig. 4-178 Installing Upper Cover
(3) Set bolts

(4) Operate the shift lever to check that
the gears mesh smoothly.
S hift lever side play standard:
3.0 ~ 7.0 mm (0.118 ~ 0.276 in)
Fig. 4-179 Installing Engine to Transmission
40. Install the engine to the transmission.
41. Install the main drive shaft.

Use SST 09210-20170-71
Fig. 4-1 8 0 Installing Main Drive Shaft
- 200 -
4 -5 7
INSTALLATION
Perform installation in the reverse order o f the removal procedure.
Caution:
o Set the oil pump in a location where it is easy to install it during the installation of the transmission with
engine.
o Connect the battery (—) terminal only after checking that the electrical wiring is correctly installed,
o Install the main drive shaft as follows:
1. Adjust the clearance between the main

drive shaft end and main drive shaft cap
to 0.5 ~ 2 mm (0.020 ~ 0.079 in.) by
varying the number o f gaskets used.
Essential:
Measure the distance between the cap instal
lation surface and the shaft end w ith either a
convex rule or a vernier caliper.
Fig. 4-181 Installing Cap
2. A pply grease liberally on the main drive

shaft cap end.
Use chassis grease.
o Differential, transmission oil capacity
Oil used: Hypoid gear oil SAE90
Clutch vehicle 11C (2.9 US gal)

Converter vehicle 5fi (1.32 US gal)
Clutch vehicle 12C (3.2 US gal)
2 ~ 3-ton vehicle
Converter vehicle 5£ (1.32 US gal)
- 201 -
FRONT AXLE
Page
GENERAL ..................................................................................................... 5 - 2
COMPONENT PARTS (1.0,1.35 ton) 5 -5
COMPONENT PARTS (1.5,1.75 ton) 5- 6
COMPONENT PARTS (2 .0 ,2 .2 5 ,2 .5 ton) 5- 7
COMPONENT PARTS (2.75,3.0 ton) 5- 8
COMPONENT PARTS (2.0, 2.25,2.5 ton) 5- 9
SPECIFICATIONS ....................................................... 5 -1 0
REMOVAL 5 -1 0
AS S EM B LY .................................................................................................... 5 -1 3
INSTALLATION ....................................................................... 5 -1 4
FRONT AXLE HOUSING,

DIFFERENTIAL HOUSING REMOVAL 5 -1 6
INSPECTION, INSTALLATION ....... .................................................... 5 -1 7
- 203 -
5 -2
general
Fig. 5-1 Front Axle Sectional V iew (1-ton, 1.35-ton)
Fig. 5-2 Front A xle Sectional V iew (1 .5-ton, 1 .75-ton)
- 204 -
5 -3
Fig. 5-3 Front Axle Sectional V iew (2-ton, 2.25-ton , 2.5-ton)
Fig. 5-4 Front A xle Sectional V iew (2.75-ton , 3-ton)
- 205 -
5 -4
Fig. 5-5 Front A xle Sectional V iew [Dual] (1-ton, 1.35-ton, 1.5-ton, 1,75-ton)
Fig. 5-6 F ro nt A xle Sectional V iew [D u al] (2-to n , 2.2 5-to n , 2,5-ton)
- 206 -
5 -5
COMPONENT PARTS (1-Ton, 1.35-Ton)
T = 16 ~ 2 2 (11 5.5 ~ 158.8)
1. " 0 " ring 8. Bearing

2. Front axle housing 9. Lock nut
3. Front axle bracket 10. Bearing lock nut
4. Brake drum 11. Oil seal
5. Oil seal 12. Gasket
6. Bearing 13. Front axle shaft
7. Front axle hub
Fig. 5-7 Front A xle Com ponent Ports (1-T o n, 1.35-Ton)
- 207 -
5 -6
COMPONENT PARTS {1.5-Ton, 1.75-Ton)
1. " O " ring 8. Bearing

7. Front axle hub 14. Dual wheel stop bolt
(Dual wheel only)
Fig. 5-8 F ro nt A xle Com ponent Parts (1.5-T o n , 1.75-Ton)
- 208 -
5 -7
COMPONENT PARTS (2-Ton, 2.25-Ton, 2.5-Ton)

3. Front axle bracket 10 . Bearing lock nut
7. Front axle hub
Fig. 5-9 Front Axle Com ponent Parts (2-T o n, 2.2 5-T o n , 2.5-T o n)
- 209 -
5 -8
COMPONENTSPARTS (2.75-Ton, 3-Ton)
T = 16 ~ 2 2 (11 5.5 — 158.8)
(86.6 ~ 101.1 )T 4
T = 12~14
(86.6 ~ 101 .1 )
T = 6 ~ 8
(43 .3 ~ 57.6)
1. “0" ring 8. F ro nt axle shaft

2. Front axle housing 9. Bearing
3. Front axle bracket . 10. Lock nut
4. Brake drum 11. Bearing lock nut
5. Oil seal 12. Oil seal
6. Bearing 13. Gasket
7. F ro nt axle hub
Fig. 5-10 F ro nt A xle Component Part (2.75 -T o n , 3-Ton)
- 210 -
5 -9
COMPONENT PARTS (2-Ton, 2.25-Ton, 2.5-Ton Dual Wheel)
T = 16 ~ 22

7. Front axle hub
Fig. 5-11 Front A xle Component Parts (2-Ton, 2.2 5-T o n , 2.5-Ton)
- 211 -
5 -1 0
SPECIFICATIONS
-------- Models 1 .0 ~ 3.0 ton vehicles
Item -------
F ro n t axle shaft system Full floating
Front axle suspension Rigidly attached to frame
Front axle shaft diameter 40 mm (1.575 in.)
No. o f axle shaft spline teeth 31
FRONT AXLE HUB & SHAFT RE

MOVAL
1. Loosen the fro n t wheel hub nuts.

2. Jack up the frame.
(1) Block the rear wheels.
(2) Jack up the frame.
(3) Support w ith stands.
3. Remove the fro n t wheels.
(1) Hub nuts
(2) Front wheel
4. Remove the fro n t axle shaft set nuts.
(A ll vehicles except 1.5 and 1.75 ton Fig. 5-12 F ro nt Wheel Removal
types.)
5. Remove the set screw dowels. (All vehicles
except 1.5 and 1.75 ton types.)
(1) Strike the center o f axle shaft flange
w ith a hammer.
(2) Spring washers.
(3) Set screw dowels.
Fig. 5-13 Removing Dowels
6. Pull o ut the fro n t axle shaft.
Caution:
° When removing the axle shaft, use care not
to damage the oil seal.
o If the axle on one side only is to be re
moved, using about a 3 0 cm (11 .8 in.)
block under the frame on the side to be
removed w ill make it unnecessary to drain
o u t the gear oil.
Fig. 5-14 Removing A xle Shaft
- 212 -
7. Remove the bearing lock nut stopper bolts.
Fig. 5-15 Removing Bearing Lock N ut Stopper Bolt
8. Remove the bearing lock nut.

Use SST 09509-55020
Fig. 5-16 Removing Bearing Lock N ut
9. Use screwdrivers and remove bearing ring.
Fig. 5-17 Removing Bearing Ring
10. Remove the fro n t axle hub and brake drum

assy.
Use SST 09310-10160-71
Use SST 09950-20012 (1.5,1.75 ton
vehicles only)
Fig. 5-18 Removing F ro nt A xle Hub
213 -
5 -1 2
DISASSEMBLY i Vr::::
l
Note:
Inspect the various parts and disassemble
if any defect is found in the bearings,
Si
fro n t axle hub, or brake drum .
1. Drive out the bearing outer race with

brass rod.
(1) Inner bearing outer race and oil
seal.
(2) Outer bearing outer race.
Fig. 5-19 Removing Bearing Outer Race
Separate the fro n t axle hub from brake

drum.
(1 ) Loosen the nut staked parts with
round bar and hammer.
(2 ) Remove the nuts.
(3) Drive out the hub bolts with press
or brass rod.
(4) Separate the fro n t axle hub from
brake drum.
Fig. 5-20 Separating Hub from Brake Drum
INSPECTION
1. Front axle shaft

(1) Cracks, wear, damage in splines.
(2) Bending.
2. Front axle hub
(1) Damage in hub bolts.
(2) Damage in hub b olt lock slots.
(3) Damage or loosening in axle shaft
set studs.
(4) Cracks or damge in fro n t axle hub.
3. Outer and inner bearings
Fig. 5-21 A xle Shaft Inspection
(1) Damage, spalling, rotating state of
bearings.
4. Oil seal
(1) Damage, deformation, deterioration
in lip.
5. Bearing lock nuts and bearing ring.
H H B H I Wmm i
Fig. 5-22 Hub and Bearing Inspection
214 -
5 -1 3
ASSEMBLY
1. Assemble the brake drum.

(1) Drive the hub bolts into lock
grooves.
(2) Fit together the hub and brake
drum.
(3) Nuts.
T = 7~9 kg-m (50.5-65.0 ft-lb)
[ 1—1.75 ton vehicles]
T = 15—19 kg-m (108.3-137.2 ft-lb)
[2~2.5 ton vehicles]
Fig. 5-23 Assembling Brake Drum
T = 17—21 kg-m (122.7-151.6 ft-lb)
[2.75, 3 ton vehicles]
(4) Stake the nuts.
Caution:
o There should be no clearance between
the hub and drum joining surface,
o Stake the nuts in cross form .
Fig. 5-24 Staking
2. Install the bearing outer races.

( 1) Inner bearing outer race.
(2) Outer bearing outer race.
Use SST 09130-30200-71
Fig. 5-25 Installing Bearing
3. Install the oil seal.

(1) Inner bearing.
(2) Oil seal.
Caution:
A pply grease to inner bearing rollers
and seal lip.
Fig. 5-26 Installing Oil Seal
215 -
1
5 -1 4
INSTALLATION
1. Pack grease into fro n t axle hub.
2. Install the fro n t axle hub w/brake drum

to the fro n t axle.
Caution:
Make sure that brake shoes are properly
positioned.
Have the adjusting screw returned about 5
to 10 notches.
Fig. 5-27 Installing A xle Hub

3. Drive in the fro n t wheel outer bearing.
Use SST 09370-10410-71
Caution:
A p p ly grease to the outer bearing rollers.
4. Install the bearing ring.
Fig. 5-28 Installing Bearing Ring
5. Tighten the bearing lock nut.

Use SST 09509-55020
(1) Bearing adjusting nuts.
(2) Tighten fu lly and then return 1/12
to 1 /6 turn.
Fig. 5-29 Tightening Bearing Lockout
(3) Mesure the preload.

Preload 2.6~7.4 kg (5.73~16.32 lb)
Essential:
Measure the preload by utilizing the hub
b olt.
Fig. 5-30 Measuring Preload
216 -
6. Install the bearing lock nut stopper bolts.
(1) Apply locking compound.
(2) Tighten the stopper bolts.
T = 1.5~2.2 kg-m (10.8-15.9 ft-lb)
Caution:
T o prevent the bearing lock nut stopper
bolts from loosening, be sure to apply
locking compound and tighten to the spec
ified torque.
Fig. 5-31 Tightening Stopper Bolts
7. Install the fro n t axle shaft.

(1) Gasket
(3) Set screw dowels.
(4) Spring washers
(5) Set nuts.
T = 3 -4 .5 kg-m (21.7-32.5 ft-lb)
[1 ,1 .3 5 ton vehicles]
T = 4—5.5 kg-m (28.9—39.7 ft-lb)
[2—2.5 ton vehicles]
T = 6 —8 kg-m (43.3—57.6 ft-lb)
Fig. 5-32 Installing A xle Shaft
Caution:
When installing the axle shaft, use care not
to injure the oil seal.
8. Install the fro n t wheel.

(1) Tighten the hub nuts finger tight.
(2) Remove the stands.
(3) Tighten the hub nuts to the speci
fied torque.
T = 1 1 -1 5 kg-m (79.4-108.3 ft-lb)
[1 ,1 .3 5 ton vehicles]
T = 1 8 -2 2 kg-m (130-158.8 ft-lb)
[ 1 .5 -2 .5 ton vehicles] Fjg 5 3 3 |nsta|Mng Front Wheej
T = 3 0 -3 3 kg-m (211.6-238.3 ft-lb)
Upon completing the job, perform the following inspection and adjustment.
(1) Differential oil quantity
(2 ) Foot brake effectiveness. If the auto adjuster had been returned, advance and reverse the
vehicle more than 10 times, depressing the brake pedal each time.
(3) Parking brake effectiveness.
(4) Presence o f abnormal noise or conditon.
- 217 -
5 -1 6
FRONT AXLE HOUSING, DIFFEREN

TIAL HOUSING REMOVAL
1. Remove the mast.
Essential:
° For mast removal, refer to procedures
under mast removal section, and endeavor
toward safe operation.
o Have the steering wheel turned fu lly to
right.
Fig. 5-34 Removing Mast
2. Loosen the fro n t wheel hub nuts.

3. Jack up the differential housing, and sup
po rt the side frame underside on stands.
4. Remove the fro n t wheels.
Fig. 5-35 Removing Front Wheels
5. Drain out the differential oil.

Clutch vehicles 12 liters (3.2 US gal)
(Together w ith transmission)
Converter vehicles 5 liters (1.32 US gal)
6. Pull out the axle shafts.
Fig. 5-36 Removing A xle Shaft
7. Remove the set bolts attaching the d if

ferential housing to the transmission
case.
8. Screw on hub nuts to the left and right

stud bolts and hook on wire rope.
Fig. 5-37 Wire Rope Hooked On
- 218 -
5 -1 7
9. Remove the set bolts attaching the fro n t

axle bracket to the frame.
( 1 ) 2 bolts at middle o f each side.
(2 ) 2 reamer bolts at upper and lower o f
each side.
Use SST 09310-22000-71
Fig. 5-38 Removing Reamer Bolt
10. Disconnect the parking brake cable.
11. Take out the fro n t axle assy from the

vehicle.
Fig. 5-39 Removing F ro nt A xle Assy
12. Separate the differential housing from the

fro n t axle housing.
INSPECTION
1. Differential housing and fro n t axle hous

ing.
Inspect fo r cracks visually or by perform
ing color check.
INSTALLATION
Perform the removal in reverse order. Fig. 5-40 Removing Differential Housing
Caution:
Check the mast to see that its forward tilt angle is 6 ° and backward tilt angle 12°.
Check the parking brake to see that there is from 4 to 6 notches pull reserve, and that the braking effective
ness is the same on left and right sides.
Check all connections to see th at there is no oil leakage.
Check the differential oil q uantity.
Check the differential housing to see th at no unusual noise is produced.
- 219 -
■ - 220 -
REAR AXLE
Page
GENERAL ..................................................................................................... 6- 2
SPECIFICATIONS ........................................................................................ 6 - 3
SERVICE STANDARDS ............................................................................. 6 - 4
COMPONENT PARTS ................................................................................. 6 - 5
REAR AXLE A S S Y .................................................... ................................ 6 - 7
REAR AXLE HUB .................................................................................... 6 -2 0
STEERING KNUCKLE & KING PIN .................................................... 6 -2 4
REAR WHEEL ALIGNMENT .................................................................. 6 -2 8
- 221 -
6 -2
general
Fig. 6-1 Rear Axle Sectional View (1 .0 ~ 1.75 Ton Vehicles)
Fig. 6-2 Rear A xle Sectional V iew (2 .0 ~ 3 .0 Ton Vehicles)
- 222 -
6 -3
SPECIFICATIONS (1.0 ~ 1.75 Ton Vehicles)
—-— _____ Models 1.75 ton

1 .0 ton 1.35 ton 1.5 ton
Item ‘
Rear axle type Eliot type
Rear axle suspension Center supported swing type
Toe in 0 mm
Camber 1°
Wheel
alignment 0°
Caster
King pin 6°
Inclination
Inner mm (in.) 160 (6.5) 160 (6.5) 150 (6 ) 150 (6 )

Minimum
turning radius 1980 (78) 2010 (79)
Outer mm (in.) 1900 (75) 1940 (76)
Tire size 5.00-8-8PR(l)
Rim size 3.00D X 8 DT
Tire inflation kg/cm 2 (psi) 7.0 (99.5)
~~~~~ — __________Models
2 .0 ton 2.25 ton 2.5 ton 2.75 ton 3.0 ton
Item f~ ~----------- _____
Rear axle type E liot type
Rear axle suspension Center supported swing type
Toe in 0 mm
Wheel Camber 1°
Alignment Caster 0°
King pin
inclination 6°
Minimum Inner mm (in.) 190(7.5) 190(7.5) 190 (7.5) 340 (13.5) 350 (14)
turning radius Outer mm (in.) 2165(85) 2190(86) 2220(87) 2410 (95) 2440 (96)
Tire size 6.00-9-1 OPR (I) 6.50-10-1 OPR (1)
Rim size 4.00E X 9DT 5.OOF X 10DT
Tire inflation kg/cm 2 (psi) 7.0 (99.5)
- 223 -
6 -4
SERVICE STANDARDS (1.0 ~ 1.75 Ton Vehicles)
Diameter standard mm (in.) 28.0 ( 1 . 1 0 )

King pin
Wear lim it mm (in.) 27.8 (1.09)
Diameter standard mm (in.) 50.0 (1.97)

Support pin

Bell crank pin
Bushing wear lim it mm (in.) 52.0 (2.05)
Steering knuckle starting foce kg (lb) 3 ~ 5 (6 .6 ~ 11.0)
Rear axle hub starting force kg (lb) 1.5 ~ 4.0 (3.3 ~ 8 .8 )
Rear axle front-rear play standard mm (in.) 0.02 ~ 0.40 (0.0008 ~ 0.016)
Hub nut T= kg-m (ft-lb) 9 ~ 12 (65.0 ~ 8 6 .6 )
Fitting bolt T= kg-m(ft-lb) 3 ~ 4.5 (21.7 ~ 32.5)
SERVICE STANDARDS (2.0 ~ 3.0 Ton Vehicles)

King pin
Diameter standard mm (in.) 50.0 (1.97)

Support pin
Wear lim it mm (in.) 48.5(1.91)

Bell crank pin
Bushing wear lim it mm (in.) 52.0 (2.05)
Steering knuckle starting force kg (lb) 3 ~ 5 (6 .6 ~ 11.0)
Rear axle hub starting force kg (lb) 1.5 ~ 4.5 (3.3 ~ 9.9)
Rear axle front-rear play standard mm (in.) 0.02 ~ 0.40 (0.0008 ~ 0.016)
Hub nut T = kg-m (ft-lb) 12 ~ 15 (8 6 .6 ~ 108.3)
Fitting bolt T= kg-m (ft-lb) 5 ~ 8 (36.1 ~ 57.6)
- 224 -
6 -5
COMPONENT PARTS
1. Bushing 10. King pin lock pin

2. Shim 11. Oil seal
3. Rear axle beam 12. Bearing
4. Bearing 13. Oil seal
5. Shim 14. Hub bolt
6. Needle bearing 15. Rear axle hub
7. Oil seal 16. Bearing
8. King pin 17. Claw washer
9. Knuckle 18. H u b cap
Fig. 6-3 Rear Axle Component Parts (1 .0 ~ 1.7 5 Ton Vehicles)
- 225 -
6 -6
COMPONENT PARTS
1. Rear axle beam 14. Oil seal

2. Stopper plate 15. Needle bearing
3. Bushing 16. Shim
4. Shim 17. Bearing
5. Bearing pin 18. King pin lock pin
6. T ie rod end No. 2 19. Oil seal
7. Shim 20. Oil seal
8. Oil seal 21. Bearing
9. Needle bearing 22. Hub bolt
10. Beil crank 2 3. Rear axle hub
11. T ie rod 24. Bearing
12. T ie rod end No. 1 25. Claw washer
13. King pin 26. Hub cap
Fig. 6-4 Rear A xle Component Parts (2 .0 ~ 3 . 0 Ton Vehicles)
- 226 -
6 -7
R EA R A X L E ASSY
REMOVAL
Caution:
o Make sure to use blocks or other stands to support the frame underside on the left and right sides,
o Make sure to apply the parking brakes and to block the wheels.
o T o enable doing the job easier, the counterweight underside should be about 4 0 0 to 500 mm (16 to 20 in.)
above the ground
1. Remove the rear wheel.

(1) Loosen the hub nuts.
(2) Jack up the vehicle.
(3) Hub nuts
(4) Rear wheel
Caution:
Support the frame underside, making sure
that they do not slip o ff.
Fig. 6-5 Removing Rear Wheel
2. Disconnect the power cylinder rod from

the bell crank.
(1) Cotter pin
(2) Castle nut
(3) Power cylinder rod
SST used 09610-20011
Fig. 6-6 Disconnecting Rod
3. Punch matching marks.

(1) Front bracket
(2) Rear bracket
Caution:
To prevent intermixing the fro n t and rear,
use different punch marks.
Fig. 6-7 Punching Match Marks
- 227 -
6 -8
4. Measure the rear axle play in front-rear

direction.
(1) Push the rear axle beam fu lly fo r
ward.
(2) Measure the rear axle play on the rear
side.
Front-rear play standard:
0.02 ~ 0.40 mm
(0.0008~0.016 in.)
Fig. 6-8 Measuring Front-Rear Play
5. Remove the rear axle brackets.

(1) Set the jack under rear axle center.
(2) Bracket bolts
(3) Rear axle brackets
Fig. 6-9 Removing Bracket
6. Remove the rear axle assy.

(1) Carefully lower the jack.
(2) Draw out in vehicle left-right direc
tion.
Fig. 6-10 Removing Rear A xle Assy
- 228 -
6 -9
DISASSEMBLY
Caution:
The procedures described here are for the
case of the rear axle assy removed from the
vehicle. However, the rear axle hub, steering
knuckle, and allied parts can be disassembled,
corrected, or adjusted while still installed on
the vehicle. For their removal and installa
tio n , refer to the applicable paragraphs.
1. Remove the grease cap.

(1) Mount the rear axle on work stand.
Fig. 6-11 Removing Grease Cap
(2) Use a screwdriver and take o ff the
grease cap.
2. Remove the rear axle hub.
( 1 ) cotter pin
(2) Castle nut
(3) Claw washer
(4) Rear axle hub
Use SST 09950-20012
Fig. 6-12 Removing Rear Axle Hub
3. Remove the inner bearing

Use SST 09950-20012
4. Remove the outer race from the hub.
Caution:
Remove only when the bearing is found w orn,
noisy, or otherwise defective.
5. Remove the oil retainer.
6. Disconnect the tie rod end.

(1) Cotter pin
(2) Castle nut
(3) Tie Rod End
Use SST 09610-20011
Caution:
Disconnect the left side tie rod when remov
ing the knuckel. (2.0 ~ 3 .0 ton vehicles)
j9 6 1 0 - 2 0 f f r f
Fig. 6-14 Disconnecting Tie Rod End
- 229 -
6 -1 0
7. Remove the king pin lock pin.

(1) Set nut
(2) Screw on a service nut and drive out
w ith suitable round bar.
Essential:
T o protect the lock pin threads against dam
ages, always screw on a service nut (one that
can be scrapped).
Fig. 6-15 Removing Lock Pin
8. Remove the king pin.

(1) Grease fittin g
(2) King pin
Fig. 6-16 Removing King Pin
9. Remove the steering knuckle.

(1) Thrust bearing
(2) Shims
(3) Steering knuckle
Caution:
Be careful not to lose the shims, and keep a
record o f the number used and their th ic k
nesses.
Fig. 6-17 Removing Steering Knuckle
10. Remove the oil seals.
Caution:
Remove only when the needle bearings or
oil seals are found damaged or worn.
Fig. 6-18 Removing Oil Seal
- 230 -
6 -1 1

UseSST 09620-30010
Caution:
Remove the needle bearings only when found
worn or damaged.
12. Remove the support pin bushings.
13. Remove the bearing pin.

(1) Stopper plate
(2) Bearing pin
Fig. 6-20 Removing Bearing Pin
14. Remove the bearing together with tie rod.
Caution:
When removing the bearing, use care not to
lose the adjusting shim.
15. Remove the tie rod from the bearing.

(1) Cotter pin
(2) Castle nut
(3) Tie rod
Use SST 09610-20011 Fig. 6-21 Removing Bearing
16. Remove the oil seals and neelde bearings

from the bearing.
(1) Oil seals
(2) Needle bearings
Caution:
Remove the oil seals and needle bearings
only when found damaged or worn.
Fig. 6-22 Removing Tie Rod
231 -
6 -1 2
INSPECTION
Caution:
° Clean or wash all disassembled parts. Inspect the following parts and replace any found defective,
o Inspect the bearings for defective rotation, noise, looseness, and damages visually and by inserting them on
a shaft.
1. Steering knuckle
(1) Cracks or damages at spindle root
and threads.
Caution:
It is desirable that inspection be made with
flaw detector or flaw detecting liquid pene
tra n t.
Fig. 6-23 Steering Knuckle Inspection
2. King Pin.
(1) Wear or damage in king pin.
Diameter standard: 28.0 mm
( 1 .1 0 in.)
Wear lim it: 27.8 mm
(1.09 in.)
(2) Bending in king pin.
Caution:
When worn over the lim it, replace together
w ith knuckle bearings.
Fig. 6 -2 4 King Pin Inspection
3. Needle bearings.
( 1 ) Wear or damage in king pin needle
bearings
(2 ) Damage in king pin oil seals
(3) Wear or damage in bearing pin needle
bearings
(4) Damage in bearing pin oil seals
Fig. 6 -2 5 King Pin Needle Bearing Inspection
- 232 -
6 -1 3
4. Support pin bushings.

(1) Wear in bushing bore
Wear lim it: 52.0 mm (2.05 in.)
Essential:
Always replace when the bushing oil reservoir
is worn out.
Fig. 6-26 Bushing Inspection
Bell crank
(1) Cracks or damages in bell crank.
(2) Wear, bending, or cracks in knob.
Fig. 6-27 Bell Crank Inspection
6 Bell crank pin.

(1) Wear or damage in bell crank pin.
( 1 .1 0 in.)
(1.09 in.)
(2) Bending in bell crank pin.
Fig. 6-28 Bell Crank Pin Inspection
7. Rear axle hub.

(1) Damage and cracks in rear axle
hub.
(2) Damage, breakage, or bending in rear
axle hub bolts.
(3) Damage in wheel bearing race sur
faces.
(4) Defective rotation, noise, or wear
in wheel bearings, and wear or
damage in rollers and holders.
(5) Damage in steering knuckle oil
retainer.
Fig. 6 -2 9 Rear Axle Hub Inspection
- 233 -
8. Rear axle beam.
(1) Bending or cracks in rear axle beam.
(2) Measure the king pin inclination.
King pin inclination standard 6 °.
(3) Wear in support pins.
(1.97 in.)
(1.91 in.)
Fig. 6 -3 0 Rear A xle Beam Inspection
9. Tie rods.
■'* . f*v ■v
(1) Bending in tie rods. mam,
(2) Damage in tie rod end threads.
Hi
Fig. 6-31 T ie Rod Inspection
ASSEMBLY
Caution:
o A fte r inspection, clean the parts once
more before assembly. Be sure to apply
grease on the bearings and king pin needle
bearings.
o Always replace rubber parts like oil seals
when disassembled.
1. Drive the needle bearings into the rear

axle beam.
(1) Drive the needle bearings into king
Fig. 6 -3 2 Driving in Needle Bearings
pin holes until flush w ith the inner
surfaces.
Use SST 09620-30010
2. Drive the needle bearings into the bearing.

(1) Drive the needle bearing into the
bearing pin hole.
Use SST 09620-30010
Fig. 6 -3 3 Driving in Needle Bearing
- 234 -
6 -1 5
Drive in the oil seals.

(1) Drive the oil seals in the rear axle
beam king pin holes to outer side o f
needle bearings.
(2) Drive the oil seals into the bearing
pin hole over the needle bearings.
Use SST 09620-30010
Caution:
Install the oil seals with the lip sides facing
outward.
Install the tie rods to the bell crank. Fig. 6-34 Driving in Oil Seals
(1) Tie rod
(2) Castle nut
T = 7~8 kg-m (50.5~57.6 ft-lb)
(3) Cotter pin
Install the bearing w ith tie rod to the

rear axle beam.
(1) Set the bearing with tie rod into the
rear axle beam.
(2) Make the shim adjustment.
1) Insert 1.0 mm (0.039 in.) into
bearing lower side.
2) Adjust the bearing upper side with Fig. 6-35 Installing T ie Rod
shims.
Clearance standard:
0.02~0.55 mm
(0.0008~0.0217 in.)
Sim sizes:
0.5 mm (0.00197 in.)
1.0 mm (0.039 in)
3) Check the bearing to see that it turns
lightly.
Fig. 6-36 Installing Bearing w ith Tie Rod
J |TT| | "j Clearanct standard
| I
0.1 mm
(0.0039 in.)
Fig. 6-37 Shim Adjustment Fig. 6 -3 8 Shim Adjustment
- 235 -
6 -1 6
(3) Insert the bearing pin and install the

stopper plate.
T = 1.9—3.1 kg-m (13.7~22.4 ft-lb)
Fig. 6-39 Inserting Bearing Pin
Make steering knucle shim adjustment.

(1) Install the steering knuckle and
thrust bearing to rear axle beam.
(2) Adjust the steering knuckle rotation
w ith shim.
Make the adjustment on thrust
bearing upper side.
Clearance standard:
0 .0 2 ~ 0 .1 2 mm
(0.0008~0.0047 in)
Shim sizes:
0.1, 0.2, 0 .5 ,1 .0 mm
Fig. 6-40 Steering Knuckle Shim Adjustment
(0.0039, 0.0079,0.0197,0.039in)
Adjust the steering knuckle preload.

(1) A fte r shim adjustment, hook a
spring scale to the end o f steering
knuckle spindle, and measure the
preload.
Steering knuckle starting force:
3 ~ 5 kg (6 .6 ~ 1 1.0 lb)
(2) If specified starting force cannot be
obtained, readjust the shims and
remeasure.
8. Install the steering knucle.

(1) A fte r adjusting preload, align the
king pin to lock pin hole position.
(2) Drive in the lock pin.
(3) Lock nut.
T = 1.9~3.1 kg-m (13.7~22.4 ft-lb)
Fig. 6-42 Installing Steering Knuckle
- 236 -
6 -1 7
9. Install the inner bearing.

(1) Oil retainer
UseSST 09370-10410-71
(2) Inner bearing
Use SST 09370-20270-71
Caution:
Be careful not to cock the bearing when
driving it in since this will damage the knuckle
spindle.
Fig. 6-43 Installing Inner Bearing
10. Install the bearing outer race to the rear

axle hub.
11. Install the rear axle hub.

(1) Pack grease into the hub.
(2) Apply grease to inner and outer
bearings.
(3) Install the rear axle hub and drive
in the outer bearing.
Use SST 09370-20270-71
(4) Claw washer
Fig. 6-44 Installing Bearing Outer Race
(5) Castle nut
12. Measure the rear axle hub preload.

(1) Hook a spring scale to the hub bolt
and measure the force required to
start turning the rear axle hub.
Rear axle hub starting force:
1 .5 -4 .0 kg (3.3—8 .8 Ib) Fig. 6 -4 5 Installing Rear Axle Hub
(1.0 — 1.75 ton vehicles)
1 .5 -4 .5 kg (3.3—9.9 Ib)
(2.0 — 3.0 ton vehicles)
Essential:
For preload adjustment, fu lly tighten the
castle nut and then loosen it about 1 /4
turn. Lightly tap the hub so as to make it
turn easier and retighten the nut, after which
measure the starting force.
(2) Cotter pin
Fig. 6 -4 6 Measuring Rear Axle Hub Preload
- 237 -
6 -1 8
13. I nstal I the grease cap.

(1) Pack grease into the grease cap
(2 ) Grease cap
Fig. 6-47 Installing Grease Cap
14. Connect the tie rod to the steering

knuckle.
Caution:
Connect the left side tie rod at the tim e the
steering knuckle is installed. (2.0 ~ 3.0
ton vehicles).
(1) Tie rod

(2) Castle nut
T = 7 -8 kg-m (50 .5 -5 7 .6 ft-lb)
(3) Cotter pin
Fig. 6 -4 8 Connecting T ie Rod
15. Measure the toe-in.
(1) Align the rear axle beam and bell
crank holes, insert a suitable round
bar and bring to straight ahead
position.
(2) Install tires on the rear axle hubs
and measure the center distance
between the treads (fro n t and
rear).
Toe-in: Omm
Fig. 6 -4 9 Measuring Toe-in
(3) If fro n t and rear side distances

diffe r, make adjustment with tie
rods.
Essential:
In adjusting w ith tie rods, adjust both the
le ft and right sides to the same amounts.
(4) Upon completing adjustment, re

move the tires.
Fig. 6 -5 0 Adjusting Toe-in
- 238 -
6 -1 9
INSTALLATION
1. Install the rear axle assy to the vehicle.

(1) Set the rear axle assy on a jack.
(2) Install shims on the center pin (to
thickness measured at removal).
(3) Apply grease on the bushings, and
insert the bushings on the pins.
(4) Position the rear axle assy under the
frame and raise the jack.
(5) Install the rear axle brackets in
accordance with the match marks.
Fig. 6-51 Installing Rear Axle
2. Measure the rear axle play.

Front-rear play standard:
0.02~0.40 mm (0.0008~0.016 in.)
Shim sizes:
0.3, 0.5, 1.2, 2.3,3.2 mm
(0.0118, 0.0197, 0.047, 0.091, 0.126 in.)
Caution:
o Make the shim adjustments on the rear
side.
o Use the thickest possible shims when
making the adjustment.
o If the play exceeds the standard, remove
the rear axle from the vehicle and read Fig. 6-52 Measuring Rear A xle Play
just the shims.
3. Tighten the rear axle brackets.

(1) Rear axle bracket
(2) Set bolts
4. Connect the power cylinder rod to the bell
crank.
5. Install the rear wheels, remove the stands,
tighten the hub nuts to the specified
torque.
T = 9 ~ 1 2 kg-m (65.0~86.6 ft-lb)
(1.0~1.75 ton vehicles)
T = 12—15 kg-m (86.6—108.3 ft-lb) Fig. 6-53 Installing Rear Wheel
T = 12 ~ 1 5 kg-m (8 6 .6 ~ 108.3 ft-lb)
(2.75, 3.0 ton vehicles)
- 239 -
6 -2 0
Caution:
The following covers the procedures for removing the necessary parts from the vehicle and performing the
disassembly and adjustment, w ith o ut removing the rear axle assy from the vehicle.
REAR A X LE HUB
REMOVAL AND DISASSEMBLY
1. Remove the rear wheel.

(1) Loosen the hub nuts
(2) Jack up
(3) Hub nuts
(4) Rear wheel
Caution:
Set supports under the fram e, and make sure
they do not slip o ff.
Fig. 6-54 Removing Rear Wheel
2. Remove the grease cap.

(1) Pry o ff the grease cap w ith screw
driver.
Fig. 6 -5 5 Removing Grease Cap
3. Remove the rear axle hub.

( 1 ) Cotter pin
(2 ) Castle nut
(3) Claw washer
(4) Rear axle hub
Use SST 09950-20012
Fig. 6 -5 6 Removing Rear A xle Hub
- 240 -
6 -2 1
4. Remove the inner bearing

Use SST 09950-20012
Caution:
Remove the bearing only when found to be
worn, noisy, or otherwise defective.
Fig. 6-57 Removing Inner Bearing
5. Remove the oil retainer.
Fig. 6-58 Removing Oil Retainer
6. Remove the bearing outer race from the

rear axle hub.
Caution:
Remove only when found defective.
Fig. 6-59 Removing Outer Race
INSPECTION M B
Rear axle hub.

(1) Damage or cracks in rear axle hub.
(2) Damage, breakage, or bending in rear
axle hub bolts.
(3) Damage in wheel bearing race sur
faces.
(4) Defective rotation, noise, or wear
in wheel bearings, and damage in
rollers and holders.
(5) Damage in steering knuckle oil
retainer. Fig. 6 -6 0 Rear Axle Hub Inspection
- 241 -
6 -2 2
ASSEMBLY & ADJUSTMENT
1. Install the inner bearing.

(1) Oil retainer
Use SST 09370-10410-71
Fig. 6-61 Installing Oil Retainer
(2) Inner bearing

Use SST 09370-20270-71
Caution:
Be careful not to cock the bearing when
driving it in since this will damage the knuckle
spindle.
09370 20270 71
Fig. 6-62 Installing Inner Bearing
2. Install the bearing outer race to rear axle

hub.
Fig. 6-63 Installing Bearing Outer Race
3. Install the rear axle hub.

(1) Pack grease into the hub.
(2) A pply grease to the inner and outer
bearings.
(3) Install the rear axle hub, and drive
in the outer bearing.
Use SST 09370-20270-71
(4) Claw washer.
(5) Castle nut.
Fig. 6 -6 4 Installing Rear Axle Hub
- 242 -
6 -2 3
4. Measure the rear axle hub preload.

(1) Hook a spring scale to hub bolt and
measure the force required to start
turning the rear axle hub.
Rear axle hub starting force:
1.5~4.0 kg (3.3~8.8 lb)
(1.0~ 1 .75 ton vehicles)
1.5~4.5 kg (3.3~9.9 lb)
Essential:
For preload adjustment, first fu lly tighten
the castle nut and then loosen it about Fig. 6-65 Measuring Rear Axle Hub Preload
1 /4 turn. Lightly tap the hub so as to make it
turn lighetr, after which retighen the nut
and measure the starting force.
(2) Cotter pin.
5. Install the grease cap.

(1) Pack grease into the grease cap.
(2) Grease cap.
Fig. 6-66 Installing Grease Cap
6. F it on the rear wheels, remove the stands,

and tighten the hub nuts to the specified
torque.
T = 9~12 kg-m (65.0~86.6 ft-lb)
(1,0 ~ 1 .75 ton vehicles)
T = 12~15 kg-m (86.6~108.3 ft-lb)
T = 12 ~ 1 5 kg-m (8 6 .6 ~ 108.3 ft-lb)
(2.75, 3.0 ton vehicles)
Fig. 6-67 Installing Rear Wheel
- 243 -
6 -2 4
STEERING KNUCKLE & KING PIN
Caution:
It is necessary that the rear axle hub be re
moved before the steering knuckle or king
pin can be removed or installed. For this
removal, refer to the procedures described in
rear axle hub section.
REMOVAL & DISASSEMBLY
1. Disconnect the tie rod end.

(1) Cotter pin
Fig. 6-68 Disconnecting Tie Rod End
(2) Castle nut
(3) Tie rod end
Use SST 09610-20011
Essential:
Disconnect the left side tie rod during
knuckle removal (2.0 — 3 ton vehicles).
2. Remove the king pin lock pin.

(1) Set nut
(2) Screw on a service nut, and drive out
w ith suitable round bar.
Essential: Fig. 6-69 Removing Lock Pin

To protect the lock pin threads against
damage, always screw on a service nut.
(One than can be scrapped.)
3. Remove the king pin.

(1) Grease fittin g
(2) King pin
Fig. 6-70 Removing King Pin
4. Remove the steering knuckle.

(1) Thrust bearing
(2) Shims
(3) Steering knuckle
Caution:
Be careful not to lose the shims, and keep a
record o f the number o f shims used and their
thicknesses.
Fig. 6-71 Removing Steering Knuckle
244 -
6 -2 5
5. Remove the oil seals.
Caution:
Remove only when the oil seals or needle
bearings are found damaged or worn.

Use SST 09620-30010
Caution:
Remove the needle bearings only when found
worn or damaged.
II ' Ifi I T|
INSPECTION
1. Steering knuckle.
(1) Cracks or damages at spindle root
and threads.
Caution:
It is desirable that the inspection be made by
using flaw detector or flaw detecting liquid
penetrant.
Fig. 6-74 Steering Knuckle Inspection
2. King pin.
(1) Wear or damage in king pin.
( 1 .1 0 in.)
(1.09 in.)
(2) Bending in king pin.
Caution:
When worn over the lim it, replace together
w ith knuckle bearings.
Fig. 6-75 King Pin Inspection
245 -
6 -2 6
3. Needle bearings.
( 1 ) Wear or damage in king pin needle
bearings.
(2 ) Damage in king pin oil seal.
(3) Wear or damage in bearing pin
needle bearings.
(4) Damage in bearing pin oil seal.
Fig. 6-76 King Pin Needle Bearing Inspection
1. Drive the needle bearings into the king

pin holes until flush w ith the inner sur
faces.
Use SST 09620-30010
Fig. 6-77 Driving-in Needle Bearings
2. Drive the oil seals into the outer side o f the

king pin needle bearings installed in king
pin holes.
Caution:
Install the oil seals w ith their lip sides facing
outw ard.
3. Make the steering knuckle shim adjust

ment.
(1) Install the steering knuckle and
thrust bearing to the rear axle
Fig. 6-78 Driving-in Oil Seal
beam.
(2) Adjust the steering knuckle rotating
condition w ith shims.
Make the shim adjustment at the
thrust bearing upper side.
Clearance standard:
0 .0 2 —0 .1 2 mm
(0.0008-0.0047 in.)
Shim sizes:
0.1, 0.2, 0 .5 , 1.0 mm
(0.0039,0.0079,0.0197,0.039 in.)
Fig. 6-79 Making Steering Knuckle Shim Adjustment
- 246 -
6 -2 7
4. Adjust the steering knuckle preload.

(1) A fte r finishing shim adjustment,
hook a spring scale to the end o f
steering knuckle and measure the
preload.
Steering knuckle starting force:
3 ~ 5 kg (6 .6 —11.0 lb)
(2) If specified starting force cannot be
obtained, readjust the shims and
remeasure.
5. Install the steering knuckle.

(1) A fter adjusting the preload, align
the king pin to lock pin hole posi
tion.
(2) Drive in the lock pin.
Fig. 6-81 Installing Steering Knuckle
(3) Lock nut.

T = 1.9~3.1 kg-m (13.7~22.4 ft-lb)
Fig. 6-82 Connecting Tie Rod
6. Connect the tie rod to the steering

knuckle.
Caution:
Connect the left side tie rod at the tim e the
steering knuckle is installed. (2.0 ~ 3 .0 ton
vehicles.)
(1) Tie rod

(2) Castle nut
T = 7~8 kg-m (50.5~57.6 ft-lb)
(3) Cotter pin
247 -
6 -2 8
REAR WHEEL ALIGNMENT
TOE-IN
Caution:
Make the measurement and adjustment with
the rear axle removed.
1. Place marks on the centerline o f both the

left and right wheels.
2. Use toe-in gage or flexible rule, and meas
ure the distance between the tire marks
parallel to the ground. Fig. 6-83 Measuring Toe-In
Measured value: A
Measure the distance between the tires
180° at oppsite side.
Measured value: B
Toe-in = A — B
Toe-in standard: 0 mm
3. If the toe-in is outside the standard value,
loosen the lock nut at the tie rod end, and
adjust the length by turning the tie rod.
Caution:
Adjust the left and right tie rod lengths to
equal amounts.
Fig. 6-84 Adjusting Toe-In
STEERING ANGLE
1. Adjust the rear wheel steering angle by

screwing in or out the knuckle stopper
bolt.
2. A fte r adjusting the steering angle, check
it measuring the minimum turning radius.
Minimum steering radius (Maximum outer
side):
1900 mm (75 n. 1 .0 ton vehicle
1940 mm (76 n. 1.35 ton vehicle
2010 mm (79 n. 1.75 ton vehicle Fig. 6-85 Adjusting Steering Angle
2165 mm (85 n. 2 .0 ton vehicle

2190 mm (8 6 n. 2.25 ton vehicle
2 2 2 0 mm (87 n. 2.5 ton vehicle
Fig. 6-86 Measuring M inim um Steering Radius
- 248 -
6 -2 9
CASTER, CAMBER, KING PIN INCLINATION
The above measurements are made w ith alignment tester.

However, adjustments cannot be made.
Camber 1°
Caster 0°
King pin inclination 6 °
- 249 -
STEERING
Page
STEERING POST ASSY ........................................................................... 7 - 2
COMPONENT PARTS ................................................................................ 7 - 3
SPECIFICATIONS & SERVICE STANDARDS 7- 7
DISASSEMBLY (1.0 - 2.0 ton VEHICLES) ......... ............................. 7 - 1 1
DISASSEMBLY (2.25 - 3.0 ton VEHICLES) ........ ......................... 7 -1 9
POWER CYLINDER ............................................. 7 -2 6
STEERING L IN K A G E ................................................................................ 7_32
■a
- 251 -
7 -2
STEERING POST ASSY
Fig. 7-1 Steering Gear Sectional V iew ( 1 . 0 ~ 2.0 Ton Vehicles)
Fig. 7-2 Steering Gear Sectional V iew ( 2 .2 5 ~ 3 .0 Ton Vehicles)
- 252 -
7 -3
COMPONENT PARTS
(28.9 ~ 3 6 .1 ) 29 30 31 32
1. Oil seal 12. Lock nut 23. Oil plug

2. Needle bearing 13. Insulator 24. Piston stopper
3. Holder 14. Mast jacket 25. Balance piston
4. Ball screw set 15. Steering stay 26. Balance spring
5. Needle bearing 16. Grommet 27. Relief valve set
6. Needle bearing 17. Clamp 28 End cover
7. Gasket 18. Clamp 29. Valve body
8. Bushing 19. Top cover 30. Gear box
9. Adjusting bolt 20. Stud bolt 31. Bushing
10 . Adjusting plate 21. Seat 32. Oil seal
11 . Cross shaft 22. Spring
Fig. 7-3 Steering Gear Component Parts (1 .0 ~ 2 .0 Ton Vehicles)
- 253 -
T = 2
(14.4
T = 5
(36.1
(36.1 ~ 4 3 . 3 )
1. Oil seal 13. Adjusting bolt 25. Clamp

2. Neelde bearing 14. Cross shaft 26. Clamp
3. Holder 15. Lock nut 27. Top cover
4. Ball screw set 16. Oil plug 28. Stud bolt
5. Needle bearing 17. Plug 29. Gear box
6. Needle bearing 18. " 0 " ring 30. Oil seal

Plate 19. Relief valve 31. Needle bearing
7.
Plug 20. Relief valve spring 32. Valve body
8.
Adjusting plate 21. Insulator 33. End cover
9.
22. Mast jacket 34. Sprign retainer
10. Snap ring
23. Steering stay 35. Spring
11. Needle bearing
12. Side cover 24. G rom m et
Fig. 7-4 Steering Gear Com ponent Parts (2.25 ~ 3 .0 Ton Vehicles)
7 -5
1. Horn spring 9. Contact seat

2. Lead plate 10. Cap
3. Steering wheel 11 . Knob
4. Contact spring 12 . Knob bracket
5. Contact bushing 13. Bracket sheet
6. Horn button 14. Bracket sheet
7. Washer 15. Sheet
8. Contact plate 16. Set plate
Fig. 7-5 Steering Wheel Component Parts
- 255 -
7 -6
Tightening torque unit: kg-m (ft-lb) T = 1 .9 ~ 3 . 1

(13.7 ~ 22.4)
1. T ie rod end N o. 1 12. Power cylinder

2. T ie rod 13. Power cylinder pipe No. 1
3. Needle bearing 14. Power cylinder pipe No. 2
4. Oil seal 15. Pitman arm
5. Shim (selective) 16. T ie rod end clamp
6. Bearing pin 17. Power cylinder end
7. Stopper plate 18. Power cylinder bracket
8. T ie rod end N o. 2 19. T ie rod end plug
9. Bell crank 20. Drag link
10. High pressure hose No. 1 21. Power cylinder rear end
11. High pressure hose No. 2 22. Cylinder cover (O pt)
Fig. 7-6 Steering Linkage Component Parts
- 256 -
7 -7
1. Piston rod
2. Piston ring
3. Piston
4. Self lock nut
5. Dust seal
6. Rear cover
7. " O " ring
8. Bushing
9. " V " packing
10. " V " packing
11. Adaptor
12. Seal spring
13. Collar
14. Power cylinder
15. Sheet
Fig. 7-7 Power Cylinder Component Parts
SPECIFICATIONS & SERVICE STANDARDS
POWER STEERING
Item 1.0~2.0 Ton Vehicles 2.25~3.0 Ton Vehicles

Steering post manufacturer Koyo Seiko Jidosha Kiki
Diameter 420mm (16.5 in.) ■<-
Steering wheel 25—50 m m (1~2 in.)
Play <-
(Engine idling)
Gear type Recirculating ball screw type
Gear ratio 1 : 18.5 1 : 19.8
Steering Gear
Lock to lock 4.1 4.5
Ball screw turn Left jfe
Below
Cross shaft adjust plate thrust clearance 0.1 mm (0.00 39 in.)
<-
w /o cross shaft 0.3 ~ 0.7 kg —

Bal I screw set (0.66 ~ 1.54 Tb)
starting torque w / cross shaft 0.7 ~ 1.5 kg 1 .0 ~ 2.1 kg
(1.54 ~ 3.31 lb) (2.21 ~ 4.63 Tb)
Type Semi integral <-
Booster Relief valve set press. 75 ~ 85 kg/cm 2 <-

(1067 ~ 1209 psi)
Reaction system Spring type <-
- 257 -
7 -8
POWER CYLINDER
Item 1.0 ~ 1 .75 Ton Vehicles 2.0~3.0 Ton Vehicles

Type w/reducing valve <-
Standard 40mm (1.57 in.) 50 mm (1.97 in.)

Cylinder bore
Wear lim it 40.2 mm (1.58 in.) 50.2 mm (1.98 in.)
Diameter standard 2 2 mm (0 .8 8 6 in.) <-
Piston rod Wear lim it 21 .8 mm (0.858 in.) <-
Bending lim it 1 mm (0.039 in.) <-
Piston effective stroke 230 mm (9.06 in.) <-
Piston actual storke 195 mm (7.68 in.) 207 mm (8.15 in.)

0.05 ~ 0.25 mm
Standard
(0.00197 ~ 0.0098 in.)
Piston ring end gap
Lim it 0.8 mm (0.0315 in.) <-
REMOVAL

(1) Horn button
(2) Set bolt
(3) Steering wheel
Use SST 09609-20010
2. Remove the toeboards.

(1) Rear toeboard
(2) Front toeboard
258 -
7 -9
3. Remove the horn.

(1) Harness
(2) Horn
Fig. 7-10 Removing Horn
4. Disconnect the power steering piping.
5. Disconnect the drag link end.

(1) Cotter p in , castle nut
(2) Drag link rod end (Pitman arm)
Use SST 09611-20014
Essential:
Remove from back side of pitman arm.
Fig. 7-12 Disconnecting Rod End
6. Remove the mast jacket set plate.

(1) Set nuts
(2) Set plate
Fig. 7-13 Removing Set Plate
- 259 -
7 -1 0
7. Remove the steering gear box.

(1) Set nuts
(2) Steering gear box
Essential:
•B efo re starting to remove the steering box,
check on the following points:
o Is the steering heavy?
° Is the vehicle straight ahead steering good?
o Is there any oil leakage?
o Is there any sticking while steering?
o Is the PS vehicle relief valve operating
properly?
o Is there any damage in the power steering Fig. 7-14 Removing Steering Gear Box
mounting parts and in the drag link?
o Others.
* l f any steering trouble develops, identify
the possible location before starting to re
move and disassemble.
RELIEF PRESSURE MEASUREMENT
1. Raise the fork.

2. Remove the relief valve plug and mount
the oil pressure gage. (Plug PF 1/4)
3. Start the engine and turn the steering
wheel slowly in both directions.
Fig. 7-15 Measuring Relief Pressure
4. Lock the rear wheels after turning them

slightly fro m ' straight ahead position,
turn the engine at maximum speed and
measure the relief pressure.
Specified relief pressure:
75 ~ 85 kg/cm 2 (1067 ~ 1209 psi)
A : Wood
Fig. 7-16 Rear Wheel Locked
- 260 -
7-11
1.0 ~ 2.0 Ton Vehicle iMS

(POWER STEERING MANUFACTURED
BY KOYO SEIKO)
DISASSEMBLY
1. Remove the mast jacket.

2. Remove the pitman arm.
Use SST 09420-10410-71
Caution:
Before starting disassembly, place match
Fig. 7-17 Removing Pitman Arm
marks on the cross shaft and pitman arm.
3. Remove the end cover.

(1) Set bolts
(2) End cover
Essential:
A fter taking o ff the end cover, use tw o o f the
end cover set bolts and bolt down the control
valve body tem porarily.
Fig. 7-18 Removing End Cover
4. Remove the lock nut.

(1) Loosen the lock nut staked parts.
(2) Lock nut.
Fig. 7-19 Removing Lock N ut
5. Remove the control valve body.

(1) Remove the temporary bolts.
(2) Control valve body and spool.
Fig. 7-20 Removing Valve Body
- 261 -
7 -1 2
6. Remove the side cover.

(1) Set bolts
(2) Adjusting bolt lock nut.
(3) Side cover
Caution:
A fte r removing the adjusting bolt lock nut,
screwing in the adjusting bolt w ill enable
removing the side cover w ith ease.
Fig. 7-21 Removing Side Cover
7. Remove the cross shaft.
Caution:
Set the ball nut to lock-to-lock center posi
tio n , and then remove the cross shaft, using
care not to damage the oil seal.
Fig. 7-22 Removing Cross Shaft
8. Remove the top cover.

(1) Set bolts M m I
(2) Top cover
Fig. 7-23 Removing Top Cover
9. Take out the ball screw set from the gear

box.
10. Remove the relief valve assy.

(1) Plug
(2) Balance piston and spring
(3) Relief valve assy.
Fig. 7-24 Removing Ball Screw Set
- 262 -
7 -1 3
INSPECTION
Caution:
Wash the disassembled parts in petroleum
solvent, and inspect them on the following
items.
1. Ball screw set.

( 1 ) Damage or crack in shaft.
(2 ) Damage in threaded parts.
(3) Damage or wear in ball nut tooth
surfaces.
(4) Ball screw rotating condition. Fig. 7-25 Ball Screw Set Inspection
2. Cross shaft.
( 1 ) Wear or damage in cross shaft serra
tions and gear.
(2 ) Measure the clearance between the
cross shaft and adjusting plate, and
select an adjusting plate that will
bring the clearance to w ithin the
lim it.
Clearance lim it: 0.1 mm (0.0039 in.)
Adjusting Plates
No. 1 Thickness 2.00 mm (0.079 in.)
Fig. 7-26 Cross Shaft Inspection
Fig. 7-27 Inspecting Adjusting Plate
3. Steering gear box. ' If V--V- £S :*V.-

(1) Damage or crack in gear box.
(2) Wear or damage in oil seal lip.
(3) Wear or damage in needle bearing.
Caution:
o Inspect the oil seal and needle bearing in
assembled state in the gear box.
o In case o f oil leakage, remove the oil
seal and needle bearing w ith bushing
tool and a press, and replace with new
parts.
Fig. 7-28 Gear Box Inspection
- 263 -
7 -1 4
Control valve. jji
(1) Damage or crack in valve body.

(2) Warping or damage in valve spool.
(3) Weakening or bending in reaction
chamber springs.
(4) Sliding action between body and
spool.
Caution:
o Clean w ith compressed air before inspect
ing.
o If any defects are found, replace the
entire valve body assy. Fig. 7-29 Control Valve Inspection
Relief valve.
(1) Sliding action and action in balance
piston and valve body.
(2) Deterioration or bending in balance
spring.
(3) Foreign matter lodged in.
(4) Disassemble the relief valve set and
check fo r weakened relief valve
spring.
Caution:
o Disassemble only if relief valve pressure
was defective before removal. Fig. 7-30 Balance Piston Inspection
o If any defect is found, replace the entire
relief valve set. ■ WM
:§
m m
1
l i u
1
Fig. 7-31 Relief Valve Inspection
6. Bearing Inspection.
Inspect fo r damage in bearing and wear in
bushings, and replace any found defective.
Fig. 7 -3 2 Bearing Inspection
- 264 -
7 -1 5
1. Assemble the ball screw set into the

gear box.
Caution:
Check the ball screw set and gear box interior
to see that no foreign m atter is present be
fore starting assembly.
Fig. 7-33 Assembling Ball Screw Set
Install the top cover.

(1) Needle bearing and snap ring
(2) Top cover
(3) Set bolts
T = 4.5~5.5 kg-m
(32.5~39.7 ft-lb)
Caution:
o. Do not forget to assemble in the top
cover " 0 " ring,
o A pply hydraulic oil on the "0" ring
and top cover insertion part.
Fig. 7 -3 4 Installing T op Cover
Install the control valve body.

(1) Plate, needle bearing, thrust plate
(2) Control valve (Valve spool and 4
sets o f reaction springs)
Caution:
o Position the larger diameter thrust plate
on the valve body side,
o Apply hydraulic oil on the " 0 " ring.
Fig. 7-35 Installing Control Valve
Install the ball screw set lock nut.

(1) Bolt down the valve body tempo
rarily w ith 2 bolts
(2) Thrust plate, needle bearing, plate
Fig. 7-36 Installing Lock N ut
- 265 -
7 -1 6
(3) Lock nut

Turn the ball screw set shaft 3 or
4 times and tighten the lock nut
in itia lly to 1.5—2 kg-m (7.2~14.5
ft-lb). A fte r wearing in, loosen.
Next, use SST 09470-10170-71 and
measure the starting force.
Starting force: 0.3~0.7 kg
(0.66~1.54 lb)
Tighten the lock: nut to obtain the
above range.
A fte r tightening, stake the lock
Fig. 7-37 Measuring Starting Force
nut securely.
Caution:
When staking, form ation of fissures in the
lock nut is permissible.
Fig. 7-38 Staking Lock N ut

5. Install the end cover.
(1) Remove the temporarily installed
bolts.
(2) End cover
(3) Set bolts
T = 4 - 5 kg-m (28.9 ~ 36.1 ft-lb)
Caution:
A p p ly hydraulic oil on the " 0 " ring before
installing.
Fig. 7-39 Installing End Cover
6. Install the cross shaft.
Essential:
o Insert the cross shaft by aligning the top
end o f its center tooth to the tooth bot
tom at center o f ball screw set.
o Have the ball screw set at lock-to-lock
center position.
Fig. 7 -4 0 Installing Cross Shaft
266 -
7 -1 7
7. Install the side cover.

(1) Side cover
(2) Adjusting plate and bolts.
(3) Set bolts
T = 4.5~5.5 kg-m
(32.5~39.7 ft-lb)
Caution:
Apply hydraulic oil on the " 0 " ring.
Fig. 7-41 Installing Side Cover
8. Install the pitman arm.

T = 16—19 kg-m (1 15.5~137.2 ft-lb)
Caution:
W ith the cross shaft set at center of lock to
lock position, align the match mark w ith that
on the cross shaft.
Fig. 7-42 Installing Pitman Arm
9. Adjust the backlash. *»■•i m 11' -. :jHlBHMHflHK .1 , ■ ■ ■ ■ ■ ■

(1) With the cross shaft set ax center of
lock to lock position, tighten the
adjusting bolt until the backlash
becomes 0 mm as measured at end of
pitman arm.
(2) Turn the ball screw set shaft 3 or 4
times, and w ith the pitman arm set
at lock-to-lock center position,
measure the combined starting force
w ith SST 09470-10170-71.
Combined starting force:
0.7~1.5 kg (1.54~3.31 lb) Fig. 7-43 Measuring Combined Starting Force
(3) If the specified combined starting
force cannot be obtained, screw in
the adjusting bolt from the above
position.
Fig. 7-44 Tightening Adjusting Bolt
267 -
7 -1 8
(4) Set a dial gage against the end of

pitman arm and check the backlash.
Lock to lock center position: 0 mm
(5) Tighten the adjusting bolt lock nut.

Lock nut: T = 3~4.5 kg-m
(21,7~32.5 ft-lb)
Cap nut: T = 3~4.5 kg-m
(21.7~32.5 ft-lb)
10. Install the mast jacket.
Fig. 7 -4 6 Tightening Lock Nut
11. A fte r completing assembling, check the

follow ing points.
(1) Turn the ball screw set shaft 3 or 4 times and check to see that it turns smoothly, w ithout
undue effort.
(2) Turn the ball screw set shaft up to the lock position, and check that shaft return smoothly
by reaction spring action.
INSTALLATIO N

A fte r installing, measure the relief pressure to see that it is at specified value.
Relief pressure standard: 75~85 kg/cm 2 (1067~1209 psi)
- 268 -
7 -1 9
2 .2 5 ~ 3 .0 T o n Vehicles
(Pow er Steering M anufactured by Jidosha
K ik i)
DISASSEMBLY
1. Remove the mast jacket.

2. Remove the pitman arm.
Use SST 09420-10410-71
Caution:
Before starting disassembly, place match
marks on the cross shaft and pitman arm. Fig. 7-47 Removing Pitman Arm
3. Remove the cross shaft.

(1) Side cover set bolts
(2) Adjusting bolt lock nut.
(3) Side cover and cross shaft
Caution:
o A t lock to lock center, set the ball nut
at center o f gear box.
o The side cover and cross shaft can be
easily removed by gradually screwing in
the adjusting bolt.
Fig. 7-49 Removing Cross Shaft
4. Remove the top cover.

(1) Set bolts.
(2) Top cover
Fig. 7-50 Removing Top Cover
269 -
7 -2 0
5. Remove the end cover.

(1) Set bolts
(2) End cover
Essential:
A fte r removing the end cover, use tw o o f the
end cover set bolts and bolt down the control
valve body tem porarily.
Fig. 7-51 Removing End Cover
6. Remove the control valve body.

(1) Loosen the lock nut staked parts.
(2) Lock nut
(3) Temporarily installed bolts
(4) Valve body and spool
(5) Needle bearings and thrust plates
Caution:
Use care not to mar or injure the spool as
this is a high precision part.
Fig. 7-52 Removing Valve Body
7. Take out the ball nut w ith main shaft

from the gear box.
Fig. 7-53 Removing Main Shaft
8. Remove the relief valve assy.

(1) Relief valve and spring
Fig. 7-54 Removing Relief Valve
270 -
7-21
INSPECTION
Inspection:
Wash the disassembled parts in petroleum
solvent, and inspect them on the following
items.
1. Ball screw set with main shaft.

( 1 ) Damage or cracks in shaft
(2, Damage in threaded parts
(3; Damage or wear in ball nut toothed
surfaces
(4) Ball screw rotating condition Fig. 7-55 Ball Screw Set Inspection
Cross shaft.
( 1 ) Wear or damage in cross shaft serra
tions and gear
(2 ) Measure the clearance between the
cross shaft and adjusting plate.
Clearance lim it. 0.1 mm (0.0039 in.)
Fig. 7-56 Cross Shaft Inspection
Adjusting Plate

(0.00 4 in.)
Fig. 7-57 Adjusting Plate Selection

3. Steering gear box.
(1) Damage or cracks in gear box
(2) Wear or damage in oil seal lip
(3) Wear or damage in formed bushing
Caution:
o Inspect the oil sea> ana formed bushing
while still installed in the gear box.
o In case of oil leakage, drive out the old
oil seal and formed bushing w ith bushing
tool and press, and replace w ith new parts.
Fig. 7-58 Gear Box Inspection
- 271 -
7 -2 2
4. Control valve.
(1) Damage or crack in valve body
(2 ) Warping or damage in spool
£
(3)
(4)
Weakening or bending in reaction
chamber springs.
Sliding action between body and
s I
spool.
Caution: In W a ■ M B
i
o Clean the parts w ith compressed air prior
to inspection,
o If any defects are found, replace the
entire valve assy. Fig. 7-59 Control Valve Inspection
Fig. 7-60 Inspecting Spool
5. Relief valve.
(1) Damage or wear in relief valve assy.
(2) Weakening or bending in valve spring.
(3) Foreign matter lodged in.
6. Relief valve disassembly and inspection.

(1) Damage in piston
(2) Loss o f tension in spring
(3) Malfunction in check ball
Caution:
o Disassemble only when the relief pressure Fig. 7-61 Relief Valve Inspection
measured before removal did not con
form to specified value,
o if found defective, replace the entire re
lief valve assy.
7. Bearing inspection.
(1) Needle bearings
Fig. 7-62 Relief Valve Disassembly & Inspection
- 272 -
7 -2 3
1 Assemble the ball screw set into the gear

box.
Caution:
Check the ball screw set and gear box interior
to see that no foreign object is present before
assembly.
Fig. 7-63 Assembling Ball Screw Set
2. Install the control valve body.

(1) Plate, needle bearing, thrust bearing
(2) Control valve
(Valve spool and 4 sets of reaction
springs)
Caution:
o Spool has no directivity, but position the
larger chamfered end at upper side.
o Position the larger diameter thrust plate
on the valve body side.
o Apply hydraulic oil on the " 0 " ring.
Fig. 7-64 Installing Control Valve
3. Install the ball screw set lock nut.

(1) Ball down the valve body tempo
rarily with 3 bolts.
(2) Thrust plate, needle bearing, plate
(3) Lock nut
First tighten the lock nut to 400
kg-cm (28.88 ft-lb). A fte r running
in, loosen and then tighten to 40
kg-cm (2.89 ft-lb).
Essential:
o Use new lock nut.
o If 4 0 kg-cm (2.89 ft-lb) measurement Fig. 7-65 Installing Control Valve
cannot be made, screw in finger tight and
then tighten about 1 /8 turn further w ith a
wrench.
Fig. 7-66 Tightening Lock Nut
- 273 -
7 -2 4
4. Install the top cover.

(1) Needle bearing, snap ring
(2) Top cover
(3) Set bolts
T = 5~6 kg-m (36.1~43.3 ft-lb)
Caution:
o Do not forget to install the top cover
" 0 " ring.
o A pply hydraulic oil to " 0 " ring and top
cover insertion part.
5. Stake the lock nut. e. -»e-j . T ^

Fig. 7-67 Installing Top Cover
Caution:
Stake the lock nut securely. Fissures formed
at staked part is permissible.
6. Install the end cover.

(1) Remove the temporarily installed
bolts
(2) End cover
(3) Set bolts
T = 5~6 kg-m (36.1~43.3 ft-lb)
Caution: Fig. 7-68 Installing End Cover

A pply hydraulic oil to the " 0 " ring.
7. Install the cross shaft.
Caution:
o Align the to oth bottom at center o f ball
screw set to the to p end o f cross shaft
center to oth when inserting the cross
shaft.
o Have the ball screw set at lock-to-lock
center position.
Fig. 7-69 Installing Cross Shaft
8. Install the side cover

(1) Side cover
(2) Adjusting plate and bolts.
(3) Set bolts
T = 5~6 kg-m (36.1~43.3 ft-lb)
Caution:
A pply hydraulic oil to the " 0 " ring.
Fig. 7 -7 0 Installing Side Cover
274 -
7 -2 5
9. Check the starting torque and main shaft

turning condition as follows:
( 1 ) Turn from lock to lock 3 or 4 times.
Does shaft turn smoothly?
(2 ) Are the reaction springs acting when
at lock?
(3) Hook on a spring scale to the steering
wheel and measure the starting
torque.
Starting force: 1.0—2.1 kg
(2.21-4.63 lb)
Fig. 7-71 Measuring Starting Force
Caution:
If the starting force w ithin the above limits
cannot be obtained, adjust by varying the
lock nut tightened state.
10. Install the pitman arm.

T = 16—19 kg-m (115.5-137.2 ft-lb)
Caution:
Align the match m ark w ith that on the cross
shaft when the cross shaft is at center of lock
to lock position.
11. Adjust the backlash.

(1) With the cross shaft set at center of
lock to lock position, tighten the
adjusting bolt until the backlash
becomes 0 mm when measured at
end o f pitman arm.
(2) Tighten the adjusting bolt and nut.
T = 2—3 kg-m (14.4-21.7 ft-lb)
12. Install the mast jacket.
13. Upon finishing the installation, make the

follwing check.
(1) Turn the main shaft 3 or 4 times to
see that it turns smoothly and uni-
formal ly w ithout undue effort. Fig. 7-73 Installing Mast Jacket
(2) Turn the main shaft up to the lock
position, and check that the shaft INSTALLATION
w ill be returned smoothly by the
reaction springs. Perform the removal in reverse order.
A fter installing, measure the relief pressure to
see that it is at specified value.
Relief pressure standard: 75—85 kg/cm 2
(1067-1209 psi)
- 275 -
POWER CYLINDER
Fig. 7-74 Power Cylinder Sectional View
REMOVAL
1. Disconnet the power cylinder piping.
Essential:
o Turn the steering wheel until the power
cylinder end sticks out fro m the rear
axle.
o Disconnect the power steering connection
by loosening and gently hand-tighten,
being careful not to spill the hydraulic
oil.
Fig. 7-75 Removing Piping
2. Disconnect the drag link end.

(1) Cotter pin
(2) Castle nut
(3) Drag link end
Use SST 09950-20012
09 9 5 0-20 01 2
Fig. 7 -7 6 Disconnecting Drag Link End
- 276 -
7-2 7
3. Disconnect the power cylinder end. (Bell

crank end)
( 1 ) Cotter pin
(2 ) Castle nut
(3) Power cylinder end
Use SST 09610-20011
Fig. 7-77 Disconnecting Power Cylinder End
4. Disconnect the power cylinder end (Frame

end).
(1) Cotter pin
(2) Castle nut
Use SST 09950-20012
Fig. 7-78 Disconnecting Power Cylinder End
5. Remove the power cylinder assy from the

vehicle.
Fig. 7-79 Removing Power Cylinder
- 277 -
7 -2 8
DISASSEMBLY
Caution:
o Before disassembling, check fo r oil leak
age, injury to piston rod, etc.
o For use as reference for assembly, meas
ure the distance between the power
cylinder ends when contracted.
Fig. 7-80 Measuring Length
1. Remove the power cylinder ends.

(1) Clamps
(2) Front and rear
Fig. 7-81 Removing Cylinder End
2. Remove the power cylinder rear cover.

(1) Loosen the staked parts.
(2) Power cyliner rear cover.
Use SST 09620-10100-71
Caution:
Use care not to damage the power cylinder
when holding it in vise.
096-2051h IIOOr-TT
■■■■■M i
Fig. 7-82 Removing Rear Cover
3. Pull out the piston rod from the cylinder.
Fig. 7-83 Removing Piston Rod
- 278 -
7 -2 9
4. Remove the piston from the piston rod.
Caution:
o Use care not to injure the piston rod when
clamping it in a vise,
o Also hold the other end w ith the wrench
to prevent the rod from turning.
Fig. 7-84 Removing Piston
Fig. 7-85 Removing Piston Ring
6. Remove the " V " packing and dust seal

from the cylinder rear cover.
(1) Snap ring and collar
(2) Spring and adaptor
(3) " V " packing and bushing
(4) Snap ring and dust seal
Caution:
Disassemble only in case of oil leakage from
rear cover.
Fig. 7-86 Removing " V " Packing
- 279 -
7 -3 0
INSPECTION
1. Damage or wear in power cylinder bore.
Essential:
Use a ' bore gage and measure the wear and
out-of-roundness at place about 200 mm
fro m the cylinder end.
Cylinder bore standard:

1.0 ~ 1.75 ton vehicles 40 mm (1.57 in.)
2.0 ~ 3.0 ton vehicles 50 mm (1.97 in.)
Cylinder bore lim it: Fig. 7-87 Inspecting Cylinder
1.0 ~ 1 .75 ton vehicles 40.2 mm
(1.58 in.)
2.0 ~ 3.0 ton vehicles 50.2 mm
(1.98 in.)
2. Piston rod.
(1) Wear, damage
Diameter standard: 22 mm
(0 .8 8 6 in.)
(0.858 in.)
(2) Bending
Bending lim it: 1 mm Fig. 7-88 Inspection Piston Rod
(0.039 in.)
3. Piston and piston rings.

(1) Wear or damage in piston
(2) Wear or damage in piston rings
(3) Piston ring end gap
Gap lim it: 0.8 mm
(0.0315 in.)
Essential:
T o check the piston end gap, insert the ring
into the cylinder and measure the end gap
w ith thickness gage.
Fig. 7-89 Piston and Ring Inspection
4. " V " packing.

(1) Wear and damage in " V " packing
(2) Wear and damage in dust seal
Caution:
Remove and replace the dust seal only when
found defective.
Fig. 7-90 " V " Packing Inspection
- 280 -
I
7-31
ASSEMBLY
1. Assemble the seal and other parts to the

cylinder rear cover.
(1) Bushing, " V " packing
(2) Adapter, spring
(3) Collar, snap ring
Caution:
Drive in the dust seal w ith hand press only
when it is being replaced.
2. Assemble the piston to the piston rod. Fig. 7-91 Assembling " V " Packing
Caution:
Use new self locking nut.
3. Assemble the piston rings to the piston.
Caution:
o Assemble the piston rings so th at their
" T " marks will be positioned toward the
outer side.
o Position the piston rings so th at their
end gaps will be on opposed sides.
Fig. 7-92 Assembling Piston
4. Insert the piston into the cylinder.

Use SST 09450-12000-71 (1.0—1.75 ton
vehicles)
Use SST 09490-20340-71 (2~3 ton ve
hicles)
0 9 4 5<||j|?p00-71
09490120340-71
Fig. 7-93 Inserting Piston
5. Assemble the rear cover to the power

cylinder.
Use SST 09620-10100-71
(1) Rear cover
(2) Stake
Essential:
A pply liquid seal to the threaded part of
power cylinder rear cover.
Fig. 9 -9 4 Staking Rear Cover
- 281 -
7 -3 2
6. Install the fro n t end and the drag link end.
Caution:
Set to the dimension measured before dis
assembly.
7. Install the power cylinder to the vehicle.
Caution:
For power cylinder installed dimension,
refer to the steering linkage adjustment
standard.
S T E E R IN G L IN K A G E
INSTALLATION
With the steering wheel positioned at center o f lock to lock, set the rear wheel to straight ahead state,
and connect the bell crank to the pitman arm w ith drag link rod.
Essential:
o In the case o f manual steering, use the above method.
o In case o f power cylinder, adjust the amount of protrusion at the power cylinder rod ends A and B,and then
make the connection. For details, refer to the steering linkage adjustment procedures below.
STEERING LINKAGE ADJUSTMENT
1. Set the power cylinder piston rod and power cylinder end B into the power cylinder rear by screwing
in 40 mm (1.57 in.) respectively.
Fig. 7 -9 5 Cylinder End Adjustment
- 282 -
7 -3 3
2. Set the power cylinder end A into the power cylinder by screwing in.
1 .0 — 1.75 ton vehicles .. 40 mm (1.57 in.)
2.0 — 3.0 ton vehicles .... 45 mm (1.77 in.)
Fig. 7-96 Cylinder End Adjustment
3. Withe rear wheels set at straight ahead position, install the power cylinder assy. Make the installation
adjustment by varying power cylinder rod stroke C.
M
O dJ: j
c
Power cylinder end A
Fig. 7-97 Power Cylinder Installed State
4. With the steering wheel set at the center o f lock to lock position, connect the pitman arm to the
power cylinder rear end w ith the drag link rod.
Essential:
Make the adjustment by varying the amounts which the power cylinder ends A and B protrude o ut, and making
it such that both A and B are screwed in to the same amounts.
- 283 -
284 -
BRAKE
Page
BRAKE SYSTEM DIAGRAMS ................................................................ 8- 2
SPECIFICATIONS & SERVICE STANDARDS .................................... 8- 4
FRONT BRAKE (1.0 - 1 . 7 5 Ton Series) ................................................ 8 - 6
FRONT BRAKE (2.0 - 2.5 Ton Series).................................................. 8- 7
FRONT BRAKE (2.75 - 3.0 Ton Series) ................................................ 8 - 8
REMOVAL, INSPECTION, ASSEMBLY ( 1 .0 - 1 .7 5 Ton Series) 8- 9
REMOVAL, INSPECTION, ASSEMBLY (2.0 - 2.5 Ton Series) ........ 8 -1 6
REMOVAL, INSPECTION, ASSEMBLY (2.75 - 3.0 Ton Series) 8 -2 3
AIR REMOVAL ......................................................................................... 8 -3 0
TESTS (Auto Adjuster Operation, Braking Effectiveness)...................... 8 -3 1
CHECK AND ADJUSTMENT OF BRAKEEFFECTIVENESS ........ 8 -3 2
MASTER C Y L IN D E R ................................................................................. 8 -3 3
BRAKE VALVE ........................................................................................... 8 -3 7
FLOW DIV ID IN G VALVE ........................................................ 8 -4 7
ACCUMULATOR ......................................................................................... 8 -5 0
PARKING BRAKE ..................................................................................... 8 -5 3
BRAKE PEDAL ........................................................................................... 8 -5 7
- 285 -
8 -2
BRAKE SYSTEM D IA G R A M S
1.0 ~ 1.75 Ton Clutch Type Vehicles
1.0 ~ 1.75 Ton Torque Converter Type Vehicles
- 286 -
8 -3
Fig. 8-3 Brake System Diagram (2.0 ~ 3.0 Ton Clutch Type Vehicles)
2.0 ~ 3.0 Ton Torque Converter Type Vehicles
- 287 -
8 -4
S P E C IF IC A T IO N S & S E R V IC E S T A N D A R D S
Item 1.0 ~ 1.75 Ton Vehicles

Foot brake Hydraulic, internal expanding, duo-servo
Type
Parking brake Mechanical, internal expanding
Brake drum inside diameter 254 mm (10 in.)
Material Molded resin
Brake lining
Dimensions (W x Th x L) 48.5x5x279mm (1.91x0.197x11.0 in.)
Wheel cylinder bore 22.22 mm (0.875 in.)
Master cylinder bore 19.05 mm (0.75 in.)
SERVICE STANDARD
Brake Pedal Parts
Brake pedal play 4 ~ 9 mm (0.157 ~ 0.354 in.)

Torsion spring free angle 40 degrees
Master Cylinder Parts

Free length 97 mm (3.82 in.)
Compression spring Installed length 63 mm (2.48 in.)
Installed load 3 kg (6.62 lb)
Foot Brake Parts

Standard 254 mm (10 in.)
Brake drum inside diameter
L im it 256 mm (10.1 in.)
Standard 5.0 mm (0.197 in.)

Brake lining thickness
L im it 1.0 mm (0.039 in.)
Drum to lining clearance 0.25 ~ 0.5 mm (0.01 ~ 0.02 in.)

Brake shoe return spring
Installed length 111 mm (4.37 in.)
Adjuster actuator spring Installed length 98.5 mm (3.88 in.)

Installed load 14 kg (30.9 lb)
- 288 -
8 -5
SPECIFICATIONS (2.0 - 3 . 0 Ton Vehicles)
Item 2.0 ~ 2.5 Ton Vehicles 2.75, 3.0 Ton Vehicles

Foot brake Hydraulic, internal expanding, duo-servo
Type
Parking brake Mechanical, internal expanding
Brake drum inside diameter 310mm (12.2 in.) <-
Material Molded resin 4-
Brake lining
Dimensions (WxThxL) 60x7.0x323mm 60x6.3x346mm
(2.36x0.276x12.72in.) (2.36x0.248x13.62in.)
Wheel cylinder bore 28.5 mm (1.122 in.) 28.58 mm (1.125 in.)
Valve spool diameter 20 mm (0.787 in.) •«-
Brake valve Valve spool stroke 4.3 mm (0.169 in.) 4-
Inlet flow 11.5fi/m in (3.03 6 USgal/min) -t-
SERVICE STANDARDS
Brake Pedal Parts

Item 2.0~2.5 Ton Series 2.75, 3.0 Ton Series
Brake pedal play 2~3m m (0.078~0.118 in.)
oo
4-
CD
Torsion spring free angle 4-
Brake Valve Parts

Item 2.0 ~.2.5 Ton 2.75, 3.0 Ton
Body to input piston (25 .4 0) (1 in) 0.16 mm (0.0063 in.) 4-
Wear lim it
in sliding Body to valve spool (200) (0.787 in) 0.032 mm (0.00126 in.) <-
parts Reaction piston to guide (120. 0.48 in 0.16m m (0.0063in .) (130)
<-(120) (0.48 in)
(130. 0.5 2 in (0.52 in)
Spring free Compression spring (12.40) (0.49 6 in 20 mm (0.787 in.) 4-

length Reaction piston return spring (19.90)
20 mm (0.787 in.) 4-
(0.79 6 in)
Foot Brake Parts

Item 2.0 ~ 2.5 Ton Series 2.75, 3.0 Ton Series
Brake drum inside Standard 310 mm (12.20 in.) 310 mm (12.20 in.)
diameter L im it 312 mm (12.28 in.) 312 mm (12.28 in.)
Brake lining Standard 7.0 mm (0.276 in.) 6.3 mm (0.248 in.)
thickness Lim it 2.0 mm (0.079 in.) 1.0 mm (0.039 in.)
Drum to lining clearance 0.8 mm (0.0315 in.) 0.35 mm (0.0138 in.)
Brake shoe Free length 106 mm (4.17 in.) 124 mm (4.88 in.)
return spring 116 mm (4.57 in.) 138 mm (23±2.3 kg)
Installed length (Load)
5.43 in. (50.7 ± 5.1 lb)
Free length 91.3 mm (3.59 in.) 8 8 mm (3.46 in.)
Actuator adjuster
Installed length 97.0 mm (3.82 in.) 108 mm (4.25 in.)
spring
Installed load 7.5 kg (16.5 lb) 14±1.4kg(30.9 ±3.1 lb)
- 289 -
8 -6
FRO NT BRAKE (1 .0 ~ 1 .7 5 T o n Series) WHEEL CYLINDER (1.0 ~ 1.75 Ton Series)
Fig. 8-6 Wheel Cylinder Sectional View
COMPONENT PARTS (1.0 ~ 1.75 Ton Series)
19 8
1. Shoe hold-down pin 13. Strut

2. Anchor to shoe spring 14. Snap ring
3. Shoe guide plate 15. Adjustment spring
4. Secondary shoe sub-assy 16. Adjusting screw
5. Cable & f itting sub-assy 17. Lever pin retainer
6. Cable guide 18. Strut to shoe spring
7. Shoe hold-down spring 19. A utom atic adjustment lever
8. Shoe hold-down cup 20. Connecting rod
9. Spring washer 21. Wheel cylinder cover
10. Primary shoe sub-assy 22. Wheel cylinder cup
11. Backing plate 23. Wheel cylinder spring
12. Parking lever 24. Wheel cylinder body
Fig. 8-7 Com ponent Parts
- 290 -
8 -7
FRONT BRAKE (2.0 ~ 2.5 Ton Series) WHEEL CYLINDER (2 .0 ~ 2.5 Ton Series)
Fig. 8-8 Front Brake Fig. 8-9 Wheel Cylinder Sectional View
COMPONENT PARTS (2.0 ~ 2.5 Ton Series)
23
1. Connecting rod 13. Backing plate

2. Dust cover 14. Brake lever
3. Piston 15. Brake shoe sub-assy
4. Piston cup 16. Adjusting spring
5. Spring 17. Strut
6. Wheel cylinder body 18. Adjuster
7. Lever pin 19. Shoe return spring
8. Shoe guide plate 20. Link
9. A nti-rattle spring 21. Pawl lever
10. Shoe hold pin 22. Actuator lever
11. Cup washer 23. A ctuator spring
12. Shoe hold-down spring 24. Sleeve
Fig. 8 -1 0 Component Parts
- 291 -
8 -8
FRONT BRAKES WHEEL CYLINDER (2.75,3.0 Ton Series)

(2.75, 3.0 Ton Series)
Fig. 8-11 Front Brake Fig. 8-12 Wheel Cylinder Sectional View
COMPONENT PARTS (2.75,3.0 Ton Series)
2223 24
21
1. Shoe hold-down pin 13. Strut

2. Anchor to shoe spring 14. Snap ring
3. Shoe guide plate 15. Adjustm ent spring
4. Cable & fittin g sub-assy 16. Adjusting screw
5. Cable & fittin g sub-assy 17. Lever pin retainer
6. Cable guide 18. S tru t to shoe spring
7. Shoe hold-down spring 19. A utom atic adjustment lever
8. Shoe hold-down cup 20. Connecting rod
9. Spring washer 21. Wheel cylinder cover
10. Prim ary shoe sub-assy 22. Wheel cylinder cup
11. Backing plate 23. Wheel cylinder spring
12. Parking lever 24. Wheel cylinder body
Fig. 8 -1 3 Component Parts
- 292 -
8 -9
Im portant:
o Brake fluid (vegetable oil) is used in the brakes fo r 1,0 ~ 1 .75 ton series. Hydraulic oil (mineral oil) is used in
the brakes for 2 .0 ~ 3 .0 ton series. Thus, care must be taken not to interm ix the parts at disassembly and
when replacing the parts.
o For removal o f the fro n t axle hub, refer to the fro n t axle section.
o The brake can be disassembled after removing the brake assy from the vehicle, or it can be disassembed
part by part while on board the vehicle. The suitable method should be taken to conform w ith the kind o f
trouble to be repaired.
REMOVAL (1.0—1.75 TON SERIES)
1. Jack up the vehicle fro n t end.

2. Remove the following parts.
(1) Front wheel
(2) Axle shaft
(3) Front axle hub
Use SST 09310-10160-71
(1.0,1.35 ton vehicles)
Use SST 09950-20012
(1.5,1.75 ton vehicles)
„ „ . 'jjn U Fig. 8 -1 4 Removing Front Axle Hub

3. Remove the adjusting screw.
(1) Adjusting screw
(2) Autom atic adjustment lever
(3) Adjusting screw
Fig. 8-15 Removing Adjusting Screw
4. Anchor to shoe springs.

( 1 ) Anchor to shoe springs
Use SST 09717-20010
(2 ) S trut lever, strut to shoe spring
(3) Cable guide
(4) Cable
Fig. 8-16 Removing Anchor to Shoe Spring
- 293 -
8 -1 0
5. Remove the hold down springs.

(1) Hold-down cups
Use SST 09510-10170-71
(2 ) Hold-down springs
6. Remove the brake shoes.

(1) Brake shoes
(2 ) Parking brake cable
Fig. 8-17 Removing Brake Shoe
7. Remove the parking lever.

(1) " U " ring
(2) Lever pin
(3) Brake lever
Fig. 8 -1 8 Removing Parking Lever

(1) Snap ring
(2) Parking brake cable
Fgi. 8 -1 9 Disconnecting Parking Brake Cable
9. Drain o ut the brake fluid.

(1) Reservoir tank
Caution:
o In case the wheel cylinder and backing
plate are to be removed, always drain out
the brake fluid .
o If the brake fluid is to be reused, keep
it in a clean container and use care to
prevent interm ixing w ith mineral oil.
(2) Breather screw
Fig. 8 -2 0 Draining O ut Brake Fluid
294 -
8-11
10. Remove the backing plate.

(1) Brake pipe
(2) Backing plate nut set
(3) Backing plate
Fig. 8-21 Remove Backing Plate
11. Remove the wheel cylinder.

(1) Set bolts
(2) Wheel cylinder
Fig. 8-22 Removing Wheel Cylinder
12. Disassemble the wheel cylinder.

(1) Wheel cylinder covers
(2) Connecting rods
(3) Pistons
(4) Wheel cylinder cups
(5) Wheel cylinder spring
Caution:
o Disassemble just before inspection. Re
place any defective parts found and re
assemble im m ediately.
o Never allow any mineral oil or grease to
to come in contact. Fig. 8-23 Wheel Cylinder Disassembed
- 295 -
j
8 -1 2
INSPECTION (1 .0 -1 .7 5 TON SERIES)
Caution:
Inspect the disassembled parts and repair or
replace any found defective.
1. Wheel cylinder.
(1) Rusting, damage or wear in the wheel
cylinder bore and pistons.
Cylinder to piston clearance
standard: 0.040—0.125 mm
(0.00016-0.0049 in.) HllllMlIl
(2) Wear, damage, deformation in piston Fig. 8-24 Inspecting Wheel Cylinder (1)
cups
Caution:
A t overhaul, replace the cups w ith new parts.
(3) Damage or deterioration in cylinder

boots
(4) Damage or deformation in connect
ing rods
(5) Deformation or loss-of-tension in
spring
Fig. 8 -2 5 Inspecting Wheel Cylinder (2)

2. Brake drum.
(1) Eccentric wear, tapering, scoring in
brake drum interior
Inside diameter standard: 254 mm
(1 0 in.)
Repair lim it: 256 mm
( 10.1 in.)
Fig. 8 -2 6 Inspecting Brake Drum
3. Brake shoes.
(1) Wear, damage, or oil adherence on
shoe linings
Lining thickness standard:
5.0 mm (0.197 in.)
Lining thickness lim it:
1.0 mm (0.039 in.)
Fig. 8-27 Inspecting Brake Lining
- 296 -
8 -1 3
4. Spring
(1) Deformation or weakening in shoe
return springs
Free length: 102 mm (4.02 in.)
(2) Deformation or weakening in adjust
ing spring
(3) Deformation or weakening in strut
shoe spring
(4) Deformation or weakening in hold
down springs
Fig. 8-28 Spring inspection
Free length: 25.7 mm (1.01 in.)
5. Adjusting screw.
(1) Wear, damage, deformation in teeth
(2) Wear, defective rotation in screw
Fig. 8-29 Inspecting Adjusting Screw
6. Shoe hold-down cups.

(1) Deformation or cracks in cups
7. Strut lever.
(1) Bending, deformation, damage in
lever
8. Adjusting parking lever.

a
(1) Deformation, cracks, wear in lever
9. Cable guide.
(1) Deformation, damage in cable guide
Fig. 8 -3 0 Adjuster, Backing Plate Parts Inspection
10. Cable and links.

(1) Stretching or damage in cable
11. Backing plate.

(1) Deformation, cracks, damage in
backing plate
Fig. 8-31 Backing Plate Inspection
- 297 -
ASSEMBLY (1 .0 -1 .7 5 TON SERIES)
Caution:
o A pply new brake fluid to all parts before
assembly.
o Do not use any oil other than brake fluid.
1. Assemble the wheel cylinder.

( 1 ) Wheel cylinder spring
(3) Pistons
(4) Connecting rods and boots
(5) Breather screw Fig. 8-32 Assembling Wheel Cylinder
2. Install the wheel cylinder assy.

(1) Backing plate
(2) Wheel cylinder assy
(3) Set bolt
T = 0 .8 -1 .2 kg-m (5 .7 8 -8 .6 6 ft-lb)
Fig. 8-33 Installing Wheel Cylinder
3. Install the backing plate.

(1) Backing plate
(2) Shoe hold pins
(3) Set nuts
T = 5—8 kg-m (36.1—57.6 ft-lb)
4. Connect the brake pipe.
Fig. 8-34 Installing Backing Plate
5. A pply "N on m elt lube" grease.

( 1 ) 6 places contacting on brake shoes
(2) Anchor pins
Fig. 8 -3 5 Greasing Points

8 -1 5
6. Connect the parking brake cable.

(1) Apply rubber packing
(3) " U " ring
7. Install the parking lever.

(1) Brake shoe (front side)
(2) Brake lever, lever pin, " U " ring
Fig. 8-36 Connecting Parking Brake Cable
8. Install the brake shoes.

( 1 ) Parking brake cable
(2 ) Brake shoes
(3) Cup washers, shoe hold down springs
(4) Cup washers 09510-31960-71
Use SST 09510-31960-71
(5) Shoe guide plate
Fig. 8-37 Installing Brake Shoes
9. Install the shoe return springs.

(1) Cable, cable guide
(2) Strut, anti-rattle spring
(3) Brake shoe return springs
(Front side first and then rear side)
Use SST 09718-20010
Fig. 8-38 Installing Shoe Return Springs
10. Install adjusting lever and screw.

(1) Adjusting screw
(3) Adjuster spring
11. Remove air by bleeding and then adjust

the brake.
Fig. 8-39 Assembling Lever and Spring
- 299 -
8 -1 6
REMOVAL (2.0~2.5 TON SERIES)

2. Remove the following parts:
(1 ) Front wheel
(2 ) Axle shaft
(3) Front axle hub
Use SST 09310-10160-71
Remove the shoe return springs.
( 1 ) Adjuster link
(2 ) Shoe return springs
Use SST 09510-20180-71
Fig. 8 -4 0 Removing Shoe Return Spring
Remove the hold-down springs.

(1) Cup washers
Use SST 09510-10170-71
(2 ) Hold-down springs
0951.0-101
(3) Sleeve w
(4) A ctuator lever
(5) Pawl lever
(6 ) A ctuator spring
Fig. 8-41 Removing Hold-Down Spring and Lever
5. Remove the brake shoes.

( 1 ) Adjuster spring
(2 ) Adjuster
(3) Strut
(4) A nti-ra ttle spring
(5) Brake shoes
Fig. 8 -4 2 Removing Brake Shoes

(1) " U " ring
(2) Lever pin
(3) Brake lever
Fig. 8-43 Removing Parking Lever
- 300 -
8-1 7

(1) " U " ' ring
(3) Rubber packing
Fig. 8-44 Disconnecting Parking Brake Cable

(1) Brake pipe
(2) Backing plate set nuts
(3) Backing plate
Fig. 8 -4 5 Removing Backing Plate

(1) Set bolt
(2) Wheel cylinder
Fig. 8 -4 6 Removing Wheel Cylinder

( 1 ) Dust covers
(2 ) Connecting rods
(3) Pistons
(4) Piston cups
(5) Spring
Caution:
Hydraulic oil is used so do not interm ix the
parts w ith those using brake fluid.
Fig. 8-47 Wheel Cylinder Disassembled
- 301 -
8 -1 8
INSPECTION (2 .0 -2 .5 TON SERIES)
Caution:
Inspect the disassembled parts and repair or
replace any found defective.
1. Wheel cylinder
(1) Rusting, damage, wear in wheel
cylinder bore and pistons
Cylinder to piston clearance stand
ard: 0.065~0.145 mm
(0.0026-0:0057 in.)
Fig. 8 -4 8 Wheel Cylinder Inspection (1)
(2) Wear, damage, deformation in piston
cups
Caution:
A t overhaul, replace the cups w ith new parts
(fo r mineral oil use).

boots
ing rods
(5) Deformation or weakening in spring
Brake drum.
( 1) Eccentric wear, taper, scoring in
brake shoe linings
Inside diameter standard:310 mm
( 1 2 .2 0 in.)
Repair lim it: 312 mm
(12.28 in.)
3. Brake shoes.
(1) Wear, damage, oil adherence on
brake shoe linings
7.0 mm (0.276 in.)
2.0 mm (0.079 in.)
(2) Bending, wear, damage on brake
shoes
- 302 -
8 -1 9
4. Springs.
return springs
in g spring
(3) Deformation or weakening in anti
rattle spring
(4) Deformation or weakening in hold-
down springs Fig. 8-52 Spring Inspection
(5) Deformation or weakening in actu
ator spring
5. Adjusting screw.
(2) Wear, defective rotation in screw
6. Shoe hold-down cups.

7. S trut lever.
(1) Bending, deformation, cracks in
lever
8. Brake, actuator, and pawl levers.

(1) Bending, deformation, cracks in
levers
9. Link.
(1) Stretched or damaged link
Fig. 8 -5 4 Inspection o f Levers and Allied Parts
10. Backing plate.

backing plate
- 303 -
8 -2 0
ASSEMBLY (2 .0 -2 .5 TON SERIES)
Caution:
o Coat the parts w ith hydraulic oil before
assembling.
o Brake fluid (vegetable oil) is not used.
Be careful not to allow interm ixture.

(1) Spring
(2) Piston cups
(3) Pistons
(4) Connecting rods, dust covers Fig. 8-56 Assembling Wheel Cylinder
(5) Breather screw
Fig. 8-57 Installing Wheel Cylinder Assy

(1) Backing plate
(2) Shoe hold pins
(3) Set nuts
T = 7~10.5 kg-m (50.5~75.8 ft-lb)
Fig. 8 -5 8 Installing Backing Plate
5. A pply "N on melt lube" grease.

(2) Anchor pins
- 304 -
8-21

(1) Rubber packing
(3) " U " ring
7. Install the brake lever.

(1) Brake shoe (front)
(2) Brake lever, lever pin, " U " ring
Fig. 8-60 Installing Brake Lever
8. Apply "Non melt lube" grease.

(1) Brake shoe, sleeve (rear)
(2) Actuator lever (at fittin g part)
(3) Adjusting screw threads and washer-

ed part

(1) Parking brake cable (Front end)
(2) Adjusting spring
(3) Adjusting screw
(4) Brake shoes
(5) Cup washer, shoe hold-down, cup
washer
Use SST 09510-10170-71
(Front side 2 places, rear side only
at upper part)
Fig. 8-63 Installing Brake Shoes
- 305 -
8 -2 2
10. Install the actuator lever.

(1) Pawl lever
(2) A ctuator lever, spring
(3) Cup washer, shoe hold-down spring,
cup washer
Use SST 09510-10170-71
(Rear brake shoe lower part only)
(4) A ctuator spring
(5) Strut, strut to shoe spring
Fig. 8 -6 4 Installing Actuator Lever
11. Install the return springs

(1) Rear side return spring
(2 ) Front side return spring
(3) Link

the brake.
Fig. 8 -6 5 Installing Springs
- 306 -
8 -2 3
REMOVAL (2.75,3.0 TON SERIES)

2. Remove the following parts:
(1) Front wheel
(2) Axle shaft
(3) Front axle hub
Use SST 09310-10160-71
Fig. 8-66 Removing Front Axle Hub
3. Remove the adjusting screw.

(3) Adjusting screw
Fig. 8-67 Removing Adjusting Screw
4. Remove the anchor to shoe springs.

(1) Anchor to shoe springs
Use SST 09717-20010
(2) Strut lever, strut to shoe spring
(3) Cable guide
(4) Cable
Fig. 8-68 Removing Anchor to Shoe Spring
5. Remove the hold-down springs.

(1) Hold-down cups
Use SST 09510-31960-71
(2) Hold-down springs 09510-31960-71
Fig. 8-69 Removing Hold-Down Springs
- 307 -
8 -2 4
6. Remove the secondary shoe.

( 1 ) Secondary shoe
Fig. 8-70 Removing Secondary Shoe
7. Remove the strut.

(1) Strut
(2) S trut spring
Fig. 8-71 Removing Strut
8. Remove the primary shoe.

(1) Primary shoe
Fig. 8-72 Removing Primary Shoe

( 1) ''U '' ring
(2) Lever pin
(3) Brake lever
Fig. 8 -7 3 Removing Parking Lever
- 308 -
8 -2 5

(1) Snap ring
Fig. 8-74 Disconnecting Parking Brake Cable

(1) Brake pipe
(2) Backing plate set nuts
(3) Backing plate
Fig. 8-75 Removing Backing Plate

(1) Set bolts
(2) Wheel cylinder

(1) Dust covers
(2) Connecting rods
(3) Pistons
(5) Wheel cylinder spring
Caution:
Hydraulic oil is used. Never confuse with
brake fluid (vegetable o il).
Fig. 8-77 Wheel Cylinder Disassembled
- 309 -
8 -2 6
INSPECTION (2.75,3.0 TON SERIES)
Caution:
Inspect the disassembled parts and repair
or replace any found defective.
1. Wheel cylinder.
(1) Rusting, damage, wear in the wheel
cylinder bore and pistons
Cylinder to piston clearance
standard: 0.054~0.087 mm
(0.00216-0.0034 in.)
(2) Wear or damage in piston cups Fig. 8 -7 8 Wheel Cylinder Inspection (1)
Note:
A t overhaul, replace the cups w ith new parts
(F o r mineral o il).

boots
ing rods
Brake drum.
(1) Eccentric wear, tapering, scoring in
brake drum inside surface.
Inside dimameter standard:
310 mm (12.20 in.)
Wear lim it:
312 mm (12.28 in.)
3. Brake shoe.
(1) Wear, damage, oil adherence on
brake shoe linings
6.3 mm (0.248 in.)
1 .0 mm (0.039 in.)
(2) Bending, wear, damage in brake
shoes
- 310 -
8-2 7
Springs.
return springs
ing spring
Free length: 8 8 mm (3.46 in.)
(3) Deformation or weakening in strut
to shoe springs
(4) Deformation or weakening in hold-
down springs Fig. 8-82 Spring Inspection
Adjusting screw.
(2) Wear,defective rotation in screw
6. Shoe hold-down cups. 9

7. Strut lever.
(1) Bending, deformation, damage in
lever
8. Adjusting parking lever.

(1) Deformation, cracks, wear in lever
9. Cable guide.
(1) Deformation or damage in cable
W I9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 m
guide Fig. 8 -8 4 Adjuster and Backing Parts Inspection
10. Cable link.

(1) Stretching or damage in cable
11. Backing plate.

backing plate
- 311 -
8 -2 8
ASSEMBLY (2.75,3.0 TON SERIES) ja p s

■
Caution:
o Coat the parts w ith hydraulic oil before ' :
■■■K m —- ■■ f —
assembling.
m ■ ■ ■ 'm
o. Brake fluid (vegetable oil) is not used. Be
careful not to allow any contact with iw-V . fW 'm
brake fluid .

m: • #' I f
(1) Spring
(2) Piston cups
(3) Pistons
Fig. 8-86 Assembling Wheel Cylinder
(4) Connecting rods, boots
(5) Breather screw
2. Install the wheel cylinder assy.

(1) Backing plate
(2) Wheel cylinder assy
(3) Set bolts
T = 1 .8 -2 .7 kg-m (1 3 .0 -1 9 .5 ft-lb)
Fig. 8-87 Installing Wheel Cylinder

(1) Backing plate
(2) Shoe hold pins
(3) Set nuts
T - 1 2 -1 4 kg-m (86.6-101.1 ft-lb)
Fig. 8 -8 8 Installing Backing Plate
5. A pply "N on melt Lube" grease.

(2) Anchor pins
312 -
(2) " U " ring
7. Install the parking lever.

(1) Primary shoe
(2) Brake lever
(3) Lever pin
(4) " U " ring
Fig. 8 -9 0 Connecting Parking Brake Cable

(2) Brake shoes
(3) Cup washers and shoe hold-down
springs
(4) Cup washers
Use SST 09510-31960-71
(5) Shoe guide plate
Fig. 8-91 Installing Brake Shoe
9. Install return springs.

(Front side first and then read side) K »18^0«l
Use SST 09718-20010
Fig. 8-92 Installing Shoe Return Spring
10. Install adjusting lever and spring.

(1) Adjusting screw

brake.
Fig. 8-93 Installing Lever and Spring
- 313 -
8 -3 0
AIR REMOVAL (1 .0 -1 .7 5 TON SERIES)
Caution:
o During the bleeding operation, make sure
th at the there is always sufficient brake
fluid in the reservoir.
o The replenishment should be made with
the same brand o f brake fluid . Never use a
container th at has mineral adhered inside.
1. Replenish the brake fluid.
Fig. 8-94 Replenishing Brake Fluid

2. Bleed the air from the wheel cylinders.
3. Bleed the air from the master cylinder.
Caution:
The bleeding operation should be done by
tw o persons, one to pum p the brake pedal
and the other to air removal at the breather
valve.
1) Depress the brake and clutch pedals sev
eral times so as to compress the air in the
piping, and hold this condition.
2) Loosen the breather plug and allow the
air to run out w ith the brake flu id . Close
the valve just before the air stops coming
Fig. 8 -9 5 Bleeding Master Cylinder
Perform this operation alternately by means

o f suitable signals. Keep repeating several
times until no more air bubbles are contained
in the brake fluid .
AIR REMOVAL (2 .0 -3 .0 TON SERIES)
1. Bleed the air from the wheel cylinder.
Essential:
o Perform the bleeding operation w ith tw o
persons.
1) S tart the engine, and w ith the brake pedal
depressed, loosen the breather plug and
allow the hydraulic oil to flo w o u t until
no more air bubbles can be seen. Then
close the breather plug.
Fig. 8-96 Bleeding Wheel Cylinder
314 -
8-31
TEST
Fig. 8-97 Operating Sequence
OPERATIONAL TEST
1. Adjust the brake shoe diameter until it

is 1 mm (0.039 in.) smaller than the brake
drum inside diameter, by turning the
adjusting screw.
1.0~1.75 ton series 2.0~2.5 ton series 2.75, 3.0 ton series
Shoe outside diam. 253 mm (10 in.) 309 mm (12.17 in.) <-
2. Test the adjusting screw action. 3. In case o f malfunction, check on the fo l

(1) Push w ith finger the fittin g cable lowing points:
(1.0~1.75 ton and 2.75, 3.0 ton (1) The adjusting lever should contact
series) and actuator lever (2.0~2.5 on the adjusting screw tooth at right
ton series) toward the rear side shoe angles.
and then release. (2) The adjusting lever should contact on
1) When the above movement is the adjusting screw at a point 5~7 mm
made, the adjusting lever should (0.197~0.276 in.) above its center
mesh into the next notch in the line.
adjusting screw.
2) When returned, the adjusting lever Caution:
should release one notch and If the above position (1) or (2) is defective,
the adjusting lever may operate but it will
return to inital position.
fail to mesh properly so that the adjusting
screw w ill fail to adjust.
- 315 -
8 -3 2
CHECK AND ADJUSTMENT OF

BRAKE EFFECTIVENESS
1. Check.
Check the brake effectiveness w ith brake
tester or by road test.
2. Adjustment.
(1) In case o f insufficient pedal reserve,
proceed as follows.
Advance and reverse several times,
and adjust the brake shoe clearance.
Fig. 8 -9 8 Checking w ith Brake Tester
The adjusting screw makes the ad
justment only when the brake pedal
is depressed while reversing.
(2) When braking force is insufficient,
contact o f linings, foreign matter
adhered on linings, brake fluid
leakage (1.0—1.75 ton series), hy
draulic oil leakage (2 .0 —3.0 ton
series), so remove the brake drum
and check the interior.
(3) If the braking is not uniform at the
le ft and right sides, or if there is
insufficient pedal reserve, the pro
bable causes would be the same as in Fig. 8-99 Checking by Road Test
(2 ) above.
- 316 -
8 -3 3
MASTER CYLINDER (1.0 ~ 1.75 Ton Series)
Fig. 8-100 Master Cylinder Sectional View
COMPONENT PARTS

1. Snap ring 8. Cylinder cup
2. Piston stop plate 9. Compression spring
3. Push rod 10. Push rod clevis
4. Piston cup 11. Boot
5. Piston 12. Gasket
6. Cylinder body 13. Cylinder cap
7. Piston cup spacer
Fig. 8-101 Master Cylinder Component Parts
- 317 -
REMOVAL
Caution:
o T o prevent the brake fluid from flowing
o u t, drain it out from the reservoir tank
and breather plug.
o Use care not to get the brake fluid on
the painted surfaces.
1. Drain out the brake fluid.

(1) Reservoir tank
(2) Breather plug
Fig. 8-1 0 2 Draining O ut Brake Fluid
2. Disconnect the brake lines.
(1) Reservoir pipe
(2) Brake pipe
Fig. 8-103 Disconnecting Brake Line
3. Remove the master cylinder.

(1) Push rod clevis pin.
Fig. 8-1 0 4 Removing Clevis Pin
(2) Master cylinder set bolts
(3) Master cylinder
Fig. 8-1 0 5 Removing Master Cylinder

8 -3 5
REMOVAL
Caution:
Use only brake fluid , (brake fluid 2400G ).
Never allow mineral oil to come in contact.
1. Remove the master cylinder boot.
Fig. 8-106 Removing Master Cylinder Boot
2. Remove the push rod.

(1) Snap ring
(2) Piston stop plate
(3) Push rod
3. Remove the piston.

(1) Piston
(2) Compression sping
Fig. 8-1 08 Removing Piston
4. Remove the cylinder cap.

(1) Cylinder cap
(2) Cylinder cup
(3) Cylinder cup spacer
Fig. 8-109 Removing Cylinder Cap
- 319 -
INSPECTION
Caution:
o Wash the parts in fresh brake fluid and
inspect them on the following points.
Replace any part found defective.
° If cylinder body, piston, or cylinder cap
should be found defective, replace the
entire master cylinder assy.
1. Wear, damage, deterioration in cylinder

cup.
(1) Distortion or clogging in cylinder
Fig. 8-1 1 0 Master Cylinder Inspection
cup spacer
2. Rusting, damage, wear in piston and cyl
inder bore.
(1) Wear, damage, deterioration in piston
cup
3. Damage or clogging in cylinder cap.
4. Weakening or deformation in compres
sion spring.
5. Deformation or damage in push rod.
6. Clogging in breather plug.
Fig. 8-111 Inspecting Piston, Cylinder, etc.
ASSEMBLY
Assemble by performing the disassembly in

reverse order.
Caution:
o Wash the parts and apply brake fluid be
fore assembling,
o Tighten the cylinder cap to the specified
torque.
T = 2 0 ~ 2 8 kg-m (1 4 4 .4 ~ 2 0 2 .2 ft-lb)
o A p p ly rubber grease on the piston cup
before assembling.
Fig. 8-1 12 Installing Cylinder Cap
INSTALLATIO N & ADJUSTMENT
Install by performing the removal in reverse order.

1. Set the master cylinder push rod and clevis.
Dimension A = 105 mm (4.13 in.)
2. Adjust the brake pedal height.
Refer to section on pedal height adjustment
3. Remove the air by bleeding.
Refer to section on fo o t brake air removal.
Fig. 8-113 Brake Pedal Adjustment
- 320 -
8 -3 7
BRAKE VALVE
Accumulator Wheel cylinder Pump

I I I
B8888888
TM M M n
fiîiaâaaaiaiiS
I I
Wheel cylinder Power steering
Power clutch
Fig. 8-114 Brake Valve Sectional View
COMPONENT PARTS
T = 5~ 8
(36.1 ~ 5 7 . 6 ) !
1. Push rod
2. Input piston
3. Retainer spring
4. Brake valve spool
5. Reaction piston guide
6. Reaction piston
7. Closed valve
8. Body
T = 6.9 ~ 11
(49.8 ~ 79.4) Tightening torque unit: kg-m (ft-lb)
Fig. 8-1 15 Brake Valve Component Parts
- 321 -
8 -3 8
TROUBLE SHOOTING
Symptom Possible Cause Remedy
Braking action slow Oil leakage in hydraulic line causing insufficient Repair, replenish
oil in tank. oil.
Insufficient stroke due to loose W nut on in Adjust

put piston.
Adjust stroke with
Input spring weakened or broken. W nut, replace if
broken
Reaction piston " 0 " ring broken. Replace
Clean and cor
Foreign matter lodged in spool. rect.
Excessive play due to loose clevis lock nut. Adjust clevis.
A ir in wheel cylinder passage. Remove air by

bleeding.
Brake drags Spool kept pushed dut to loose piston lock Adjust
nut.
Clean and cor

Foreign matter lodged in spool.
rect.
Braking poor when Oil leakage in hydraulic line causing insufficient Repair, replenish
engine stalls oil in tank. oil.
Insufficient stroke due to loose W nut on in Adjust

put piston.
Adjust stroke with
Input spring weakened or broken. W nut, replace if
broken
Reaction piston " 0 " ring broken. Replace.
Clean and cor

Foreign matter lodged in spool.
rect.
Excessive play dut to loose clevis lock nut. Adjust clevis
Remove air by
A ir in wheel cylinder passage. bleeding.
Oil leakage in accumulator passage (including Repair, replace

check valve).
Oil leakage in accumulator. Repair
Defective seal due to foreign object lodged

between closed valve seat and ball.
Caution:
If any o f the above symptoms develop, do not disassemble the brake valve at once. First check to see if there is
sufficient pressure between the brake valve and wheel cylinder. If insufficient, check the brake valve input
piston stroke and the pump pressure rise. A fte r making sure that the trouble is in the brake valve, then dis
assemble and inspect.
- 322 -
8 -3 9
BRAKE VALVE OPERATIONAL CHECK
(a) Check the brake operating pressure.

1. Mount an oil pressure gage (150
kg/cm2 , 2133 psi) on brake valve
wheel cylinder pressure putlet.
2. With the engine idling, fu lly depress
the brake pedal and check if the
oil gage reading conforms to the
value shown in Table 1.
Fig. 8-116 Checking Hydraulic Pressure
(b) Check the accumulator function.

3. With the engine running at around Pressure Gage
Vehicle
kg/cm 2 (psi)
1 ,0 0 0 rpm, turn the steering to
2 .0 ~ 2 .5 to n series 62 (924)
full lock in both left and right
directions 4 or 5 times, and when the 2.7 5, 3,0 to n series 73 (10 38 )
accumulator is at maximum pressure Std. tem p. 50°C (122°F) .flo w 11,5 fi/m in (3.04 US g a l/m in )
storage, turn o ff the engine.
Table 1. Brake O perating Pressure (Engine id lin g )
A t this condition, fu lly depress the
brake pedal (maximum stroke) and Vehicle Pressure Gage
check if the oil gage reading conforms 2 .0 ~ 2 .5 to n series 35 kg /c m 2 (498 psi) m in im u m
to the value in Table 2. 2.7 5, 3.0 to n series 4 5 kg /cm 2 (640 psi) m in im u m
T able 2 ..Brake F lu id Pressure (Engine Stopped)

4. Bring the accumulator once more to
fu lly pressure stored condition and
then stop the engine. With the engine
stopped, depress the brake pedal to
maximum stroke fo r 5 times. A t the
5th time, check the pressure gage to
see that it reads at least 35 kg/cm 2
(498 psi).
Caution:
Turning the steering wheel so as to build up
maxim um accumulator stored pressure will
require sufficient road resistance. Thus,
with the vehicle unladen, select a road surface
that has ample resistance. Sufficient road Fig. 8-117 Accum ulator Stored Pressure
resistance cannot be obtained if the surface
is w et or sandy.
5. With the acumlator at maximum

stored pressure, stop the engine and
allow to stand fo r 5 minutes. A fte r
5 minutes, depress the brake pedal
to maximum stroke 5 times as in
par. 4 above. A t the 5th stroke,
check pressure gage to see that there
is no change from that in par. 4.
Fig. 8-118 Checking Hydraulic Pressure
- 323 -
8 -4 0
REMOVAL
Caution:
W ith the engine stopped, pump the brake
pedal to full stroke for about 10 times so as
to relieve all pressure in the accumulator
before starting w ork.
1. Disconnect the brake valve piping.
Fig. 8-119 Disconnecting Pipe
2. Remove the brake valve.

(1) Brake valve set bolts
Fig. 8-1 20 Removing Set Bolt
(2) Brake valve
Fig. 8-121 Removing Brake Valve
3. Remove the flo w dividing valve.
Fig. 8-122 Removing Flow Dividing Valve
324 -
8-41
DISASSEMBLY
1. Remove the boot.
Fig. 8-123 Removing Boot
2. Remove the lock nut.
Caution:
Avoid removing unless the piston is to be re
placed. (If removed, stroke adjustment or
pressure adjustment becomes necessary.)
Fig. 8-1 2 4 Removing Lock N ut
3. Remove the input piston.

(1) Snap ring
(2) Plate washer

(3) Input piston
Fig. 8-1 26 Removing Input Piston
- 325 -
8 -4 2
4. Remove the compression spring.
Fig. 8-127 Removing Spring
5. Remove the hole plug.
6. Remove the closed valve.

(1) Closed valve
(2) Valve return spring
7. Remove the brake valve spool.

(1) Reaction piston guide
(2) Reaction piston
(3) Brake valve spool
Fig. 8-1 30 Removing Brake Valve Spool
- 326 -
8 -4 3
INSPECTION
1. Brake valve inspection.
Fig. 8-131 Brake Valve Inspection
2. Valve body.
(1) Spool sliding surface
1) Extreme marring
2) Eccentric wear
3) Rusting
Fig. 8-132 Inspecting Valve Body
3. Closed valve.
(1) Damage or foreign matter lodged in
valve
(2) Damage in " 0 " ring
Fig. 8-1 33 Closed Valve Inspection
Reaction piston guide.

(1) Reaction piston sliding surface
1) Extreme marring
2) Eccentric wear
3) Rusting
(3) Reaction piston f it wear lim it
Wear lim it: 0.16 mm (0.0063 in.
Fig. 8-134 Reaction Piston Guide Inspection
327 -
8 -4 4
5. Brake valve spool, reaction piston.

(1) Spalling or wear in sliding surface
(2) Damage in ring
(3) Wear in fittin g surface
Wear lim it: 0.032 mm (0.00126
in.) (Diameter clearance)
Fig. 8-1 35 Brake Valve Spool Inspection
Input piston.
(1) Wear, damage, deformation in cyl
inder cup
(2) Weakening or deformation in spring
(3) Spool outer diameter sliding sur
face a iJ i£ r!=i
1)
2)
Extreme marring
Eccentric wear
6=----- } n
3) Rusting
(4) Wear in fittin g surface
Wear lim it: 0.16 mm (0.0063
in.) (Diameter clearance)
Fig. 8-1 36 Input Piston Inspection
Springs.
(1) Weakening or deformation in springs
1) No clearance at part a in in
put piston sub-assy spring
(outer diameter side).
2) Compression spring w ithin
spool
Free length: 20 mm
(0.787 in.)
3) Reaction piston return spring
Free length: 20 mm
(0.787 in.)
Fig. 8-1 37 Spring Inspection
- 328 -
8 -4 5
ASSEMBLY
Caution:
o Coat the parts with hydraulic oil before
assembling.
o Apply silicone grease on the cylinder cup
and hydraulic oil on the " 0 " rings and
similar parts.
1. Assemble the reaction piston into the

brake valve.
(1) Brake valve
(2) Reaction piston Fig. 8-138 Assembling Piston (1)
(3) Reaction piston guide
(4) Spring retainer
2. Assemble the piston into the valve body.

(1) Brake valve body
(2) Brake valve, reaction piston, reaction
piston guide
(3) Valve return spring
(4) Closed valve
3. Install the plug hole.
Caution:
Fig. 8-1 3 9 Assembling Piston (2)
Check the piston to see th at it moves smooth
ly.
Fig. 8-1 40 Installing Plug Hole
4. Install the input piston.

(2) Input piston
Fig. 8-141 Installing Input Piston
- 329 -
8 -4 6
5. Install the snap ring.

(1) Plate washer
(2) Snap ring
Fig. 8-1 42 Installing Snap Ring
6. Tighten the hole plug to specified torque.

T = 6.9—11 kg-m (49.8~79.4 ft-lb)
Fig. 8-143 Tightening Hole Plug
Adjust the input piston stroke.

Dimension A: 11±0.3 mm
(0.43±0.0118 in.)
Lock the nuts after adjusting.

T = 5 ~ 8 kg-m (36.1~57.6 ft-lb)
Fig. 8-1 4 4 Adjusting Input Piston Stroke
INSTALLATIO N

A fte r installing, check the brake valve operating
pressure. (Refer to section 8-39 on checking
brake valve operation.)
Adjust the brake operating pressure as follows:
If above specified value, increase dimension A.
If below specified value, decrease dimension A.
Fig. 8-1 4 5 Locking the Nuts
- 330 -
8 -4 7
FLOW DIVIDING VALVE
COMPONENT PARTS
1. Snap ring
2. Hole plug
3. " 0 " ring
4. " 0 " ring
5. Flow dividing valve
6. Flow dividing spool
Fig. 8-147 Flow Dividing Valve Component Parts
- 331 -
8 -4 8 __________________
DISASSEMBLY
1. Remove the snap ring.
2. Remove the hole plug.
Fig. 8-1 49 Removing Hole Plug
3. Remove the flo w divider spool.
M illS
M M l
Fig. 8-1 50 Removing Flow Divider Spool
Disassemble the flo w divider spool.

(1) Remove the snap ring.
- 332 -
8 -4 9
5. Remove the flo w divider orifice.

(1) Flow divider orifice
(2) Steel ball
(3) Flow divider spring
Fig. 8-152 Removing Flow Divider Orifice
INSPECTION
1. Damage in body, mars on sliding surface.

2. Damage on flo w divider spool sliding sur
face. m ttk
3.
4.
Breakage or weakening in spring.
Stepped wear in steel ball.
- a m ■
W Bt
|| |y a ;/ 1 ^
|gP ||
y J P S m
Fig. 8-153 Flow Dividing Valve Inspection
ASSEMBLY
INSTALLATION
1. Apply grease on brake valve joining sur

face " 0 " ring.
Fig. 8-1 54 Applying Grease
2. Tighten the set bolts.
Fig. 8-1 55 Installing Valve
- 333 -
8 -5 0
ACCUMULATOR
/■
-H ----------- -----------( I T
I f i ) ------------- . — — ti
&
y
ft — ••~ - - - - • .... m L------ “—La]i
k.f e - ..... -M y
Fig. 8-1 56 Accum ulator Sectional View
COMPONENT PARTS
Backup ring
" O " ring
Piston
Body cover
Stroke switch rod
"O" ring
" O " ring
Check valve
Body
Fig. 8-1 57 Accum ulator Component Parts
- 334 -
8-51
REMOVAL
Caution:
Before starting to remove the accumulator,
stop the engine and pump the brake pedal 5
to 10 times so as to completely drain out the
hydraulic oil from the accumulator.
1. Disconnect the accumulator pilot light

switch wiring.
2. Disconnect the piping.

(1 ) Accumulator pipe Fig. 8-158 Disconnecting Piping
(2) Accumulator to valve pipe
(3) Low pressure hose
3. Remove the accumulator.

(1) Set bolts
(2) Accumulator
Fig. 8-159 Removing Accumulator
DISASSEMBLY
1. Remove the accumulator pilot switch.

2. Remove the body cover.
Fig. 8-1 6 0 Removing Body Cover
3. Remove the stroke switch rod.
4. Remove the accumulator piston.
Fig. 8-161 Removing Accumulator Piston
- 335 -
8 -5 2
INSPECTION
1. Body and cover.

(1) Damage on piston sliding surface
(2) Spring breakage
(3) Cracks in body
Fig. 8-1 62 Body Inspection
2. Piston.
(1) Damage in piston outer surface
Fig. 8-163 Piston Inspection
ACCUMULATOR OPERATIONAL CHECK
1. Remove the accumulator p ilo t light switch.

2. Remove the accumulator internal pressure.
3. Use vernier caliper and measure the dis
tance from the switch hole to the switch
stroke rod (dimension A).
4. Start the engine, and w ith the engine run
ning at around 1 ,0 0 0 rpm, turn the steering
wheel to the le ft and right lock positions
4 or 5 times so as to have maximum stored
pressure in the accumulator.
5. A t this condition, measure the distance to Fig. 8-1 6 4 Checking Accumulator
the switch stroke rod (dimension B).

Standard stroke (B—A ): 30 mm
(1.18 in.)
6. Also check the brake valve operating pres
sure. (Refer to section 8-39 on checking
brake valve operation.)
Fig. 8-1 6 5 Checking Accumulator
- 336 -
8 -5 3
PARKING BRAKE
COMPONENT PARTS
m Parking brake handle assy

2. Bushing
3. Parking brake lever sub-assy
4. Equalizer bar sub-assy
5. Parking brake wire pulley
6. Parking brake wire set clip
7. Hand brake RH cable sub-assy
8. Hand brake LH cable sub-assy
9. Wire sub-assy
10. Clip
Fig. 8-167 Parking Component Parts
- 337 -
8 -5 4
PARKING BRAKE REMOVAL
1. Remove the parking brake handle.

(1) Clip
Fig. 8-1 68 Removing Clip
(2) Set bolts

(3) Wire
Fig. 8-1 69 Removing Parking Brake Handle
2. Remove the wire sub-assy.

(1) Straight pin
(2) Clip
Fig. 8-1 7 0 Driving O ut Pin
(3) Wire
(4) Parking brake lever
(5) Spring
(6 ) Stopper
Fig. 8-171 Pulling O ut Wire
- 338 -
8 -5 5
3. Disconnect the cables.

(1) Loosen the lock nut.
Fig. 8-172 Loosening Lock N ut
(2) Remove the wire set clamp.
Fig. 8-173 Removing Wire Set Clamp
(3) Disconnect the left and right cables.
Fig. 8-174 Disconnecting Cables
4. Remove the brake lever and wire pulley.

(1) Set bolts
(2) Brake lever, wire pulley
(3) Return spring.
Fig. 8-175 Removing Brake Lever
339 -
8 -5 6
INSPECTION
Caution:
Inspect the parts, and repair or replace any
found defective.
1. Parking brake handle assy.

(1) Damage or deformation in parking
brake lever bracket
(2) Deformation, crack, weakening in
spring
(3) Deformation or wear in stopper
(4 ) Bending or worn groove in parking Fig. 8-176 Handle Assy Inspection
brake lever
2. Wire.
(1) Fracture in wire
(2) Damage in wire end
Fig. 8-177 Inspecting Wire
3. Parking brake lever.

(1) Damage or deformation in parking
brake lever
4. Return spring.
5. Parking brake wire pulley.
(1) Damage or deformation in wire
pulley
eai
to
INSTALLATIO N

Fig. 8-1 7 8 Brake Lever Inspection
Caution:
A p p ly a light coat o f MP grease uniform ally
on the handle sliding surfaces.
ADJUSTMENT
A djust the parking brake handle pull reserve by

means o f the economizer adjusting nut, and lock
securely w ith lock nut.
Pull reserve: 4 to 6 notches
Fig. 8-1 7 9 Adjusting Parking Brake
- 340 -
8 -5 7
BRAKE PEDAL (1.0-1.75 TON SERIES)
1. Reserver tank
2. Pedal bracket
3. Reservoir bracket
4. Reservoir plate
5. Brake pedal
6. Master cylinder
7. Pedal pad
Fig. 8-180 Brake Pedal Component Parts
ADJUSTMENT
1. Brake pedal height and play.

(1) Adjust the pedal stop set bolt and
make pedal height as follows:
Pedal height: 130 mm
(5.12 in.)
(2) Move the master cylinder push rod
up and down by hand to check that
the rod moves freely.
(3) If defective, change the push rod
length so as to obtain free move
ment.
(4) A fte r determining the pedal height,
measure the pedal play.
Pedal play: 4—7 mm
(0.157-0.276 in.)
2. Brake pedal reserve travel.

(1) Measure the distance between brake
pedal lever and protector to check
that its is over 40 mm (1.57 in.).
Fig. 8-182 Adjusting Brake Pedal
- 341 -
8 -5 8
BRAKE PEDAL (2 .0 -3 .0 TON SERIES)
Fig. 8-183 Brake Pedal Component Parts
ADJUSTMENT
1. Brake pedal height and play.

(1) Adjust the pedal stopper to make
the brake pedal height as follows:
Pedal height: 128m m
(5.04 in.)
Fig. 8-1 84 Adjusting Brake Pedal
(2) A djust the brake valve push rod

length so as to obtain brake pedal
play o f 2~3 mm (0.079~0.118
in.) at pedal tip.
The push rod must be in free state.
Fig. 8-1 8 5 Adjusting Brake Pedal
- 342 -
BODY
Page
COMPONENT PARTS 9- 2
ENGINE HOOD REMOVAL & INSTALLATION 9- 3
TOEBOARD REMOVAL & INSTALLATION ..................................... 9- 3
BALANCE WEIGHT REMOVAL & INSTALLATION 9- 3
WIRING D IAG RAM S.................................................................................. 9 - 4
- 343 -
9 -2
COMPONENT PARTS
1. D raw bar 6. Engine hood stay

2. Engine hood 7. Front mud guard
3. Rear toeboard 8. Mud guard
4. Front toeboard 9. Drain plug
5. Instrument panel
Fig. 9-1 Body & Frame Com ponent Parts
- 344 -
9 -3
ENGINE HOOD REMOVAL & IN

STALLATION

(1) Engine hood stay
(2) Radiator cover set bolts
(3) Engine hood (w/driver's seat)
TOEBOARD REMOVAL & INSTAL

LATION
Fig. 9-2 Engine Hood Removal & Installation
Remove the rear toeboard.
( 1 ) Open the engine hood.
(2 ) Rear toeboard
Remove the fro n t toeboard.

( 1) Clutch, brake, and accelerator
links (2~3 ton series)
(2 ) Accelerator pedal bracket set
(2~3 ton series)
(3) Front toeboard set bolts
(4) Front toeboard
- g H ja a h w
■ha..
Fig. 9-3 Removing Front Toeboard
BLANCE WEIGHT REMOVAL &

INSTALLATION
1. Remove the balance weights.

(1) Suspend the balnce weight (just
enough so that rear end stays on
ground)
(2) Weight set bolts
(3) Balance weight (Approximate
weight shown below)
Fig. 9-4 Removing Balance Weight
Vehicle Weight kg (lb) Vehicle Weight kg (lb)
1.0 ton 540 (1191) 2 .0 ton 1260 (2778)

1.35 ton 750 (1654) 2.25 ton 1400 (3087)
1.5 ton 880 (1940) 2.5 ton 1595 (3517)
1.75 ton 1020 (2249) 2.75 ton 1780 (3925)
_____— -— r - ,’j . _____— ' y 3.0 ton 1990 (4388)
- 345 -
9 -4
WIRING DIAGRAM (DIESEL ENGINE VEHICLES)

I
| Flasher Unit
|
Switch
Flasher Lamp
Fig. 9-5 W iring Diagram (Diesel Engine Vehicles)
- 346 -
9 -5
WIRING DIAGRAM (GASOLINE ENGINE VEHICLES)
- 347 -
MATERIAL HANDLING SYSTEM
Page
GENERAL .................................................................................................... 10- 2
MAST .............................................. ............................. .......................... 10- 7
CYLINDER ................................................................................................... 1 0 -2 7
OIL PUMP ............................ 1 0 -4 5
OIL CONTROL V A L V E ............................................................................ 1 0 -5 5
- 349 -
10-2
GENERAL
The material handling system consists o f the following components:

1. Mast.
The construction remains the same as before but inner mast cushion has been provided to reduce
knocking noise.
2. Chains.
Roller chains (1.0~2.0 ton, 2.75 ton, 3.0 ton vehicles)
Leaf chains (2.25 ton and 2.5 ton vehicles)
3. L ift cylinder and t ilt cylinder.
L ift cylinder remains unchanged but the t ilt cylinders have been made shorter and their mounting
positions on the frame located further ahead so as to afford easier access into the vehicle.
4. Oil pump.
New type KRP4 series having 10-tooth gears have been adopted. The oil pump is directly driven
by PTO gear, the same as before.
5. Oil control valve.
The construction remains unchanged but has now been made so that the levers do not pass under
the instrument panel.
6. Oil tank.
23 liters (6.1 US gal) (1.0~1.75 ton series)
28 liters (7.4 US gal) (2.0~3.0 ton series)
- 350 -
10-3
7. Oil filters.
Return oil filte r is the same as before.
Two kinds o f suction oil filters have been adopted.
100 mesh, height 76 mm (2.99 in.) (1.0—1.75 ton series)
100 mesh, height 97 mm (3.82 in.) (2.0~3.0 ton series)
8. Hydraulic oil.
9. Hydraulic piping.
The piping in the 1.0—1.75 ton series remains unchanged, but in the 2.0~3.0 ton series, additional
piping has been provided as shown in the diagram below due to the central hydraulic system re
quired by the adoption o f the power clutch and power brake.
Fig. 10-3 Clutch Hydraulic Piping Diagram
- 351 -
NATURAL DROP TEST
1. With the mast positioned upright under

specified load, raise the fork about 1~
1.5 m (40~60 in.), and stop the engine.
Fig. 10-4 Specified Load Condition
2. Draw reference lines on the inner and outer

mast, and measure the amount o f drop
after 15 minutes.
Vehicle Natural Drop Am ount

1.0 ~ 1 .75 ton series 5 0 ~ 1 6 0 m m (1 .9 7 ~ 6 .3 0 in.)
2.0~2.5 ton series 8 0 ~ 2 4 0 m m (3 .1 5 ~ 9 .4 5 in.)
2.75, 3.0 ton series 5 0 ~ 1 6 0 m m (1 .9 7 ~ 6 .3 0 in.)
Fig. 10-5 Measuring Natural Drop
NATURAL FORWARD T IL T TEST

specified load, raise the fork about 50 cm
(2 0 in.), and stop the engine.
Fig. 10-6 Specified Load Condition
2. A fte r 15 minutes, measure the amount o f

elongation in the t ilt cylinder.
Vehicle Natural T ilt Am ount

mm (in.)
1.0~1.75 ton series 8~30 (0.315-1.18)
2.0~2.5 ton series 1 4 -5 0 (0.55-1.97)
2.75, 3.0 ton series 1 8 -6 0 (0 .71-2.36)
Fig. 10-7 Measuring A m ount o f Natural Forward T ilt
- 352 -
10-5
O IL LEAK TEST
LIFT CYLINDER

specified load, raise the fork about 1~
1.5 m (40~60 in.).
2. Carefully t ilt the fork forward, and stop
the engine. A fte r 5 minutes, disconnect the
oil control valve to oil tank hose connec
tion, and by placing a graduated cylinder
against the elbow, measure the amount of
Fig. 10-8 Specified Load Condition (Forward T ilt)
oil flowing out fo r one minute.
Oil leak standard (at lift port):
6 ~ 16 cc (0.37 ~ 0.98 cu.in.)
Essential:
o Measure at hydraulic oil temperature of
5 0 °~ 6 0 °C (12 2 ° ~ 1 4 0 ° F )
o If natural drop is large even when oil
leak is at specified value, the lift cylinder
packing is defective.
Fig. 10-9 Oil Leak Test (L ift)
T IL T CYLINDER

specified load, raise the fork about 50 cm
(2 0 in.).
2. Stop the engine and after 5 minutes,
disconnect the oil control valve to oil
tank hose connection, and by placing a
graduated cylinder against the elbow,
measure the amount of oil flowing out for
one minute.
Oil leak standard (Total lift & tilt):
1 4 ~ 3 4 cc (0.85~2.08 cu.in.) Fig. 10-10 Specified Load Condition (Neutral)
3. The oil leak (for entire lift part) is the
amount o f leak from the t ilt port.
Essential:
o Measure at hydraulic oil temperature of
5 0 ~ 6 0 °C (122—1 4 0°F ).
o If natural forward tilt is large even when
the oil leak is at specified value, the tilt
lock valve or tilt cylinder packing is
defective.
Fig. 10-11 Oil Leak Test (Total)
- 353 -
10-7
MAST
Page
COMPONENT PARTS ............................................................................... 10- 8
MAST ASSY ................................................................................................ 10-9
LIFT B R A C K E T .......................................................................................... 1 0 -1 5
CHAIN .......................................................................................................... 1 0 -1 6
CHAIN WHEEL ........................................................................................... 1 0 -1 8
F O R K ............................................................................................................. 1 0 -1 9
MAST ADJUSTMENT ....................................................... ........................ 1 0 -2 0
- 355 -
9
1. Backrest
2. Fork stopper 10. Mast strip
3. L ift bracket 11. Shim
4. Fork 12. " O " ring
5. Shim 13. Outer mast
6. L ift roller 14. Mast support metal
7. L ift roller 15. L ift roller
8. Snap ring
Fig. 10-12 Mast Component Parts
- 356 -
10-9
M A S T ASSY
REMOVAL
Caution:
o Before removing the mast, check the operating condition of the various parts and the roller clearances,
and accurately determine the location of trouble,
o In removing the mast assy, the w ork will be made relatively easier if the lift bracket is first removed.
1. Disconnect the chains.

(1) Slacken the chains by operating the
lift and t ilt levers so as to bring the
lift bracket to the maximum lowered
and forward tilted position.
(2) Remove the chain adjusting nuts at
the lift cylinder chain anchor brack
et.
Caution:
When removing the chain adjusting nuts, hold
the chain by hand to prevent the chain from
dropping down by its own weight. Fig. 10-13 Disconnecting Chain
2. Remove the lif t bracket.

(1) With the inner mast positioned up
right, raise it up until it clears the
lift brackt.
(2) Back up the vehicle.
Caution:
Support the lift bracket to prevent toppling
over and carefully back out the vehicle.
Fig. 10-14 Removing L ift Bracket
3. Disconnect the hoses.

(1) Overflow hose (Oil tank end)
(2) High pressure hoses
Fig. 10-15 Disconnecting Hose
- 357 -
1 0 -1 0
4. Pass wire rope around the mast hooks,

and have the mast lifted up slightly.
Fig. 10-16 Mast Suspended
5. Punch match marks on the mast support

caps.
6. Remove the mast support caps.

(1) Set bolts
(2) Mast support cap
Fig. 10-18 Removing Mast Support
7. Remove the t ilt cylinder fro n t pins.

(1) Lock b olt
(2) Front pin
Use SST 09810-20170-71
Fig. 10-19 Removing Front Pin
- 358 -
1 0 -1 1
8. Remove the mast assy.
Fig. 10-20 Removing Mast Assy
9. Lay down the mast.

Rest the outer mast upper and lower tie
beams on wood blocks or stands.
Caution:
It would be extrem ely dangerous to have the
mast standing against a wall. Always have it
resting down on stands.
Fig. 10-21 Mast Resting Method
DISASSEMBLY
1. Remove the spring pins.

( L ift cylinder support guide)
Use SST 09700-30200-71
Fig. 10-22 Removing Spring Pin
2. Remove the stopper bolt.
Fig. 10-23 Removing Stopper Bolt
- 359 -
1 0 -1 2
3. Remove the lif t cylinder.
Caution:
Wrap waste around the lift cylinder to pre
vent marring the painted surface.
Fig. 10-24 Removing L ift Cylinder
4. Remove the inner mast stoppers.

(1) Set bolts
(2 ) Inner mast stoppers
Fig. 10-25 Removing Inner Mast Stopper
5. Remove the lif t rollers.

( 1) Outer mast lif t rollers
(2 ) Shims
(3) Inner mast lif t rollers
(4) Shims
Use SST 09950-20012
Fig. 10-26 Removing L ift Roller
6. Remove the mast strips.

(1) Mast strip
(2 ) " 0 " ring
(3) Shim
Caution:
Replace the mast strips when the oil pockets
are w orn o ff.
Fig. 10-27 Removing Mast Strip
- 360 -
10-13
Fig. 10-28 Removing Inner Mast
Fig. 10-29 Inspecting L ift Roller
(2) L ift roller list.
Places Used Item 1,0~1.75 ton series 2.0~2.5 ton series 2.75, 3.0 ton series
Standard 94.5 (3.72) 109.7 (4.32) 109.7 (4.32)
QE
O E
108.7 (4.28)
C
(A) Lim it 93.5 (3.68) 108.7 (4.28)

L ift bracket
upper & lower Standard 35.0 (1.377) 40.0 (1.57) 40.0 (1.57)
I.D.
mm(in.) Lim it 35.02 (1.379) 40.02 (1.576) 40.02 (1.576)
O.D. Standard 93.3 (3.67) 108.5 (4.27) 108.5 (4.27)

(B) mm(in.) Lim it 92.5 (3.64) 107.5 (4.23) 107.5 (4.23)
L ift bracket
center I.D. Standard 35.0 (1.377) 40.0 (1.57) 65.0 (2.558)
mm(in.) Lim it 35.02(1.379) 40.02 (1.576) 65.02 (2.56)
O.D. Standard 114.5(4.51) 125.5 (4.94) 125.5 (4.94)

(C) mm(in.) Lim it 113.5 (4.47) 124.5 (4.90) 124.5 (4.90)
Inner mast
lower Standard 35.0 (1.377) 40.0 (1.57) 40.0 (1.57)
I.D.
mm(in.) Lim it 35.02 (1.379) 40.02 (1.576) 40.02 (1.576)
Standard 94.5 (3.72) 109.7 (4.32) 109.7 (4.32)
o "E
O E
(D) Lim it 93.5 (3.68) 108.7 (4.28) 108.7 (4.28)

Outer mast
upper I.D. Standard 35.0 (1.377) 40.0 (1.57) 40.0 (1.57)
mm(in.) Lim it 35.02 (1.397) 40.02 (1.576) 40.02 (1.576)
- 361 -
10-14
(3) L ift roller O/S list

O/S lift rollers have been prescribed for (A) and (C) lift rollers.
1) (A) lift bracket upper and lower
1.0 ~ 1.75 ton series 2.0 ~ 2.5 ton series 2.75, 3.0 ton series
STD O.D. std. mm (in.) 94.5 (3.72) 109.7 (4.32) 109.7 (4.32)
M size O.D. std. m m (in.) 95.2 (3.75) 110.4 (4.35) 110.2 (4.34)
Lsize O.D. std. mm (in.) 95.9 (3.78) 111.1 (4.37) 111.1 (4.37)
2) (C) inner mast lower
1.0 ~ 1.75 ton series 2.0 ~ 2 .5 ton series 2.75, 3.0 ton series
STD O.D. std. mm (in.) 114.5 (4.51) 125.5 (4.94)
M size O.D. std. mm(in.) 115.3 (4.54) 126.3 (4.97) #*
2. Outer mast and inner mast.

(1) Warping, bending, spalling
(2) Cracks at welded parts (Visually or
w ith flaw detecting penetrant)
(3) Spreading
3. Mast strips.
(1) Damage, spalling
(2) Wear (Replace when oil pockets
are worn out)
ASSEMBLY
Fig. 10-30 Inspecting Mast Strips
Caution:
o Install the rollers in the mast in sequence w hile making shim adjustments in accordance w ith mast adjust
m ent standards.
o A p p ly MP grease to the mast strip inner mast sliding surfaces.
o A p p ly chassis grease special to the mast support metals and tilt cylinder fro n t pins before installing them .
Assemble by performing the disassembly in

reverse order.
INSTALLATIO N

order.
- 362 -
10-15
L IF T B R A C K E T
REMOVAL
Caution:
The lift bracket alone should be removed
when replacing the lift bracket rollers or
adjusting its shims.
1. Remove the chains.

(1) Slacken the chain by bringing the
mast to its maximum lowered and
forward tilted position. Fig. 10-31 Removing Chains
(2) Remove the chains from the chain
wheels.
2. Remove the lift bracket.

(1) Position the inner mast upright,
and lif t it until its clears the bracket.
(2) Backward the vehicle.
Caution:
Support the lift bracket to prevent it from
toppling over, and carefully back up the
vehicle so as to leave enough working space.
Have the lift bracket supported fo r safety.
DISASSEMBLY
1. Remove the lif t rollers.

(1) L ift rollers
Use SST 09950-20012
(2) Shims
ASSEMBLY AND INSTALLATION
Assemble and install by performing the dis

assembly and removal in reverse order. Fig. 10-33 Removing L ift Roller
- 363 -
1
10-16
C H A IN
REMOVAL
1. Disconnet the chains.

(1) Slacken the chains by operating the
lif t and t ilt levers so as to bring the
lift bracket to its maximum lowered
and forward tilted position.
(2) Remove the chain adjusting nuts at
the lif t cylinder chain anchor brack
et.
Fig. 10-36 Disconnecting Chain
Caution:
When removing the chain adjusting nut, hold
the chain by hand to prevent the chain from
dropping down by its own weight.

(1) Cotter pin
(2) Plate washer
(3) Chain
Fig. 10-38 Removing Chain
INSPECTION
1. Chains.
(1) Strectching, cracking
(2) Damage, bending (anchor bolts)
(3) Link movment
INSTALLATIO N
Installation is the reverse o f removal.
Fig. 10-39 Chain Inspection
- 364 -
10-17
ADJUSTMENT
1. Set the vehicle on level surface, and posi

tion the mast upright.
2. Raise and lower the fork several times

w ithout load and then check left and right
chains to see if they are equally tensioned.
3. Adjust the chains with the chain adjusting

nuts such that the chains w ill not slacken
and that fork underside w ill not contact on
Fig. 10-40 Checking Chain Tension
the ground.
Essential:
h A B
o The clearance between the fo rk underside
mm(in.) mm(in.) mm(in.)
and ground is the distance " h " measured
at the location indicated in Fig. 10-41. 0~5 5 76
1.0 ton V eh icle
o When the fork is fully lowered, the lift (0—0.197) (0.197) (2.99)
bracket rollers should not protrude out
1.35 ~ 1.75 ton 0~10 30 101
from the inner mast more than distance
vehicles (0~0.39) (1.18) (3.98)
"A ".
o When the fo rk is fully raised, the chain 2.0 ~ 2.5 ton 0~10 40 99
anchor on the lift bracket should not vehicles (0~0.39) (1.57) (3.90)
approach the chain wheel closer than 80
2.75, 3.0 ton 0~5 40
distance "B ". vehicles (0—0.197) (1.57) (3.15)
4. Check that the chain tensions are equal at

left and right sides.
5. Check that specified lift can be attained.
- 365 -
10-18
CHAIN WHEEL
REMOVAL

(1) Fork fu lly lowered, mast fu lly tilted
forward.
(2) Chains (chain wheels)
Fig. 10-43 Removing Chains
2. Remove the spring pins.

(1) Raise the chain wheel support.
(2) Spring pin
Use SST 09700-30200-71
Fig. 10-44 Removing Spring Pins
3. Block the inner mast to prevent it from

lowering.
(1) Raise the lif t cylinder about 50 cm
(2 0 in.).
(2) Insert wooden block between inner
mast lower tie beam and upper mast.
Caution:
Raise until the chain wheel support guide
pulls o u t.
A : Wooden block
Fig. 10-45 Blocking
4. Support the lif t cylinder.
5. Lower the lif t cylinder to lowest position,

and turn the chain wheel support 90
degrees.
Fig. 1-46 Chain Wheel Support Rotated
- 366 -
10-19
6. Remove the chain wheels.

(1) Snap ring
(2) Chain wheel
Caution:
If tight fit, use SST 0 9 95 0-20 01 2.
INSPECTION
1. Chain wheels.
(1) Cracks, damage
(2) Poor rotation, noise, looseness in
Fig. 10-47 Removing Chain Wheel
chain wheel bearings
INSTALLATION
ADJUSTMENT
Refer to Chain Adjustment.
FORK
REMOVAL
Fig. 10-48 Inspecting Chain Wheel
1. Raise the fork about 20 cm (7.9 in.)
2. Place a block under the fork rail slot.
3. Move the forks one at a time to the rail
center.
4. Lower the fork and remove.
INSTALLATION
Fig. 10-49 Fork Removal
INSPECTION
Forks.
(1) Bending, cracks
Fork end uneveness lim it:
10 mm (0.39 in.)
Bending lim it:
15 mm (0.59 in.)
Fig. 10-50 Fork Inspection
- 367 -
MAST ADJUSTMENT
LIFT BRACKET LIFT ROLLER ADJUST

MENT
1. Preparations fo r adjustment.
(1) Have available screwdriver, thickness
gage, dial gage, wire rope.
(2) Spread out the forks to maximum,
and slightly t ilt the mast forward.
(3) When adjusting upper rollers, attach
wire rope to the back rest and raise.
When adjusting lower rollers, attach
wire rope to finger bar underside
and raise.
Essential:
Stop raising just before the lift bracket Fig. 10-51 L ift Bracket at Raised Position
upper rollers start to protrude out from the
inner mast.
2. Adjustm ent in fore-and-aft direction.

(1) Insert a screwdriver between the inner mast and finger bar, and press the lift bracket upper
and lower rollers against the inner mast.
(2) Insert thickness gage between the roller and inner mast rolling surface, and measure the
clearance.
Clearance standard: 0.5 ~ 2.0 mm (0.0197 ~ 0.079 in.)
(3) If not w ith in the lim its, replace w ith oversize lif t rollers. For replacement procedure, refer to
“ L ift Bracket" section.
When replacing w ith oversize rollers, do not reduce the clearance to less than 0.5 mm (0.0197
in.).
O/S lif t roller list
1.0 ~ 1.75 ton series 2.0 ~ 2.5 ton series 2.75, 3.0 ton series
STD O.D. std. mm (in.) 94.5 (3.72) 109.7 (4.32) 109.5(4.31)
M size O.D. std. mm (in.) 95.2 (3.75) 110.4 (4.35) —
Lsize O.D. std. mm (in.) 95.9 (3.78) 111.1 (4.37) —
Contact
Fig. 10-52 Standard Clearance Fig. 10-53 Adjusting in Lateral Direction
- 368 -
1 0 -2 1
3. Adjustment in lateral direction.

(1) Mount dial gage on the inner mast.
(2) From the opposite side, press the
inner mast against the bracket with
a screwdriver. Then, contact dial
gage on the lift bracket and set in
dication to 0 .
(3) Insert a screwdriver between the
lift bracket (dial gage side) and inner
mast, and press the lift bracket
center and lower rollers against the
inner mast.
Fig. 10-54 Adjusting in Lateral Direction
(4) Measure the amount o f shift in lat
eral direction at the center o f lower
roller.
Shift standard:0 ~ 0 .8 mm
(0—0.315 in.)
(5) If defective, correct by adjusting
w ith shims, evenly divided between
the left and right sides.
Shim sizes:
.............. Thickness 0.5,1.0 mm
(0.0197, 0.039 in.)
Fig. 10-55 Shim Adjustment
Front
Contact Contact
Contact
0 — 0 .8 mm
~ 0 .0 3 1 5 in.)
I
Fig. 10-56 Input Bracket Roller to Inner Mast Clearance
- 369 -
1 0 -2 2
MAST LIFT ROLLER ADJUSTMENT
1. Preparations fo r adjustment.
(1) Have available screwdriver, dial gage,
and wire rope.
(2) Spread out the forks to maximum
and slightly t ilt the mast forward.
(3) Raise the inner mast fu lly , and stop
the engine.
Essential:
For safety, attach wire rope to inner mast
lower tie beam, and suspend w ith hoist.
2. Adjust the inner mast rollers.

(1) M ount the dial gage on outer mast
inner side.
inner mast roller against the outer Fig. 10-57 Inner Mast Raised
mast w ith a screwdriver. Then

contact the dial gage against the in
ner mast inner side and set it to 0
indication.
inner mast (dial gage side) and
outer mast so as to press the inner
mast rollers against the outer mast.
(4) Measure the amout of lateral shift
in the inner rollers.
S hift standard: 0~0.8 mm
(0~0.0315 in.)
Fig. 10-58 Adjusting Inner Mast Rollers
inner roller shims.
- 370 -
10-23
3. Outer mast roller adjustment.

(1) Mount a dial gage on the outer
mast side.
inner mast against the out mast roller
with a screw driver. Then, contact
the dial gage against the inner mast
inner surface and set its indication to
0.
inner mast (dial gage side) and the
outer mast, and press the inner mast p jg 1 Q ^ 0 Adjusting 0 u ter Mast Roller
against the outer mast rollers.
(4) Measure the amount o f lateral shift
in inner mast.
Shift standard: 0~0.8 mm
(0 -0.0315 in.)
outer mast rollers.
Front
Fig. 10-61 Inner Mast to Outer Mast Roller Clearance
4. Roller and shim adjustment.

(1) Jack up the vehicle fro n t and set
blocks under the tires.
Fig. 10-62 Wood Block Set Under Tire
- 371 -
10-24
(2) Suspend the inner mast.

(3) Remove the inner mast stoppers.
(4) Lower the suspended inner mast.
Essential:
Have the mast positioned at maximum back
ward tilt.
Fig. 10-63 Removing Stoppers
(5) Remove the inner mast rollers.

Use SST 09950-20012
O/S L ift Roller List
1.0—1.75 2 .0 -3 .0
'ton series ton series
STD O.D. std. mm (in.) 114.5 125.5

(4.51) (4.94)
M size O.D. std. mm (in.) 115.3 126.3

(4.54) (4.97)
Fig. 10-64 Removing Inner Mast Roller
(6 ) Select shims fo r inner mast rollers,

and distribute evenly between left
and right sides.
Shim sizes: Thickness 0.5, 1.0 mm
(0.0197,0.039 in.)
Fig. 10-65 Adjusting w ith Shims
(7) Remove the outer mast rollers.

Use SST 09950-20012
om sm m om
Fig. 10-66 Removing O uter Mast Roller
- 372 -
10-25
(8 ) Select shims fo r outer mast rollers

and distribute evenly between left
and right sides.
Shim sizes: Thickness 0.5,1.0 mm
(0.0197, 0.039 in.)
Fig. 10-67 Adjusting w ith Shims
MAST STRIP ADJUSTMENT
1. Preparations fo r Adjustment.
(1) Have thickness gage available.
(2) Have inner mast fu lly raised and fu lly
tilted forward.
2. Adjust clearance between mast strip
(outer mast side) and inner mast.
(1) Measure the clearance between the
mast strip and inner strip w ith thick
ness gage.
Clearance standards:
1 -1 .8 mm (0.039-0.071 in.) Fig. 10-68 Adjusting Mast Strips
(1.0 —1.75 ton Series)

0.5—0.8 mm (0.0079-0.0315 in.)
(2.0—3.0 ton Series)
Note:
Confirm that inner mast is contacting on
outer mast rollers.

w ith shims.
Remove the inner mast stoppers, and
lower the inner mast. Then, remove
the mast strips and adjust w ith shims.
Fig. 10-69 Adjusting with Shims
Shim sizes: Thickness 0 .5,1.0 mm
(0.0197, 0.039 in.)
Fig. 10-70 Mast Strip to Inner Mast Clearance
373 -
10-27
CYLINDERS
Page
LIFT CYLINDER .............................................................................. 10-28
SPECIFICATIONS ..................................................................... 10-28
SERVICE STANDARDS ........................................................... 10-28
COMPONENT PARTS............................................................... 10-29
REMOVAL ............................................................................... 10-30
DISASSEMBLY ..................................................................... 10-32
INSPECTION ............................................................................. 10-33
ASSEMBLY & INSTALLATION.............................................. 10-34
FLOW REGULATOR V A L V E .................................................. 10-35
TILT CYLINDER ............................................................................... 10-37
SPECIFICATIONS..................................................................... 10-37
SERVICE STANDARDS ........................................................... 10-37
COMPONENT PARTS................................................................ 10-38
REMOVAL ............................................................... 10-39
DISASSEMBLY ......................................................................... 10-40
INSPECTION 10-42
ASSEMBLY 8i INSTALLATION.............................................. 10-43
- 375 -
10-28
LIFT CYLINDER
Piston rod guide

Stopper ring
Piston rod L ift cylinder
Dust seal
Wear ring
sf.Wr-'wSSJ
si:
a r \
a — ---- 1 mm. . . ■ . . . J [ f e z g L -
Piston " U " packing Flow regulator

valve
" U " packing
Fig. 10-71 L ift Cylinder Sectional View
SPECIFICATIONS
L ift cylinder type Single action
Piston stroke 1,500mm (59 in.) [L ift height 3,000 mm (118 in.)]
Piston sealing system “ U " packing
Rod sealing system " U " packing
Others W /flow regulator valve
SERVICE STANDARDS
Item Standard Lim it
1 ~ 2.5 ton series 70.00(2.76) 70.35 (2.77)
L ift cylinder bore mm (in.)
2.75, 3 ton series 80.00(3.15) 80.40 (3.17)
1 ~ 2.5 ton series 50.00(1.97) 49.96 (1.970)
Piston rod diameter mm (in.)
2.75, 3 ton series 60.00(2.36) 59.96 (2.360)
Piston rod bending mm (in.) — 2 .0 (0.08)
Piston rod to sleeve clearance mm (in.) 0.1 (0.0039) 0.4 (0.016)
376
10-29
COMPONENT PARTS
(21 1.6 ~ 28 8.8)
1. Chain wheel 10. L ift cylinder spacer 19. Chain wheel support
2. Stopper plate 11. Piston rod 20. Dust sheet
3. Anchor bolt clamp 12. Stopper ring 21. L ift cylinder cover
4. Anchor bolt 13. Wear ring 22. " U " packing
5. Adjusting nut 14. Piston 23. Bushing
6. Chain 15. Back up ring 24. Rod guide
7. Special washer 16. " U " packing 25. L ift cylinder
8. Special washer 17. Back up ring 26. Flow regulator valve
9. Chain eye joint kit 18. Damper
Fig. 10-72 L ift Cylinder Component Parts
- 377 -
10-30
REMOVAL
1. Fully lower the fork and remove the chains

from the chain wheels.
Fig. 10-73 Removing Chain

(1) Raise the inner mast.
(U ntil it pulls out from the inner
bracket)
(2) Slowly back up the vehicle.
(3) Chain adjusting nuts
Note:
When removing the chain adjusting nuts,
remove the paint w ith wire brush.
(4) Backward enough to provide safe

working space. Fig. 10-74 Removing L ift Bracket
3. Disconnect the high and low pressure

hoses.
( 1) Open the engine hood
(2 ) Rear toeboard
(Oil tank end)
(4) High pressure hose
(L ift cylinder end)
Fig. 10-75 Disconnecting High Pressure Hose
4. Attach wire rope on the lif t cylinder

5. Remove the chain wheel support.
(1) Set bolts
(2) Chain wheel support
Fig. 10-76 Removing Chain Wheel Support
- 378 -
10-31
6. Remove the lift cylinder stopper bolt.
Fig. 10-77 Removing Stopper Bolt
7. Take out the lif t cylinder assy.
Caution:
Always rest the lift cylinder on its side.
8. Disconnect the low pressure hose.

(1) Hose Clamp
Fig. 10-78 Removing L ift Cylinder Assy
- 379 -
10-32
DISASSEMBLY
1. Remove the lift cylinder cover.

(1) Cover
Use SST 09620-10160-71
Fig. 10-79 Removing L ift Cylinder Cover
2. Draw out the piston rod.

Use SST 09810-20170-71
Caution: r0.981P?201,70a71
o Use care not to mar the piston rod plated
surface.
o Draw the piston parallel to the cylinder.
Fig. 10-80 Drawing O ut Piston Rod

(1) Snap ring
(2) Piston
(3) Snap ring
(4) Wear ring, " U " packing, back up
ring
Caution:
Remove only when visual inspection of the
piston shows evidence of wear, damage, or
other defect.
4. R em ove the flo w regulator valve. Fig. 10-81 Removing Piston
Caution:
Remove only when the flo w regulator valve or
cylinder is found to be defective.
Fig. 10-82 Removing Flow Regulator Valve
- 380 -
10-33
INSPECTION
Caution:
o Oil leakage develops when the rod guide
" U " packing or dust seal becomes defec
tive.
o Defective " U " packing in piston will be
accompanied by natural drop,
o Wash the parts and replace any found
defective.
L ift cylinder inspection.

(1) Damage or wear in cylinder bore
Cylinder bore wear lim it: Fig. 10-83 L ift Cylinder Inspection
70.35 mm (2.77 in.)
(1—2.5 ton series)
80.40 mm (3.17 in.)
(2.75, 3.0 ton series)
(2) Deformation, damage, rusting in cyl
inder
(3) Excessive dents in cylinder outside
surface
Piston rod inspection.
(1) Damage or wear in piston rod sliding
surface
Piston rod wear lim it:
49.96 mm (1.970 in.) Fig. 10-84 Piston Rod Inspection
(1—2.5 ton series)
59.96 mm (2.360 in.) £ _______
(2.75, 3.0 ton series)
(2) Peeling, damage, rusting in plated
surface L SMI
(3) Bending in piston rod.
Piston rod bending lim it: 2.0 mm
(0.08 in.)
3. Rod guide inspection
(1) Wear or damage in guide sleeve
Rod to sleeve clearance standard:
0.1 mm (0.0039 in.) ■ ■ I ■B B S
Rod to sleeve clearance lim it:

0.4 mm (0.016 in.)
(2) Wear, damage, deterioration in "U "
packing
(3) Wear, damage, deterioration in dust
seal and " 0 " ring
(4) Damage in cylinder cover
Fig. 10-86 Cylinder Cover Inspection
- 381 -
10-34
4. Piston inspection.
( 1 ) Wear or damage in piston
(2 ) Wear or damage in wear ring
(3) Wear, damage, deterioration in "U '
packing
(4) Damage in back up ring
(5) Damage in stop ring
Fig. 10-87 Piston Parts Inspection

ASSEMBLY
Caution:
o Do not assemble the parts in dry condition. Always coat them w ith hydraulic oil before assembling,
o When reassembling, always use new " 0 " rings, " U " packings, and dust seals.
INSTALLATION
Caution:
o Adjust the lift chain tensions equally on left and right sides.
o Raise and lower to full stroke under no load several times to drive out the air and to see if operating prop
erly.
o A fte r confirm ing the operation, check the hydraulic oil w ith oil level gage, and replenish w ith hydraulic
oil # 9 0 if found low .
o Check the lift to see if at specified value.
- 382 -
FLOW REGULATOR VALVE
Fig. 10-88 Flow Regulator Valve Sectional View
Lowering Speed Specifications
Vehicle Unladen Laden Vehicle Unladen Laden

mm/sec (fpm) mm/sec (fpm) mm/sec (fpm) mm/sec (fpm)
1 ton series 550 (108) 420 (82) 2 ton series 550(108) 400 (78)
1.5 ton series 550 (108) 420 (82) 3 ton series 530 (104) 400(78)
REMOVAL
Caution:
o In repairing a faulty flow regulator valve, the disassembly may be made on board the vehicle if it is judged
th at the job can be done properly and w ith o ut d ifficu lty.
1. Spread the forks fu ily apart.
2. Lower the fork to lowest position and t ilt

the mast fu lly backward.
3. Remove the flo w regulator valve.
Fig. 10-89 Removing Flow Regulator Valve
- 383 -
10-36
INSPECTION
1. Damage or pulling out from top cover.

2. Check ball movment, and clogged check
hole.
3. Piston movment.
4. Breakage in return spring.
5. Damage or weakening in " 0 " ring.
INSTALLATION

Fig. 10-90 Flow Regulator Valve Inspection
Flow regulator valve tightening torque.
T = 9.0~10.0 kg-m (65.0~72.2 ft-lb) '
- 384 -
10-37
TILT CYLINDER
Piston
Fig. 10-91 T ilt Cylinder Sectional View
SPECIFICATIONS
T ilt cylinder type Double action
Piston stroke mm (in.) 171 (6.73)
Piston sealing system " U " packing
Rod sealing system ''U '' packing
SERVICE STANDARD
T ilt cylinder bore mm (in.) 70.00 (2.76) 70.35 (2.77)
Piston rod diameter mm (in.) 30.00 (1.18) 29.96 (1.179)
Piston rod bending mm (in.) 1.0 (0.039)
Piston rod to sleeve clearance mm (in.) 0.1 (0.0039) 0.4 (0.016)
- 385 -
10-38
COMPONENT PARTS
Tightening torque unit: kg-m (ft-lb ) 26
1. Grease seal 10 . " U " packing 19. Piston

2. Rod joint 11 . Stopper plate 20. " U " packing
3. T ilt cylinder cover 12. Front pin 21. " U " packing
4. Dust seal 13. Shim 22. Castle nut
5. Rod guide 14. Spacer 23. T ilt cylinder
6. Back up ring 15. " 0 " ring 24. Bushing
7. " 0 " ring 16. Spacer 25. Collar
8. Guide rod sleeve 17. Piston rod 26. Rear Pin
9. Back up ring 18. " 0 " ring
Fig. 10-92 T ilt Cylinder Component Parts
- 386 -
10-39
REMOVAL
Caution:
The " U " packing in the tilt cylinder can be
replaced on board the vehicle w ith o ut remov
ing the tilt cylinder, but the procedures
related below are mainly on disassembly
after removal from the vehicle.
1. Lower the fork to lowest position and t ilt

the mast fu lly forward.
Caution:
Fig. 10-93 Removing Front Pin
To ensure safety, have the mast assy suspend
ed w ith wire rope.
2. Remove the t ilt cylinder front pin.

(1) Set bolt
(2) Front pin
Use SST 09810-20170-71
3. Disconnect the piping.

(1) Rear end high pressure hose
(2) Front end high pressure hose

4. Remove the t ilt cylinder rear pin.
(1) Set bolt
(2) Rear pin
Fig. 10-95 Removing Set Bolt
5. Remove the t ilt cylinder assy.
Fig. 10-96 Removing T ilt Cylinder Assy
- 387 -
10-40
DISASSEMBLY
1. Remove the piston rod joint.

(1) Set bolt
(2) Rod jo in t
Caution:
Record the am ount the jo in t has been screw
ed in.
Fig. 10-97 Removing Rod Joint
2. Wind vinyl tape around the rod threads

and slot.
Fig. 10-98 Winding Vinyl Tape
3. Remove the t ilt cylinder cover.

Use SST 09620-10160-71
SwLt.-
Fig. 10-99 Removing T ilt Cylinder Cover
4. Draw out the piston rod.
Caution:
Draw o u t the piston rod parallel to the
cylinder.
Fig. 10-100 Drawing Out Piston Rod
- 388 -
10-41
5. Remove the rod guide.

(1) Cotter pin, castle nut
(2) Piston
Caution:
o Remove only when the piston or piston
rod is found defective,
o Inspect the " U " packings while still in
the piston, and replace if found defective.
Fig. 10-101 Removing Rod Guide
7. Remove the " U " packings.
Caution:
Wind tape around a spatula, and carefully
remove the " U " packings using care not to
damage them.
Fig. 10-102 Removing " U " Packing
8. Disassemble the piston rod guide.

(1) Snap ring
(2) Stop plate
(3) " U " packings
(4) Back up ring
Caution:
Force out the sleeve w ith a press only if
found defective.
Fig. 10-103 Disassembling Rod Guide
9. Remove the dust seal.

(1) Snap ring
(2) Dust seal
Caution:
Remove and replace with new part only when
oil leakage or other defects develop.
Fgi. 10-104 Removing Dust Seal
- 389 -
10-42
INSPECTION
Caution:
o Oil leakage develops when the " U " pack-
ing or dust seal at the rod guide becomes
defective.
o Defective " U " packings in the cylinder
w ill be accompanied by natural tilt in fo r
ward direction.
o Wash the parts and replace any found
defective or damaged.
T ilt cylinder inspection.

( 1) Damage or wear in cylinder bore
Cylinder bofe wear lim it:
70.35 mm (2.77 in.)
(2 ) Deformation, damage, rusting in
cylinder
(3) Partial dents in cylinder outside
surface
Piston rod inspection.

( 1) Damage or wear in piston rod sliding
surface
(2 ) Peeling, rusting, damage in plated
surface
(3) Bending in piston rod Fig. 10-106 Inspecting Piston Rod
Piston rod bending lim it:
1.0 mm (0.039 in.)
Piston inspection.
( 1 ) Wear or damage in piston
(2 ) Wear, damage, deformation in " U "
packings
Rod guide inspection.

( 1 ) Wear o f damage in guide sleeve
Rod to sleeve clearance standard:
0.1 mm (0.0039 in.)
Rod to sleeve clearance lim it:
0.4 mm (0.016 in.)
( 2 ) Wear, damage, deterioration in " U "
packing
(3) Wear, damage, deterioration in dust
seal, " 0 " ring, back up ring
(4) Damage in rod guide
(5) Damage in cylinder cover
- 390 -
10-43
ASSEMBLY
Caution:
° Avoid assembling the parts in dry condition. Coat them with hydraulic oil before assembling,
o Replace the " U " packings and "0" rings w ith new parts unless they are in good condition or have been in
use fo r short tim e,
o Cylinder cover tightening torque
T = 2 9 ~ 3 5 kg-m (20 9.4 ~ 25 2.7 ft-lb)
o Piston castle nut tightening torque
T = 23 ~ 2 9 kg-m (166.1 - 2 0 9 . 4 ft-lb)
INSTALLATION
Caution:
o When installing the rod jo in t, make sure that the rod join t installed length has been made to the same length
recorded at removal.
o Raise the fo rk about 2 0 0 mm (8 in .), and check and adjust the forward and backward tilt angles,
o Tighten the rod jo in t set bolt to T = 4 — 8 kg-m ( 2 9 — 58 ft-lb ).
o Place match marks on the join t and rod (red paint).
o Slowly tilt the mast forward and backward 2 or 3 times and check the operating condition,
o Check the hydraulic oil level w ith level gauge and replenish if low.
o A pply chassis grease on the insertion part of tilt cylinder fro n t pin.
o A pply MP grease on the insertion part o f tilt cylinder rear pin.
o T ilt fu lly forward and backward, and check fo r mast lameness.
Lameness lim it: 1.5 mm (0.05 9 in.) (A t piston rod)
- 391 -
- 392
• Li n M f i * ■
1 0 -4 5
OIL PUMP
Page
OIL PUMP DRIVE ............................................................................ 10-46
OIL PUMP .......................................................................................... 10-46
SPECIFICATIONS & SERVICE STANDARDS ................................ 10-47
COMPONENT PARTS ....................................................................... 10-47
REMOVAL .......................................................................................... 10-48
DISASSEMBLY .................................................................................. 10-48
INSPECTION ...................................................................................... 10-51
ASSEMBLY ......................................................................................... 10-53
TEST PROCEDURES ......................................................................... 10-54
- 393 -
10-46
OIL PUMP DRIVE
Camshaft
Tim ing adjusting m ark [ P.T.O gear
C ran kshaft pulley
Fig. 10-109 Oil Pump Drive Sectional View
OIL PUMP
Fig. 10-110 Oil Pump Sectional V iew
- 394 -
10-47
SPECIFICATIONS & SERVICE STANDARD
1, 1,5ton series 4P, 5R

2 ton series 1, 1.5ton series 2J
Application 2ton series 5R, 5P, 2J
4P 3t series 5P
3ton series 2J
Oil pump type KRP4-21C KRP4-23C KRP4-27C
Drive system PTO gear drive <-
Discharge £/min -30 0 (1 7 9) 32.8 (18.7) 38.3 (10.1)

(Pump 1500 rmp)(USgal/min) û.u ( l/ . y )
1 : 1.190 . . . Oo c
(1.0-1.75ton series) '•
Speed ratio w ith (4P engine) (5R engine) 1 • 1 ok
engine 1 : 1-087 1 - 1 25 /r-n • X
(2.0-2.5ton series) ',' . , (5P engine)
(4P engine) W e n 9 |n e >
Theoretical suction
2 1 .0 (1.28) 22.9 (1.4) 26.5(1.6)
cc/rev (cu-in/rev)
Body inner surface «- <r-
0.1 mm (0.0039 in.)
scoring depth lim it
Gear shaft dia. lim it 18.935 mm (0.745 in.) «- ■*-
Bushing bore lim it 19.123mm (0.753 in.) <- •<-
Bushing axial length <- <-

26.411mm (1.040 in.)
lim it
COMPONENT PARTS
1. Pump body 7. Oil pump gasket

2. Bushing 8. Oil seal
2 3 4 5 6 7 8 9
3. Bushing seal 9. Snap ring
4. Backing ring RH 10. Pump cover
5. Backing ring LH 11. Body seal
6. Mounting flange 12. Gear set
Fig. 10-111 Oil Pump Component Parts
- 395 -
REMOVAL
1. Drain out the hydraulic oil from hydraulic

oil tank drain.
Hydraulic o il: 23C (6.1 US gal)
(1.0—1.75 ton series)
28£ (10.0 US gal)
(2 .0 —3.0 ton series)
3. Remove the air cleaner. (5P & 2J engines

Fig. 10-112 Engine Hood Removal
only.)
4. Remove the oil pump.

(1) Inlet hose
(2) O utlet pipe pump end set bolts
(3) Oil pump set bolts
(4) Oil pump
Fig. 10-113 Oil Pump Removal
DISASSEMBLY
Caution:
o Perform the w ork in a clean place,
o Use fresh hydraulic oil to wash the parts.
1. Punch match marks on the pump body and

cover.
2. Remove the pump cover.

(1) Set bolts
(2) Pump cover
Fig. 10-115 Removing Pump Cover
- 396 -
10-49
3. Take o ff the seals.

(1) Body seal
(2) Packing rings
(3) Bushing seals
Fig. 10-116 Removing Seals
4. Remove the bushings.
Fig. 10-117 Removing Bushings
5. Remove the pump gears.

(1) Place match marks
(2) Drive gear
(3) Driven gear
Fig. 10-118 Removing Pump Gears
6. Remove the mounting flange.

(1) Turn the oil pump upside down
(2) Mounting flange
Fig. 10-119 Removing Mounting Flange
- 397 -
10-50
7. Take o ff the seals.

(1) Body seal
(2 ) Backing rings
(3) Bushing seals
Fig. 10-120 Removing Seals
8. Remove the bushings.
Fig. 10-121 Removing Bushings
9. Remove the oil seals from the mounting

flange.
(1) Snap ring
(2) Oil seal
Caution:
Remove the oil seal only if found defective.
- 398 -
10-51
INSPECTION
Caution:
Check the degree of dirtying or discoloration
on the disassembled parts, and then wash and
inspect.
1. Body, cover, flange.

( 1] Gear contact abrasion on body
inner surface at suction side
(Normal = Abrasion on about 1/3 of
body inner circumference)
( 2) Damage on joining surfaces of body, Fig. 10-123 Pump Body Inspection
cover, and flange

(3) Damaged threads in mounting parts
(4) Scars in body inner surface
Body inner surface scar depth
lim it: 0.1 mm (0.0039 in.)
2. Bushings.
( 1) Bore sliding surface contacting condi
tion
(Normal = About 1/2 o f suction side
should show shiny contact.)
(2) Scars in bore sliding surface
Bushing bore lim it: 19.123 mm
(0.753 in.)
(3) Side surface contact

(Normal = Contact in which suction
side is rather strong and discharge
side slight.)
(4) Side surface scars
Bushing axial length lim it:
26.411 mm (1.040 in.)
Fig. 10-126 Checking Bushing
- 399 -
10-52
3. Gears.
(1) Cracks in tooth tips, scars in side
surfaces
(2) Damage or deterioration in tooth
faces
(3) Damage in gear shaft
Gear shaft lim it: 18.935 mm
(0.745 in.)
Essential:
Gear replacement must always be done by
set.
Fig. 10-127 Inspecting Gears
4. Seals. H
(1) Frayed or broken packing ring
Caution:
Always use new body seals and bushing seals
at reassembly.
Fig. 10-128 Seal Inspection
(2) Damage or distortion o f lips on oil

seal o f mounting flange
Fig. 10-129 Oil Seal Inspection
- 400 -
10-53
ASSEMBLY
1. Wash the parts and blow dry with com

pressed air.
2. Coat the parts lightly with grease.
(1) Body seals
(2) Bushing seals
(3) Oil seal lip
3. Insert the tw o mounting flange'side bush
ings into the body.
Essential:
o Position such that the dowels are facing
the suction side,
o Have the body interior coated with
hydarulic oil.
o Do not pound in the bushings,
o Make sure th at the bushings are in cor
rect combination,
o Have the bushing joining surfaces proper
ly aligned.
4. Install the drive and driven gears.

(1) Turn the body upside down.
(2) Drive gear and driven gear
Caution:
Position such that the previously meshing
surfaces will again be contacting together.
5. Insert the tw o cover side bushings into the

body.
6. Assemble the seals.
Fig. 10-131 Bolting Down Cover
(1) Bushings seals
(2) Backing rings
(3) Body seals
Caution:
Assemble the backing rings such that they do
not overlap at center.
7. Fit on the mounting flange and pump

cover to the body and tighten down with repeat.
set bolts. 9. Upon completing assembly, fill hydraulic
(1) Mounting flange oil into the oil pump.
(2) Pump cover
(3) Set bolts INSTALLATION
T = 4.7~4.96 kg-m (33.9~35.8 ft-lb)
8. Check the oil pump assembled condition. Perform the removal in reverse order.
(1) Lightly clamp the drive gear shaft in
a vise.
(2) Turn the oil pump.
(3) Pump is satisfactory if it turns light
ly. If heavy to turn, disassemble and
- 401 -
10-54
TEST PROCEDURES
Caution:
T o attain accurate results, a bench test must be performed. As this is not possible under actual service
conditons, the pump is installed on the vehicle, and the oil pump discharge capacity checked to see if satis
factory by raising the lift cylinder.
1. Mount an oil pressure gage (200 kg/cm2) (2844 psi) and engine tachometer.
2. Start the engine.
3. Set the oil control valve lever to neutral position, and run the engine at around 1,500 to 2,000 rpm
fo r 1 0 minutes.
4. If the oil pump shows no unusual condition, run the engine at around 1,500 to 2,000 rpm for
1 0 minutes.
Caution:
If any unusual condition is noted in par. 3 and 4 above, stop the engine at once and disassemble the pump once
more.
5. Check the oil control valve relief set pressure to see if according to specifications. For details, refer
to Oil Control Valve Adjustment.
6. Check the engine speed to see if according to specifications.
For details, refer to Engine Speed Adjustment.
7. Lifting speed list
L ift Speed mm/sec (fpm)

Vehicles Engine Oil Pump
Unladen Laden
4P KRP4-23C 490 (96) 470 (92).
1.0—1.75 ton series 5R KRP4-23C 510 (100) 490 (96)
2J KRP4-27C 520 (102) 500 (98)
4P KRP4-21C 430 (84) 420 (82)
5R KRP4-23C 470 (92) 450 (8 8 )

2.0—2.5 ton series
5P KRP4-23C 440 (8 6 ) 430 (84)
2J KRP4-23C 440 (8 6 ) 430 (84)
5P KRP4-27C 400 (78) 400 (78)

2.75, 3.0 ton series
2J KRP4-23C 400 (78) 400 (78)
- 402 -
10-55
OIL CONTROL VALVE
Page
OIL CONTROL V A L V E .................................................................... 10-56
RELIEF VALVE ............................................................................... 10-56
CHECK V A LV E .................................................................................. 10-57
TILT LOCK VALVE ......................................................................... 10-57
FLOW DIVIDER VALVE .................................................................. 10-57
SPECIFICATIONS.............................................................................. 10-58
COMPONENT PARTS ....................................................................... 10-59
REMOVAL ......................................................................................... 10-60
DISASSEMBLY .................................................................................. 10-61
INSPECTION ....................................................................................... 10-64
ASSEMBLY ........................................................................................ 10-66
ADD-ON PROCEDURE ..................................................................... 10-68
ADJUSTMENT ................................................................................... 10-69
- 403 -
10-56
OIL CONTROL VALVE
T ilt spool T ilt rock valve
L ift spool Check valve
Fig. 10-132 Oil Control Valve Sectional V iew
RELIEF VALVE
Fig. 10-134 Relief Valve Sectional V iew (T ilt)
- 404 -
10-57
CHECK VALVE
Fig. 10-135 Check Valve Sectional View
TILT LOCK VALVE
Fig. 10-136 T ilt Lock Sectional V iew
FLOW DIVIDER VALVE

Pump port
J! £ l l l
Check valve ^ port
Fig. 10-137 Flow Divider Valve Sectional View
- 405 -
10-58
SPECIFICATIONS
1.0 ~ 1.75 ton series 2.0 ~ 3.0 ton series

Type Add on type <-
L ift 140 kg/cm 2 (1991 psi) 185 kg/cm 2 (2631 psi)

Relief set press
T ilt 1 2 0 kg/cm 2 (1706 psi) 150 kg/cm 2 (2133 psi)
With t ilt lock
Others «-
With floating valve
SPRING SPECIFICATIONS
Coil Diameter Free Length Spring Constant

Spring Name
mm (in.) mm (in.) kg/mm
Spool spring 26.0 ( 1 .0 2 ) 37 (1.46) 1.03
Check valve spring 7.2 (0.28) 38 (1.50) 0.072
Relief valve spring 9.5 (0.37) 40(1.57) 0.0335
Relief valve p ilo t spring 6.3 (0.25) 26.5 (1.04) 7.47
T ilt lock valve spring 9.2 (0.36) 39.5 (1.56) 3.35
T ilt lock valve check ball spring 5.7 (0.22) 13 (0.51) 0.0581
Flow divider spring 12.7 (0.5) 103 (4.06) 0.559
- 406 -
10-59
COMPONENT PARTS
1. O utlet housing 15. Spring

2. Steel ball 16. L ift relief valve
3. Spring 17. T ilt relief valve
4. Spring 18. Collar
5. T ilt lock stopper 19. Collar
6. Spring holder 20. O rifice tuning wire
7. Spring 21. Spring
8. Washer plate 22. Check plunger
9. Spring cover 23. Stopper
10 . Plug P T 3 /8 24. Check valve
11. Back up ring 25. Plug P T 1 /4
12. Seal holder 26. Insert seat
13. Stopper 27. Plug P T 1 /4
14. Stopper 28. Valve seat
Fig. 10-138 Oil Control Valve Component Parts
- 407 -
10-60
REMOVAL
1. Remove the toeboards.

( 1 ) Open the engine hood.
(2) Reartoeboard
(3) Front toeboard
2. Disconnect the control levers.

(1) Slip up the boots
(2) Cotter pins
(3) Clevis pins
Fig. 10-140 Disconnecting Control Lever
3. Disconnect the piping fo r material handling

and power steering.
Caution :
Before disconnecting the piping, set the mast
upright and the forks lowered to lowest
position, and relieve all residual pressure in
the material handling system piping.
Fig. 10-141 Disconnecting Wiring

(1) Set bolts
Fig. 142 Removing Control Valve
408 -
10-61
DISASSEMBLY
Caution:
o Perform the w ork in a clean place,
o Parts have all been finished to high pre
cision so use care not to injure them .
1. Remove the seal holders.

(1) Set screws
(2) Seal holder
Fig. 10-143 Removing Seal Holder
2. Remove the spring covers.

(1) Set screws
(2) Spring cover
Fig. 10-144 Removing Spring Cover
3. Take out the lif t and t ilt spools.
4. Disassemble the lift and t ilt spools.

( 1 ) Set the SST.
Use SST 09610-10160-71
(2 ) Snap ring
Fig. 10-145 Removing Spool
(3) Plate washer
(5) Spring holder
(6 ) Seal holder
(7) Back up ring
(8 ) " 0 " ring
Fig. 10-146 Disassembling Spool
- 409 -
10-62
5. Remove the lif t relief valve.

(1) Relief valve
(2) Spring
(3) Collar
(4) Main plunger
Fig. 10-147 Removing L ift Relief Valve
(5) Stopper
Fig. 10-148 Removing Stopper
(6 ) Valve seat
Use SST 09700-30200-71
Fig. 10-149 Removing Valve Seat
6. Remove the t i lt relief valve.

1
Fig. 10-150 Removing T ilt Relief Valve
- 410 -
10-63
7. Use an Allen (hollow) wrench, and dis

assemble the relief valves.
( 1) Lock nut
(2 ) Adjusting nut
(3) Adjusting screw
(4) Stopper
(5) Needle valve
Fig. 10-151 Disassembling Valve
8. Remove the flo w divider valve.

( 1 ) Stopper (upper)
(2 ) Stopper (lower)
(3) Spring
(4) Piston
(5) Check valve
Fig. 10-152 Removing Flow Divider Valve
9. Use an Allen wrench and remove the check

valve.
(1) Plug
(2) Spring
(3) Check plunger
Fig. 10-153 Removing Check Valve
10. Remove the t ilt lock valve from the t ilt

spool.
0 9 7 0 0 -3 0 2 0 0 i
Use SST 09700-30200-71 and vise.
(1) Clamp the spool upper end in the
vise.
(2) Insert the SST through the t ilt lock
stopper and loosen it.
(3) T ilt lock stopper
Fig. 10-154 Removing T ilt Lock Stopper
- 411 -
10-64
(4) Spring
(5) T ilt lock plunger
(6 ) Spring
(7) Steel ball
Fig. 10-155 Disassembling T ilt Lock Valve
11. Remove the outlet housing.

(1) Set bolts
(2) O utlet housing
Fig. 10-156 Removing O utlet Housing
INSPECTION
Caution:
o Thoroughly wash the parts and repair or
replace any found defective,
o Some o f the parts can be disassembed
but are not provided w ith service parts.
In such cases, the replacement must be
made as an assembly.
1. Body and outlet housing.

(1) Sliding damage by spools
(2) Shouldered wear or cracks in check
valve seat Fig. 10-157 Body Inspection
(3) Damages in eblows and caps
2. Spools.
(1) Damage in lif t spool
(2) Damage in t ilt spool
Essential:
Determ ine the spool wear by oil leak test.
Fig. 10-158 Spool Inspection
- 412 -
10-65
3. L ift relief valve.

(1) Shouldered wear in needle valve
(2) Defective contact or damage in
valve seat
(3) Weakening in springs
Fig. 10-159 L ift Relief Valve Inspection
4. T ilt relief valve.

(1) D irt or clogging in filte r cap
(2) Shouldered wear in needle valve
(3) Defective contact or damage in
valve seat
(4) Weakening in springs
A : Filter cap
— be * . 7 " SHB
Fig. 10-160 T ilt Relief Valve Inspection
5. T ilt lock valve.

(1) Sliding condition o f t ilt lock plunger
(2) Breakage or weakening in springs
(3) Shouldered wear in steel ball
Fig. 10-161 T ilt Lock Valve Inspection
6. Flow divider valve.

(1) Piston sliding condition
(2) Damage in check valve
(3) Breakage or weakening in spring
Fig. 10-162 Flow Divider Valve Inspection
- 413 -
1 0 -6 6
7. Check valve.
(1) Shouldered wear in check plunger
(2) Breakage or weakening in spring
Fig. 10-163 Check Valve Inspection
ASSEMBLY
1. Wash the parts and blow dry w ith com

pressed air.
2. Install the outlet housing.
(1) O utlet housing
(2) Set bolts
T = 3.5~4.5 kg-m (2 5 .3-32.5 ft-lb)
Fig. 10-164 Installing O utlet Housing
3. Assemble the t ilt lock valve to t ilt spool.

( 1 ) Steel ball
(2 ) Spring 09700-3020<T7§
(3) T ilt lock plunger
(4) Spring
(5) A pply locking compound on the t ilt
lock stopper and tighten.
Use SST 09700-30200-71
Fig. 10-165 Assembling T ilt Lock Valve
4. Assemble the check valve.

(1) Check plunger
(2) Spring
(3) Plug
Fig. 10-166 Assembling Check Valve
- 414 -
10-67
5. Assemble the flo w divider valve.

( 1 ) Piston
(2 ) Check valve
(3) Spring
(4) Stopper (lower)
(5) Stopper (upper)
Fig. 10-167 Assembling Flow Divider Valve
6. Assemble the relief valve had been dis

assembled, make sure to fu lly return the
adjusting screw.
Essential:
If the relief valve had been disassembled,
make sure to fu lly return the adjusting screw.
(1) T ilt relief valve

(2) L ift relief valve
1) Valve seat
2) Stopper
3) Main plunger Fig. 10-168 Returning Adjusting Screw
4) Collar
5) Spring
6) Relief valve
Fig. 10-169 Assembling Relief Valve
7. Install the lif t and t ilt spools into control

valve.
( 1 ) " 0 " ring, back up ring
(2) Seal holder
(3) Spring holder
(5) Plate washer
(6 ) Snap ring
Use SST 09610-10160-71
Fig. 1 0 -1 7 0 Assembling Springs
- 415 -
1 0 -6 8
(7) L ift spool

(8 ) T ilt spool
8. Install the spring covers.

( 1 ) Spring covers
(2) Set screws
Fig. 10-171 Installing Spring Covers
9. Install the seal holders.

( 1) Seal holders
( 2) Set screws
Fig. 10-172 Installing Seal Holders
ADD-ON PROCEDURES
1. Remove the outlet housing.

2. Add on a three-port valve body assy.
Caution:
A p p ly light coat o f grease to prevent the
" 0 " ring fro m folding or coming o ff.
Fig. 10-173 Adding on Three-Port Valve Body
3. Install the o utle t housing.

(1) O utlet housing
(2) Set bolts
T = 3.5~4.5 kg-m (25.3~32.5 ft-lb)
Fig. 10-174 Installing O utlet Housing
- 416 -
10-69
INSTALLATION
Install by performing the removal in reverse order.
Essential:
o Install the toeboard after finishing the adjustment,
o Apply special chassis grease on the oil control valve lever linkage.
ADJUSTMENT
Caution:
The adjustment must be made in accordance
w ith the following procedures. Any un
warranted adjustment made could result in
faulty pressure, with possible danger of
damaging the oil pump or other hydraulic
equipment.
A: Pressure detecting plug
1. Remove the plug (PT 1/4) from upper part
o f oil control valve, and mount an oil
pressure gage.
Fig. 10-175 Pressure Gage Mounting Location
2. Remove the cap nut from the lif t relief
valve at upper part of oil control valve,
and verify that the relief valve adjusting
screw is fu lly loosened. If not, loosen fu lly.
3. Start the engine and verify that there is
no oil leakage or unusual noise.
4. Set the control lever to lift position, and
screw in the adjusting screw gradually
until the lif t starts to rise. Read the pres
sure gage when the fork reaches its highest
position. Adjust the set screw to obtain
the specified pressure at this point.
Essential: Fig. 10-176 Measuring Hydraulic Pressure

o Confirm that the no-load controlled m ax
imum speed conforms to specified value.
For details, refer to Engine Adjustment,
o if specified pressure is exceeded, return
the control lever to neutral position at
once.
A : Follow wrench
Fig. 10-177 Adjusting Hydraulic Pressure
- 417 -
10-70
5. A fte r completing pressure adjustment, tighten the lock nut and cap nut.
6. Next, remove the cap nut from t ilt relief valve, and check the adjusting screw to see if fu lly loosen
ed, as in par. 2 above.
7. Set the control lever to backward t ilt position and gradually tighten the adjusting nut until the
mast starts to t ilt backward. Read the pressure gage when the mast is fu lly tilted backward. Adjust
the set screw to obtain the specified pressure at this point.
8. A fte r completing pressure adjustment, tighten the lock nut and cap nut.
9. Remove the pressure gage and install the toeboard.
1.0 ~ 1.75 ton series 2.0 ~ 3.0 ton series
L ift relief set pressure kg/cm 2 (psi) 140 (1991) 185 (2631)
T ilt relief set pressure kg/cm 2 (psi) 1 2 0 (1706) 150 (2133)
- 418 -
A PPEN D IX
Page
LIST OF SST 11- 2
1 1
- 419 -
1 1 -2
Fig.
No. S. S. T. Part Number Part Name
1 09010-20110-71 Hanger, engine

i \
2 09010-20120-71 Hook, engine

I? tfi
3 09120-20110-71 Hanger, engine
4 09130-10170-71 Remover & replacer, gear shift lever cap
5 09130-30200-71 Replacer, oil tight transmission case

f S r
SST $ k a 'P i
6 09210-20170-71 Remover & replacer, main drive shaft
Remover & replacer, torque converter

7 09220-20200-71
clutch drum spring
1 ^
Remover & replacer, torque converter

8 09220-30200-71
clutch drum spring
j g al
9 09228-44010 Wrench, oil filte r
10 p—< Nf _ 09230-20150-71 Remover, torque converter drive cover
11 09230-30150-71 Gage, torque converter driver cover

0
12 09310-10160-71 Remover, fro n t axle hub
13 09310-22000-71 Remover, fro n t axle set bolt

|0 ; > !
14 09330-30010 Holding tool, universal jo in t
..
- 420 -
11-3
- 421 -
1 1 -4
Fig.
No. S. S. T. Part Number Part Name
29 Remover & replacer, oil control

09610-10160-71
M s valve spring
30 09610-20011 Puller, pitman arm
31 09611-20014 Puller, pitman arm
32
J 09620-10100-71 Remover, cylinder cap
33 09620-10160-71 Remover & replacer, cylinder cap
34 09620-30010 Repiacer set, steering gear box

^ O S
35 09700-30200-71 Pin tool, spring
36 09717-20010 Remover, brake shoe return spring

s r ®
37 09718-20010 Remover, brake shoe return spring
38 09810-20170-71 Remover, jo in t pin
39 09950-20012 Puller, universal
- 422 -
MOrfARO<T 4 . SO TO M ATOYOT
Prepared by
TOYOTA M OTO R CORPORATION
No. 23-22 Izumi 1-chome, Higashi-ku
Nagoya,Japan
1st Printing: A pril 1980

6th Printing: June 1984
No. 95650-1
Printed in Japan

Toyota Forklift

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TOYOTA FORKLIFT

maintain top operating condition through appropriate maintenance.

ration o f this manual. A ll subsequent m odifications shall be n o tifie d to you

through the Toyota Parts and Service News.

TOYOTA 4P ENGINE REPAIR M A N U A L No. 95649

TOYOTA 5R ENGINE REPAIR M A N U AL No. 95648

TOYOTA 5P ENGINE REPAIR M A N U AL No. 95647

TOYOTA 2J ENGINE REPAIR M N A U AL No. 95646

TOYOTA MOTOR CORPORATION

VEHICLE EXTERIOR VIEWS ............................................ .................. 0- 2

VEHICLE LISTING ............. ................................................................... 0- 3

FRAME NUMBERING SYSTEM .. ............................................... 0- 5

LOADING CURVE ................................................................................... 0- 6

VEHICLE DIMENSIONS ................ ................................................ °“ 7

TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS .. 0- 9

ABBREVIATIONS AND OPERATIONAL TIPS .............................. 0 -1 1

RECOMMENDED LUBRICANT Q UANTITY & KIND .................. 0 -1 2

PERIODIC MAINTENANCE ................................................................. 0 -1 3

LUBRICATION CHARTS .............. ....................................................... 0 -2 1

Fig. 0-2 Rear V iew

Payload Model Engine Type Drive System Remarks

3FG20 11" Clutch (PS) (PB) (P()

Payload Model Engine Type Drive System Remarks

3FD30 11" Clutch

(PB) : Power Brake Standard Equipment

(P£) : Power Clutch Standard Equipment

FRAME NUMBERING SYSTEM

Fig. 0-3 Frame Serial Num ber Location

Fig. 0-4 Frame Serial Num ber

FRAME NUMBERING SYSTEM

4P Engine FG18-20011 3FG25-20011 —

5R Engine 40 FG 18-20011 40 3FG25-20011 —

5P Engine — 60 3FG25-20011 2FG30-20011

2J Engine FD18-20011 3FD25-20011 3FD30-20011

TO 80 90 100 110 120

so 60 70 80 90 100 110 120

1.5 Ton I 1100

80 60 70 80 90 100 110 120 130

t—8 jin l’. |

i 60 70 80 90 100 110 120 130

s= 60 70 80 90 100 110 120 130

Fig. 0-5 Loading Curve Fig. 0-6 Loading Curve

fc 00 — c~- CM LO — — — — LO _ o~- LO — " _

< DC Q LU LL QC X — “ 3 _l z O CL a DC CO 1- 3 > 5 X > N <

TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS

Nominal Specified Torque kg-cm (ft-lb)

6 1.0 47 3.39) 40- 70 2 .9 - 5.1)

8 1.25 111 8.01) 100- 160 7 .2 - 11.6)

10 1.25 225 16.2) 190 ~ 310 1 3 .7 - 22.4)

4T 10 1.5 214 15.5) 180- 300 1 3 .0 - 21.7)

12 1.25 (ISO) 441 31.8) 350 - 550 2 5 .3 - 39.7)

12 1.75 374 27.0) 300 ~ 500 2 1 .7 - 36.1)

14 1.5 633 45.7) 500 - 800 36.1 - 57.6)

14 2.0 593 42.8) 470 — 770 3 3 .9 - 55.6)

16 1.5 957 69.1) 750 ~ 1100 5 4 .2 - 79.4)