1 INDEX

SERVICE SPECIFICATIONS S-1

S-7E-15

CHAPTER S
SERVICE SPECIFICATIONS

REPAIR SPECIFICATIONS ........................................................ S - 2

METRIC INFORMATION ............................................................ S - 43

DECIMAL AND METRIC EQUIVALENTS .................................. S - 44

STANDARD TIGHTENING TORQUE ......................................... S - 45

RECOMMENDED LUBRICANTS ............................................... S - 46

S
 1 page 1
S-2 SERVICE SPECIFICATIONS

REPAIR SPECIFICATIONS
CLUTCH
Models FD, FE and FF
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Clutch facing thickness 10.16 – 7.62 Replace

(0.40) (0.30)

Clutch disc runout 0 - 0.38 – More than Replace

(0 - 0.0149) 0.38 (0.0149)
Clearance between clutch disc and 0.05 - 0.15 – 0.5 Replace
transmission input shaft spline (0.0020 - 0.0059) (0.020)

Pressure plate surface runout 0 - 0.102 – 0.76 Replace

(0 - 0.040) (0.029)

Flywheel face runout – – 0.2 Replace

(0.008)

Flywheel wear 0.05 (0.002) – 1.0 Replace

or less (0.039)

Clutch pedal free play 50 - 65 – 35 Adjust

(1.97 - 2.55) (1.38)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Clutch cover assembly to flywheel fitting bolt 190 - 260 14 - 18
Release fork lock bolt 140 - 180 11 - 13
Clutch housing to transmission case fitting bolt 2,500 - 3,300 181 - 238
 1 page 1
SERVICE SPECIFICATIONS S-3

REPAIR SPECIFICATIONS
CLUTCH
Model SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Rivet head depth 2.75 – 1.6 Replace

(0.1083) (0.063)

Clutch facing thickness 4.75 – 3.6 Replace

(0.1870) (0.142)

Clutch disc runout 0 - 1.2 – More than Replace

(0 - 0.047) 1.2 (0.047)
Clearance between clutch disc and 0.05 - 0.15 – 0.5 Replace
transmission input shaft spline (0.0020 - 0.0059) (0.020)
Free length 88.5 (3.484) – 84.1 (3.311) Replace
Clutch booster

Setting length 59.6 (2.346) – – –

less

Setting load kg (lb) 116.4 (257) – 98.8 (218) Replace

Compression Squareness – – 5.0 (0.197) Replace
spring Free length 92.9 (3.657) – 88.3 (3.476) Replace
With clutch
booster

Setting length 59.6 (2.346) – – –

Setting load kg (lb) 131 (289) – 112.8 (249) Replace
Squareness – – 5.0 (0.197) Replace

Pressure plate surface runout 0 - 0.1 0.5 – Regrind or replace

(0 - 0.003) (0.020)

Pressure plate thickness 23 – 22 Replace

(0.91) (0.87)

Flywheel housing face runout – – 0.2 Replace

(0.008)

Clutch pedal free play 50 - 65 – 35 Adjust

(1.97 - 2.55) (1.38)

Flywheel depth 48 – 49 Replace

(1.89) (1.93)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Strap plate bolt 400 - 500 29 - 36
Clutch cover assembly to flywheel fitting bolt 650 - 870 47 - 62
Release lever support nut lock plate bolt 100 - 150 8 - 10
Release fork lock bolt 140 - 180 11 - 13
*M 16 1,700 - 2,300 123 - 166
SG1J

Clutch housing to *M 20 3,500 - 4,700 254 - 339

transmission case fitting
SG2J

bolt *M 18 2,500 - 3,300 181 - 238

*See "METRIC INFORMATION" in this CHAPTER.

 1 page 1
S-4 SERVICE SPECIFICATIONS

REPAIR SPECIFICATIONS
CLUTCH CONTROL
Models FD, FE, FF and SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method
Clearance between push rod and 0.5 – – Adjust
main cylinder piston (0.020)

Push rod play at pedal top Approx. 3.0 – – Adjust

(0.12)
Clearance between release 2.0 – – Adjust
bearing and release lever (0.08)

Model FD – – 33.0
(1.29)

Models FE and FF – – 15.5

Exposed threaded (0.61) Replace the
length of slave clutch disc
cylinder Model SG1J – – 37.0 assembly
(1.46)

Model SG2J – – 17.5

(0.69)

Models FD, FE and FF 185 - 199 – – –

(7.29 - 7.83)
Pedal height
Model SG 199 - 213 – – –
(7.84 - 8.38)

Models FD, FE and FF 210 - 230 – – –

(8.27 - 9.05)
Pedal stroke
Model SG 230 - 250 – – –
(9.06 - 9.84)

Pedal play 50 - 65 – 35 Adjust

(1.97 - 2.55) (1.38)

Travel of slave cylinder push rod More than 20 – – Re-bleeding

(0.79)

TIGHTENING TORQUE
Tightening Torque kg·cm lb·ft.
Clutch pedal shaft fitting nut 650 - 870 47 - 62
Clutch pedal push rod lock nut 190 - 260 14 - 18
Over center lever fitting bolt and nut (Model SG only) 190 - 260 14 - 18
Hydraulic hose to accumulator 450 - 600 33 - 43
Oil pipe to elbow 330 - 360 24 - 26
Main cylinder bolt 25 - 45 1.9 - 3.2
Main cylinder fitting bolt and nut 650 - 870 47 - 62
Hydraulic line to main cylinder 300 - 360 22 - 26
Slave cylinder fitting bolt 380 - 500 28 - 36
Hydraulic hose to slave cylinder 450 - 600 33 - 43
Hydraulic hose to hydraulic pipe 200 - 300 15 - 21
Slave cylinder push rod lock nut 460 - 610 34 - 44
 1 page 1
SERVICE SPECIFICATIONS S-5

TRANSMISSION
Model FD
LF06 Series
SERVICE STANDARD Unit: mm (in.)
Corrective
Item Assembly standard Service limit
method
Input shaft and counter gear 0.04 - 0.12 (0.0016 - 0.0047) 0.4 (0.016) Replace
Fifth gear and counter gear 0.04 - 0.12 (0.0016 - 0.0047) 0.4 (0.016) Replace
Fourth gear and counter gear 0.04 - 0.12 (0.0016 - 0.0047) 0.4 (0.016) Replace

Gear Third gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
backlash Second gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
First gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Reverse gear and idle gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Reverse idle gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Fifth gear 0.175 - 0.475 (0.0069 - 0.0187) 0.5 (0.020) Replace
Fourth gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Third gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Gear Second gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
end play
First gear and reverse gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Reverse gear 0.20 - 0.35 (0.0079 - 0.0137) 0.5 (0.020) Replace
Reverse idle gear 0.15 - 0.60 (0.0060 - 0.0236) 0.7 (0.028) Replace
Fifth gear 0.019 - 0.064 (0.0008 - 0.0025) – Replace
Fourth gear 0.020 - 0.119 (0.0008 - 0.0046) – Replace

Gear Third gear 0.020 - 0.070 (0.0008 - 0.0027) – Replace

radial play Second gear 0.022 - 0.071 (0.0009 - 0.0027) – Replace
First gear 0.033 - 0.111 (0.0013 - 0.0043) – Replace
Reverse gear 0.033 - 0.111 (0.0013 - 0.0043) – Replace
Side clearance between shift fork and shift sleeve 0.20 - 0.45 (0.0079 - 0.0177) 1.0 (0.039) Replace

Side clearance between 2nd — 4th gear 1.0 - 1.8 (0.040 - 0.070)
0.2 (0.008) Replace
synchronizer ring and cone 5th, 6th gear 1.2 - 2.0 (0.048 - 0.078)
Synchronizer ring contact area 90% or more 90% Replace
Distance from case to counter front bearing 1.5 - 2.0 (0.060 - 0.078) – –
Clutch pedal play 50 - 65 (1.97 - 2.55) 35 (1.38) Adjust
Parking brake lever stroke 3 - 6 clicks 8 clicks Adjust

Oil capacity Approx. 7.0 liters – –

(7.40 USQt./6.16 lmp.Qt.)
 1 page 1
S-6 SERVICE SPECIFICATIONS

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Reverse idle gear shaft lock plate 190 - 260 14 - 18
Front bearing retainer 550 - 700 40 - 50
Rear bearing retainer 550 - 700 40 - 50
Parking brake 900 - 1,200 66 - 86
Universal joint flange coupling 6,000 - 8,000 434 - 578
Gear shift housing 380 - 500 28 - 36
Parking brake drum 650 - 870 47 - 62
Power take-off cover 200 - 300 15 - 21
Clutch housing to transmission case 2,500 - 3,300 181 - 238
Clutch housing to flywheel housing 380 - 500 28 - 36
Link rod end nut 250 - 380 19 - 27
Clutch slave cylinder 380 - 500 28 - 36
Propeller shaft to transmission 650 - 870 47 - 62
Propeller shaft center bearing holder 380 - 500 28 - 36
Inner shift lever set screw 250 - 300 19 - 21
Back-up lamp switch 270 - 320 20 - 23
Speedometer driven gear set screw 83 - 110 6.1 - 7.9
Drain plug 800 - 1,200 58 - 86
Control rod end nut 380 - 500 28 - 36
Shift lever shaft housing 380 - 500 28 - 36
Engine side bracket 380 - 500 28 - 36
Cross shaft
Chassis side bracket 650 - 870 47 - 62
 1 page 1
SERVICE SPECIFICATIONS S-7

TRANSMISSION
Models FE, FF and SG2J
LJ06 Series
SERVICE STANDARD Unit: mm (in.)
Corrective
Item Assembly standard Service limit
method
Input shaft and counter gear 0.04 - 0.12 (0.0016 - 0.0047) 0.4 (0.016) Replace
Sixth gear and counter gear 0.04 - 0.12 (0.0016 - 0.0047) 0.4 (0.016) Replace
Fourth gear and counter gear 0.04 - 0.12 (0.0016 - 0.0047) 0.4 (0.016) Replace

Gear Third gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
backlash Second gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
First gear and counter gear 0.08 - 0.18 (0.0032 - 0.0070) 0.4 (0.016) Replace
Reverse gear and idle gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Reverse idle gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Sixth gear 0.15- 0.50 (0.0060 - 0.0196) 0.5 (0.020) Replace
Fourth gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Third gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Gear Second gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
end play
First gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Reverse gear 0.20 - 0.35 (0.0079 - 0.0137) 0.5 (0.020) Replace
Reverse idle gear 0.15 - 0.60 (0.0060 - 0.0236) 0.7 (0.028) Replace
Sixth gear 0.021 - 0.062 (0.0009 - 0.0024) – Replace
Fourth gear 0.021 - 0.095 (0.0009 - 0.0037) – Replace

Gear Third gear 0.020 - 0.068 (0.0008 - 0.0026) – Replace

radial play Second gear 0.022 - 0.071 (0.0009 - 0.0027) – Replace
First gear 0.033 - 0.111 (0.0013 - 0.0043) – Replace
Reverse gear 0.033 - 0.111 (0.0013 - 0.0043) – Replace
Side clearance between shift fork and shift sleeve 0.20 - 0.45 (0.0079 - 0.0177) 1.0 (0.039) Replace

Side clearance between 2nd, 3rd and 4th gear 1.0 - 1.8 (0.040 - 0.070)
0.2 (0.008) Replace
synchronizer ring and cone 5th and 6th gear 1.2 - 2.0 (0.048 - 0.078)
Synchronizer ring contact area 90% or more 90% Replace
Distance from case to counter rear bearing 1.6 - 2.1 (0.063 - 0.082) – –
Clutch pedal play Models FE and FF 50 - 65 (1.97 - 2.55) 35 (1.38) Adjust
Parking brake lever stroke 3 - 6 clicks 8 clicks Adjust

Oil capacity Approx. 8.0 liters – –

(8.45 USQt./7.04 lmp.Qt.)
 1 page 1
S-8 SERVICE SPECIFICATIONS

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Reverse idle gear shaft lock plate 190 - 260 14 - 18
Front bearing retainer 550 - 700 40 - 50
Rear bearing retainer 650 - 870 47 - 62
Parking brake Models FE and FF 1,100 - 1,500 80 - 108
Universal joint flange coupling 6,000 - 8,000 434 - 578
Gear shift housing 380 - 500 28 - 36
Parking brake drum Models FE and FF 650 - 870 47 - 62
Power take-off cover 200 - 320 15 - 23
Clutch housing to transmission case 2,500 - 3,300 181 - 238
Clutch housing to flywheel housing 380 - 500 28 - 36
Link rod end nut 250 - 380 19 - 27
Clutch slave cylinder 380 - 500 28 - 36

Propeller shaft to Models FE and FF 650 - 870 47 - 62

transmission flange Model SG2J 1,300 - 1,600 95 - 115

Propeller shaft center Models FE and FF 380 - 500 28 - 36

bearing holder Model SG2J 650 - 870 47 - 62
Inner shift lever set screw 250 - 300 19 - 21
Back-up lamp switch 270 - 320 20 - 23
Speedometer driven gear set screw 83 - 110 6.1 - 7.9
Drain plug 800 - 1,200 58 - 86
Control rod end nut 380 - 500 28 - 36
Engine side bracket 380 - 500 28 - 36
Cross shaft
Chassis side bracket 650 - 870 47 - 62
Shift lever shaft housing 380 - 500 28 - 36
 1 page 1
SERVICE SPECIFICATIONS S-9

TRANSMISSION
Model SG1J
MF06 Series
SERVICE STANDARD Unit: mm (in.)
Corrective
Item Assembly standard Service limit
method
Input shaft and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Fifth gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Fourth gear and counter gear 0.05 - 0.13 (0.0020 - 0.0051) 0.4 (0.016) Replace

Gear Third gear and counter gear 0.05 - 0.13 (0.0020 - 0.0051) 0.4 (0.016) Replace
backlash Second gear and counter gear 0.05 - 0.13 (0.0020 - 0.0051) 0.4 (0.016) Replace
First gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Reverse gear and idle gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Reverse idle gear and counter gear 0.08 - 0.16 (0.0032 - 0.0062) 0.4 (0.016) Replace
Fifth gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Fourth gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Third gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Gear Second gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
end play
First gear 0.15 - 0.30 (0.0060 - 0.0118) 0.5 (0.020) Replace
Reverse gear 0.25 - 0.40 (0.01 - 0.0157) 0.5 (0.020) Replace
Reverse idle gear 0.30 - 0.75 (0.0119 - 0.0295) 1.2 (0.047) Replace
Fifth gear 0.010 - 0.058 (0.0004 - 0.0023) – Replace
Fourth gear 0.045 - 0.091 (0.0018 - 0.0035) – Replace
Third gear 0.022 - 0.071 (0.0009 - 0.0027) – Replace
Gear
radial play Second gear 0.022 - 0.071 (0.0009 - 0.0027) – Replace
First gear 0.023 - 0.101 (0.0010 - 0.0040) – Replace
Reverse gear 0.023 - 0.101 (0.0010 - 0.0040) – Replace
Reverse idle gear 0.024 - 0.076 (0.0012 - 0.0119) – Replace
Side clearance between shift fork and shift sleeve 0.20 - 0.45 (0.0079 - 0.0177) 1.0 (0.039) Replace

Side clearance between 2nd gear 1.1 - 2.5 (0.044 - 0.098)

0.2 (0.008) Replace
synchronizer ring and cone Other gear 1.1 - 1.9 (0.044 - 0.074)
Synchronizer ring contact area 90% or more 90% Replace
Distance from case to counter rear bearing 6.5 - 7.0 (0.26 - 0.28) – –
Clutch pedal play 50 - 65 (1.97 - 2.55) 35 (1.38) Adjust

Oil capacity Approx. 11.5 liters – –

(12.22 USQt./10.06 lmp.Qt.)
 1 page 1
S-10 SERVICE SPECIFICATIONS

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Reverse idle shaft seal cover 380 - 500 28 - 36
Front bearing retainer 650 - 870 47 - 62
Rear bearing retainer 750 - 950 55 - 68
Thrust washer to counter shaft 650 - 870 47 - 62
Universal joint flange coupling lock nut 6,000 - 8,000 434 - 578
*M 10 450 - 550 33 - 39
Transmission case cover
*M 14 950 - 1,200 69 - 86
Shift lever shaft housing 380 - 500 28 - 36
Power take-off cover 200 - 250 15 - 18

Clutch housing to transmission *M 20 3,500 - 4,700 254 - 339

case *M 16 1,700 - 2,300 123 - 166
Clutch housing to flywheel housing 380 - 500 28 - 36
Clutch slave cylinder 380 - 500 28 - 36
Propeller shaft to transmission 1,300 - 1,600 95 - 115
Propeller shaft center bearing holder 650 - 870 47 - 62
Back-up lamp switch 350 - 400 26 - 28
Speedometer driven gear set screw 190 - 260 14 - 18
Drain plug 800 - 1,200 58 - 86
Link rod end nut 250 - 380 19 - 27
Inner shift lever set screw 250 - 300 19 - 21

*See "METRIC INFORMATION" in this CHAPTER.

 1 page 1
SERVICE SPECIFICATIONS S-11

TRANSMISSION CONTROL
Models FD, FE, FF and SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

FD, FE and FF 310 - 312 – – Adjust

(12.20 - 12.28)
Length of the link rod “A”
SG 393 - 395 – – Adjust
(15.48 - 15.55)

FD, FE and FF 422 - 424 – – Adjust

(16.61 - 16.69)
Length of the link rod “B”
SG 527 - 529 – – Adjust
(20.75 - 20.82)

Length of the link rod “C” 1,816 - 1,818 – – Adjust

(71.50 - 71.57)

FD 1,660 - 1,662 – – Adjust

(65.36 - 65.43)
Length of the link rod “D”
FE, FF and SG 1,632 - 1,634 – – Adjust
(64.26 - 64.33)

Length of the link rod “E” 324 - 326 – – Adjust

(12.76 - 12.83)

Length of the link rod “F” 319 - 321 – – Adjust

(12.56 - 12.63)

Length of the link rod “G” 230 - 232 – – Adjust

(9.06 - 9.13)

FD and FE 330 - 350 – – Adjust

Shift lever knob position (12.993 - 13.779)
from steering wheel center 390 - 410
FF and SG – – Adjust
(15.354 - 16.141)
267 - 287 – – –
Shift lever knob position from instrument cluster (10.512 - 11.299)
 1 page 1
S-12 SERVICE SPECIFICATIONS

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Link rod lock nut 180 - 270 14 - 19
Control rod lock nut 380 - 500 28 - 36
Floor fitting bolt 190 - 260 14 - 18
Gear shift lever Bracket 250 - 380 19 - 27
Link rod end 250 - 380 19 - 27
Lever Pin 190 - 260 14 - 18
Idler lever Bracket 190 - 260 14 - 18
(Floor of the cab)
Link rod end 380 - 500 28 - 36
Lever Pin 190 - 260 14 - 18
Idler lever Bracket 380 - 500 28 - 36
(No. 1 Crossmember)
Control rod end 380 - 500 19 - 27
Engine side bracket 380 - 500 28 - 36
Chassis side bracket 650 - 870 47 - 62
Cross shaft
Control rod end 380 - 500 28 - 36
Link rod end 180 - 270 14 - 19
Bracket 380 - 500 28 - 36
Lever shaft 250 - 380 19 - 27
Link lever
Control rod end 380 - 500 28 - 36
Link rod end 180 - 270 14 - 19
Bracket 380 - 500 28 - 36
Idler lever Lever shaft 250 - 380 19 - 27
(Transmission)
Link rod end 180 - 270 14 - 19
 1 page 1
SERVICE SPECIFICATIONS S-13

PROPELLER SHAFT
Models FD, FE and FF
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Runout of propeller shaft 0 - 0.6 – 1.0 Correct

(0 - 0.023) (0.039)

At spline 0.062 - 0.174 – 0.25

(0.0025 - 0.0068) (0.0098)
Spline backlash Replace
At sliding yoke lug 0.155 - 0.435 – 0.63
(0.0062 - 0.0171) (0.0248)
FD: 27.55
(1.0846)
Universal joint spider outside diameter – – Replace
FE and FF: 29.13
(1.1468)
Clearance between universal joint spider 0.024 - 0.064 – 0.1 Replace
and needle roller bearing (0.0010 - 0.0025) (0.004)

Universal joint starting torque 15 - 50 kg·cm – – Correct

(14 - 43 lb.in.)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Flange nut 6,000 - 8,000 434 - 578
Center bearing plate bolt 190 - 260 14 - 18
Universal joint yoke to flange bolt 650 - 870 47 - 62
Center bearing holder bolt 380 - 500 28 - 36
 1 page 1
S-14 SERVICE SPECIFICATIONS

PROPELLER SHAFT
Model SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Runout of propeller shaft 0 - 0.5 – 1.0 Correct

(0 - 0.019) (0.039)

At spline 0.062 - 0.174 – 0.3

(0.0025 - 0.0068) (0.012)
Spline backlash Replace
At sliding yoke lug 0.165 - 0.464 – 0.8
(0.0065 - 0.0182) (0.031)

Universal joint spider outside diameter 31.12 – – Replace

(1.2252)
Clearance between universal joint spider 0.020 - 0.054 – 0.1 Replace
and needle roller bearing (0.0008 - 0.0021) (0.004)

Universal joint starting torque 10 - 40 kg·cm – – Correct

(9 - 34 lb.in.)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Universal joint flange nut 8,000 - 10,000 579 - 723
Center bearing plate bolt 190 - 260 14 - 18
Universal joint yoke/universal joint flange bolt 1,300 - 1,600 94 - 115
Center bearing holder bolt 650 - 870 47 - 62
Universal joint bearing cap bolt 260 - 320 19 - 23
 1 page 1
SERVICE SPECIFICATIONS S-15

REAR AXLE
Models FD, FE, FF and SG
SERVICE STANDARD
[For models FD and FE] Unit: mm (in.)
Item Assembly standard Service limit Corrective method

Clearance between spider and pinion 0.141 - 0.181 0.4 Replace pinion and/or spider
(0.0056 - 0.0071) (0.016)

Side gear 1.5 - 1.7 1.3 Replace thrust washer

Thrust washer standard (0.060 - 0.066) (0.051)
thickness 1.45 - 1.75 1.3
Pinion gear Replace thrust washer
(0.057 - 0.068) (0.051)

Backlash between side gear and pinion 0.20 - 0.60 0.90 Replace the pinion and/
(0.0079 - 0.0236) (0.0354) or thrust washer

Ring gear and pinion backlash 0.25 - 0.33 – Adjust

(0.0099 - 0.0129)

[For models FF and SG] Unit: mm (in.)

Item Assembly standard Service limit Corrective method

Clearance between spider and pinion 0.140 - 0.261 0.4 Replace pinion and/or spider
(0.0056 - 0.0102) (0.016)

Side gear 1.9 - 2.1 1.7 Replace thrust washer

Thrust washer standard (0.075 - 0.082) (0.067)
thickness 1.7 - 1.9 1.5
Pinion gear Replace thrust washer
(0.067 - 0.074) (0.059)

Backlash between side gear and pinion 0.20 - 0.60 0.90 Replace the pinion and/
(0.0079 - 0.0236) (0.0354) or thrust washer
0.25-0.33 – Adjust
Gear ratio 4.100, 5.857 (0.0099 - 0.0129)
Ring gear and pinion
backlash 0.30-0.41
Gear ratio 4.625, 5.428 – Adjust
(0.0119 -0.0161)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Hub bolt lock nut 4,000 - 4,800 290 - 347
ABS sencer holder mounting 351 - 527 25 - 38

Hub bearing lock nut 5,000 - 6,000 362 - 433

back off 1/4 - 1/3 turn
Model FD 85 - 110 6.2 - 7.9
Hub bearing lock plate bolt
Models FE, FF, SG 190 - 260 14 - 18
Axle shaft to wheel hub 870 - 1,100 63 - 79
Brake drum set bolt 200 - 400 15 - 28
Models FD, FE 1,700 - 2,200 123 - 159
Differential case
Models FF, SG 2,500 - 3,000 181 - 217
Ring gear to differential case 3,700 - 4,300 268 - 311
Flange yoke coupling 6,000 - 8,000 434 - 578
Pinion cage to differential carrier 1,100 - 1,500 80 - 108
 1 page 1
S-16 SERVICE SPECIFICATIONS

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Cylindrical roller bearing lock plate bolt 190 - 260 14 - 18
Side bearing cap bolt 2,800 - 3,600 203 - 260

Adjusting nut lock plate bolt 190 - 260 14 - 18

Differential carrier to housing 1,100 - 1,500 80 - 108

Propeller shaft to differential Models FD, FE, FF 650 - 870 47 - 62

carrier flange yoke Model SG 1,300 - 1,600 94 - 115
Models FD, FE, FF 1,500 - 2,000 109 - 144
ABS sensor bolt
Model SG 1,700 - 2,300 123 - 166
 1 page 1
SERVICE SPECIFICATIONS S-17

FRONT AXLE
Model FD
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Inside diameter of axle beam 35.0 – 35.1 Replace

(1.378) (1.382)
Outside diameter 35.0 – 34.85 Replace
king pin (1.378) (1.3720)
King pin and bushing
Clearance 0.010 - 0.051 – 0.35 Replace
(0.0004 - 0.0020) (0.0138)

Wheel hub bearing grease (per hub) 350 g – – –

(12 oz)

Turning torque, hub bearing (pre-load) 40 - 60 kg·cm – – –

(2.9 - 4.3 lb·ft.)

Toe-in 0-2 – – Adjust

(0 - 0.08)
Camber 1˚00' – 0˚00' - 2˚00' Replace
Caster 2˚00' – 0˚00' - 4˚00' Correct
King pin inclination 7˚00' – 6˚00' - 8˚00' Replace

Rotating angle of Outside 34˚ 32˚ - 36˚

– Adjust
knuckle Inside 47˚ 44˚ - 48˚

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Wheel hub bolt nut 4,000 - 4,800 290 - 347
U-bolt 2,200 - 2,700 160 - 195
Shock absorber 1,100 - 1,500 80 - 108
King pin lock bolt 380 - 500 28 - 36
King pin cover bolt 190 - 260 14 - 18
Knuckle arm 6,000 - 8,000 434 - 578
Tie-rod arm 6,000 - 8,000 434 - 578
Tie-rod ball stud 1,500 - 2,500 109 - 180
Drag link ball stud 1,500 - 2,500 109 - 180
Drum setting bolt 200 - 400 15 - 28
Tie-rod clamp bolt 650 - 870 47 - 62
ABS sencer holder mounting 351 - 527 26 - 38
 1 page 1
S-18 SERVICE SPECIFICATIONS

FRONT AXLE
Models FE, FF and SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Inside diameter of axle beam 40.0 – 40.1 Replace

(1.575) (1.579)

Outside diameter 40.00 – 39.85 Replace

(1.5748) (1.5689)
King pin and bushing
Clearance 0.010 - 0.048 – 0.35 Replace
(0.0004 - 0.0018) (0.0138)
Wheel hub bearing grease (per hub) 750g (26.5 oz) – – –

Turning torque, hub bearing (pre-load) 50 - 90 kg·cm – – –

(3.5 - 6.3 lb·ft.)
Toe-in 0 - 2 (0 - 0.08) – – Adjust
Camber 1˚00' – 0˚00' - 2˚00' Replace
Caster 2˚00' – 0˚00' - 4˚00' Correct
King pin inclination 7˚00' – 6˚00' - 8˚00' Replace
Model FE with tires Outside 36˚ 34˚ - 38˚ –
of 10R22.5, 11R22.5,
255/70R22.5 Inside 47˚ 44˚ - 48˚ –
Outside 36˚ 34˚ - 38˚ –
Rotating Models FF and SG
angle of 44˚ - 48˚ (FF) Adjust
knuckle with tires of 11R22.5 Inside 47˚ –
(Tire size) 44° - 47°30' (SG)
Outside 34˚ 32˚ - 36˚ –
Models FE, FF and SG
with tires of 39˚ - 43˚ (FE,FF)
295/75R22.5 Inside 42˚ –
39° - 42°30' (SG)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Wheel hub bolt nut 4,000 - 4,800 290 - 347
U-bolt 2,700 - 3,200 196 - 231
Shock absorber 1,200 - 2,000 87 - 144
King pin lock bolt 380 - 500 28 - 36
King pin cover bolt 250 - 350 19 - 25
Brake chamber bracket (Model SG) 1,100 - 1,500 80 - 108
Knuckle arm 7,000 - 12,000 507 - 872
Tie-rod arm 7,000 - 12,000 507 - 872
Tie-rod ball stud 1,500 - 3,500 109 - 253
Drag link ball stud 1,500 - 2,500 109 - 180
Hub bearing nut lock plate bolt 200 - 300 15 - 21
Drum setting bolt 200 - 400 15 - 28
Tie-rod clamp bolt 900 - 1,200 65 - 87
Hub cap bolt 380 - 500 28 - 36
ABS sencer holder mounting 351 - 527 26 - 38
 1 page 1
SERVICE SPECIFICATIONS S-19

STEERING
Models FD, FE, FF, and SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method
Thrust play of steering shaft Within 0.1 – – Adjust by
[30 kg (66.1 lb) of pressure] (0.0039) retainer ring

Steering wheel play 15 - 35 – – –

(0.59 - 1.38)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Steering wheel lock nut 500 - 800 37 - 57
Pitman arm lock nut 3,000 - 4,000 217 - 289
Steering gear box fitting nut 1,500 - 2,300 109 - 166
Worm shaft yoke lock nut 500 - 600 37 - 43
Sliding shaft yoke lock nut 500 - 600 37 - 43
Ball stud nut (Drag link fitting nut) 1,500 - 2,500 109 - 180
Pivot bolt lock nut 150 - 220 11 - 15
Lock bolt (adjusting column) 170 - 225 13 - 16
Adjusting column lever fitting nut 300 - 400 22 - 28
Horn bottom holding screw 15 - 25 1.1 - 1.8
Pipe flare nut 680 - 700 44 - 50
 1 page 1
S-20 SERVICE SPECIFICATIONS

SERVICE BRAKE
Models FD, FE, and FF
Air Over Hydraulic Brake
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Inner diameter of brake drum 320 321 322 Replace

(12.60) (12.64) (12.68)

Runout of brake drum 0 - 0.1 – 0.2 Replace

(0 - 0.004) (0.008)
13.0 4.0
Wheel brake, For Model FD

Lining thickness – Replace

(0.512) (0.157)
cylinder
Wheel

Clearance between 0.03 - 0.13 – 0.25 Replace

cylinder and piston (0.0012 - 0.0051) (0.0098)
Front 179.6 (7.071) – – –
Setting length
return spring

Rear 220.6 (8.685)

Brake shoe

29.7 - 36.3
Front (65.477 - 80.027)
Setting load kg (lb) – – –
36.9 - 45.1
Rear (81.350 - 99.427)

Drum and lining clearance adjustment 0.25 - 0.6 – – –

(0.0099 - 0.0236)
For Models FE and FF

Inner diameter of brake drum 400 402 403 Replace

(15.75) (15.83) (15.86)
Wheel brake,

Runout of brake drum 0 - 0.1 – 0.2 Replace

(0 - 0.004) (0.008)

Lining thickness 15.0 – 5.0 Replace

(0.591) (0.197)
 1 page 1
SERVICE SPECIFICATIONS S-21

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method
Wheel brake, For Models FE and FF

cylinder
Wheel

Clearance between 0.03 - 0.13 – 0.25 Replace

cylinder and piston (0.0012 - 0.0051) (0.098)

228.4
Brake shoe return spring

Front – – –
(8.992)
Setting length
Rear 266.6 – – –
(10.496)

Front 35.1 - 42.9 – – –

(77.382 - 94.577)
Setting load kg (lb)
Rear 47.7 - 58.3 – – –
(105.160 - 128.528)
0.25 - 0.7
Drum and lining clearance adjustment (0.0099 - 0.0275) – – –

Free length 33.5 – –

(1.319)

Main spring outer Setting length 27.2 – – Replace

(1.071)

Setting load kg (lb) 18.5 - 20.5 – –

(40.79 - 45.19)

Free length 28.7 – –

(1.130)
Brake valve, For Models FD and FE

Main spring inner Setting length 27.2 – – Replace

(1.071)

Setting load kg (lb) 8.71 - 10.11 – –

(19.20 - 22.29)

Free length 34.0 – –

(1.339)

Setting length 31.5 – – Replace

(1.240)

Sub spring Setting load kg (lb) 26.4 - 32.2 – –

(58.202 - 70.988)

Stem setting height 40.8 - 41.2 – –

(1.602 – 1.622)
Adjust
Spring tension 0-1 – –
kg (lb) (0 - 2.205)

Free length 86.0 – –

(3.386)
Return spring

Primary piston Setting length 24.0 – – Replace

(0.945)

Setting load kg (lb) 9.0 - 11.0 – –

(19.842 - 24.250)
 1 page 1
S-22 SERVICE SPECIFICATIONS

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method

Free length 29.0 – –

(1.142)
Secondary Setting length 14.5 – – Replace
piston (0.571)

Setting load kg (lb) 1.1 - 1.3 – –

(2.426 - 2.865)

Free length 23.5 – –

Return spring

(0.925)
Primary Setting length 13.0 – – Replace
feed valve (0.512)

Setting load kg (lb) 4.8 - 5.8 – –

(10.583 - 12.786)

Free length 20.5 – –

(0.807)
Secondary Setting length 12.5 – – Replace
Brake valve, For Models FD and FE

feed valve (0.492)

Setting load kg (lb) 3.6 - 4.4 – –

(7.937 - 9.70)

Installation height 194 - 204 – – Adjust

(7.64 - 8.03)

Angle 36° - 40° – – Adjust

Depression angle 20.5° - 24.5° – – Adjust

(Full stroke)

Pedal depression Primary 0.1 - 0.3 – – Adjust

(1.422 - 4.267)
Brake pedal

angle 2.3° - 4.3°

kg/cm2 (lb/sq.in.) Secondary 0 - 0.1 – – Adjust
Discharge pressure

(0 - 1.422)

Pedal depression Primary 1.4 - 2.0 – – Adjust

(19.908 - 28.440)
angle 9° - 12°
kg/cm2 (lb/sq.in.) Secondary 1.3 - 1.9 – – Adjust
(18.486 - 27.018)

Pedal depression Primary 4.1 - 4.9 – – Adjust

(58.302 - 69.678)
angle 14° - 17°
kg/cm2 (lb/sq.in.) Secondary 4.4 - 5.2 – – Adjust
(62.568 - 73.944)

Secondary feed valve movement 0.8 – – Adjust

(0.0315)
 1 page 1
SERVICE SPECIFICATIONS S-23

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method

Free length 30.5 – –

(1.201)

Main spring Setting length 27.7 – – Replace

(1.091)

Setting load kg (lb) 21.8 - 24.1 – –

(48.10 - 53.13)

Free length 34.0 – –

(1.339)

Setting length 31.5 – – Replace

(1.240)

Sub spring Setting load kg (lb) 26.4 - 32.2 – –

(58.202 - 70.988)

Stem Setting height 40.2 - 40.6 – –

(1.583 - 1.598)
Adjust
Spring tension kg (lb) 0-1 – –
(0 - 2.205)
Brake valve, For Model FF

Free length 108.0 – –

(4.252)
Primary Setting length 24.0 – – Replace
piston (0.945)

Setting load kg (lb) 12.5 - 14.5 – –

(27.558 - 31.966)

Free length 29 – –
(1.142)
Secondary Setting length 14.5 – – Replace
piston (0.571)
Return spring

Setting load kg (lb) 1.1 - 1.3 – –

(2.426 - 2.865)

Free length 23.5 – –

(0.925)
Primary Setting length 13.0 – – Replace
feed valve (0.512)

Setting load kg (lb) 4.8 - 5.8 – –

(10.583 - 12.786)

Free length 20.5 – –

(0.807)
Secondary Setting length 12.5 – – Replace
feed valve (0.492)

Setting load kg (lb) 3.6 - 4.4 – –

(7.937 - 9.70)
 1 page 1
S-24 SERVICE SPECIFICATIONS

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method

Installation height 44 - 50 – – Adjust

(1.74 - 1.96)

Installation angle 18° - 20° – – Adjust

Depression angle 12.1° - 16.1° – – Adjust

(Full stroke)

Pedal lever rod length 147 - 149 – – Adjust

Brake valve, For Model FF

(5.79 - 5.86)
Pedal lever

Primary 0.1 - 0.3 – – Adjust

Lever depression (1.422 - 4.267)
angle 1.1° - 3.1°
kg/cm2 (lb/sq.in.) Secondary 0 - 0.1 – – Adjust
(0 - 1.422)
Discharge pressure

Primary 1.5 - 2.1 – – Adjust

Lever depression (21.330 - 29.862)
angle 5.8° - 8.5°
kg/cm2 (lb/sq.in.) Secondary 1.4 - 2.0 – – Adjust
(19.908 - 28.440)

Primary 4.2 - 5.0 – – Adjust

Lever depression (59.724 - 71.100)
angle 8.8° - 11.8°
kg/cm2 (lb/sq.in.) Secondary 4.4 - 5.2 – – Adjust
(62.568 - 73.944)

Secondary feed valve movement 0.8 – – Adjust

(0.0315)
Brake air booster (Rear) Brake air booster (Front)

Clearance between hydraulic piston 0.07 - 0.14 – 0.16

and cylinder (0.0028 - 0.0055) (0.0062)

Free length 161 – 154

(6.34) (6.06)
Replace
Compression Setting length 132 – –
spring (5.20)

Setting load kg (lb) 8 – 6

(17.633) (13.226)

Free length 168.9 – 161

(6.65) (6.34)
Compression Setting length 107.4 – –
spring (4.23) Replace

Setting load kg (lb) 7.2 - 8.4 – 6.8

(15.874 - 18.518) (14.991)

Free length 41.0 – –

(1.614)
Compression spring Setting length 35.9 – – Replace
(Piston) (1.413)
Pressure regulator

Setting load kg (lb) 31.6 - 49.0 – –

(69.67 - 108.03)

Free length 26.0 – –

(1.024)
Compression spring Setting length 17.4 – – Replace
(Push rod) (0.685)

Setting load kg (lb) 0.7 - 0.9 – –

(1.55 - 1.98)
 1 page 1
SERVICE SPECIFICATIONS S-25

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method

Free length 34.0 – –

(1.339)
Safety valve

Valve spring Setting length 24.0 – – Replace

(0.945)

Setting load kg (lb) 5.6 - 6.2 – –

(12.346 - 13.668)

Free length 17.6 – 16.5

(0.693) (0.649)
Check valve

Valve spring Setting length 15.4 – – Replace

(0.606)

Setting load kg (lb) 0.08 – –

(0.176)
60.0
Protection valve

Free length – –
(2.362)

Valve spring Setting length 49.0 – – Replace

(1.929)

Setting load kg (lb) 11.1 - 13.5 – –

(24.472 - 29.762)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Bleeder screw 70 - 120 5.1 - 8.6
ø8mm(0.315in) 170 - 250 13 - 18
Wheel cylinder assembly ø10mm(0.394in) 380 - 500 28 - 36
Wheel cylinder ø12mm(0.472in) 600 - 880 44 - 63
For Model FD ø14mm(0.551in) 1,500 - 2,000 109 - 144
Hose (front) 450 - 600 33 - 43

Oil pipe ø4.76mm(0.187in) 130 - 180 9.4 - 13.0

ø6.35mm(0.25in) 200 - 220 14.5 - 15.9
Cylinder cover 180 - 270 13.1 - 19.5
Bleeder screw 70 - 120 5.1 - 8.6
Wheel cylinder Wheel cylinder assembly ø10mm(0.394in) 380 - 500 28 - 36
For Models ø14mm(0.551in) 1,250 - 1,700 91 - 122
FE and FF
Hose (front) 450 - 600 33 - 43

Oil pipe ø4.76mm(0.187in) 130 - 180 9.4 - 13.0

ø6.35mm(0.25in) 200 - 220 14.5 - 15.9
Drum set bolt 200 - 400 15 - 28
Install the wheels 4,000 - 4,800 290 - 347
 1 page 1
S-26 SERVICE SPECIFICATIONS

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Secondary valve body 60 - 75 4.4 - 5.4
Piston spring setting bolt 30 - 50 2.2 - 3.6
Brake valve
(Models FD Pedal assembly to valve body 100 - 200 8 - 14
and FE)
Pedal assembly to floor 380 - 500 28 - 36
Adjusting bolt lock nut 30 - 50 2.2 - 3.6
Secondary valve body 60 - 75 4.4 - 5.4
Piston spring setting bolt 30 - 50 2.2 - 3.6

Brake valve Valve cover to valve body 100 - 200 8 - 14

(Model FF) Valve cover to bracket 380 - 500 28 - 36
Pedal assembly to floor 380 - 500 28 - 36
Adjusting bolt lock nut 30 - 50 2.2 - 3.6
Hydraulic cylinder to end plate 200 - 300 15 - 21
Warning switch 80 - 120 5.8 - 8.6
Power piston lock nut 200 - 300 15 - 21
(Front)
Power piston shell lock nut 110 - 160 8 - 11
Brake
air booster Air bleeder screw 70 - 130 5.1 - 9.3
Brake air booster to bracket 190 - 260 14 - 18
Oil pipe 200 - 220 14.5 - 15.9
Air pipe 400 - 500 29 - 36
Warning switch 80 - 120 6-9
End cap 700 - 800 51 - 57
Air bleeder screw 70 - 120 5.1 - 8.6
Power piston lock nut 200 - 300 15 - 21
Power piston shell lock nut 180 - 270 13.1 - 19.5
(Rear)
Brake Housing to power cylinder shell 70 - 120 5.1 - 8.6
air booster Return valve assembly to power
control valve 30 - 60 2.2 - 4.3
with ABS
control valve
Power control valve to bracket 30 - 60 2.2 - 4.3
Brake air booster to bracket 67.5 - 100.5 4.9 - 7.2
Oil pipe 200 - 220 14.5 - 15.9
Air pipe 400 - 500 29 - 36
Bracket to frame 617 - 935 45 - 67
 1 page 1
SERVICE SPECIFICATIONS S-27

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Filter 5 - 10 0.36 - 0.72

Pressure Regulator installing bolt 190 - 260 14 - 18

regulator Adjusting screw lock nut 24 - 36 1.8 - 2.6
Air pipe 200 - 220 14.5 - 15.9
Adjusting screw lock nut 200 - 300 15 - 21
Safety valve
Safety valve install 350 - 400 26 - 28
Body cap 450 - 550 33 - 39
Check valve Air pipe 10.0 (0.394) 400 - 500 29 - 36
Pipe dia. mm (in.) 12.0 (0.472) 600 - 700 44 - 50

Protection Body cap 400 - 500 29 - 36

valve Adjusting screw lock nut 150 - 250 11 - 18

Quick release Cover to body 50 - 60 3.7 - 4.3

valve Valve assembly to bracket 190 - 260 14 - 18
*M8 190 - 260 14 - 18
ABS sensor holder fitting nut
Wheel brake *M10 380 - 500 28 - 36
ABS sensor holder fitting bolt 351 - 527 25 - 38
*See "METRIC INFORMATION" in this CHAPTER.
 1 page 1
S-28 SERVICE SPECIFICATIONS

SERVICE BRAKE
Model SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Front 34 - 41 – –
(1.34 - 1.61)
Brake chamber rod stroke Adjust
Rear 39 - 45 – –
(1.54 - 1.77)

Runout of brake drum 0 - 0.1 0.2 – Regrind

(0 - 0.003) (0.008)

Inner diameter of brake drum 406.4 409.4 410.4 Replace

(16.00) (16.118) (16.157)

Lining thickness 15.5 – 5.5 Replace

(0.610) (0.217)
Clearance between anchor pin and 0.02 - 0.07 – 0.25 Replace pin
brake shoe bushing (0.0008 - 0.0027) (0.0098) and/or bushing

Front 228.0 – – –
(8.98)
Brake shoe return spring

Setting length Outer 272.0 – – –

(10.71)
Rear
Inner 275.5 – – –
(10.85)
Wheel brake

Front 54.0 - 66.0 – – –

(119.05 - 145.50)

Setting length kg (lb) Outer 31.0 - 35.0 – – –

(68.35 - 77.16)
Rear
Inner 47.0 - 57.0 – – –
(103.62 - 125.66)

Front 38.0 – 37.7

(1.496) (1.484)
Camshaft diameter Replace
Rear 39.8 – 39.5
(1.567) (1.555)

Front 0.03 - 0.10 – 0.6

Clearance between (0.0012 - 0.0039) (0.0236)
camshaft and spider Replace bushing
bushing Rear 0.23 - 0.30 – 0.6
(0.0091 - 0.0118) (0.0236)
Clearance between camshaft Rear 0.23 – 0.30 – 0.6 Replace bushing
and camshaft bracket bushing (0.0091 - 0.0118) (0.0236)
 1 page 1
SERVICE SPECIFICATIONS S-29

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method
Slack adjuster

Axial play 1.5 – 3.0 Replace worm

(0.059) (0.118) gear or camshaft

Circumference play 3.0 – 10.0 Replace worm

(0.118) (0.393) gear or camshaft
Brake chamber (FRONT) 169 - 171 – – Adjust
clevis setting dimension (6.66 - 6.73)

Free length 30.5 – –

(1.201)

Main spring Setting length 27.7 – – Replace

(1.091)

Setting load kg (lb) 21.8 - 24.1 – –

(48.10 - 53.13)

Free length 34.0 – –

(1.339)

Setting length 31.5 – – Replace

(1.240)

Sub spring Setting load kg (lb) 26.4 - 32.2 – –

(58.202 - 70.988)

Stem setting height 40.2 - 40.6 – –

(1.583 - 1.598)
Adjust
Spring tension 0-1 – –
kg (lb) (0 - 2.205)
Brake valve

Free length 108.0 – –

(4.252)
Primary Setting length 24.0 – – Replace
piston (0.945)

Setting load kg (lb) 12.5 - 14.5 – –

(27.558 - 31.966)

Free length 29 – –
(1.142)
Return spring

Secondary Setting length 14.5 – – Replace

piston (0.571)

Setting load kg (lb) 1.1 - 1.3 – –

(2.426 - 2.865)

Free length 23.5 – –

(0.925)
Primary Setting length 13.0 – – Replace
feed valve (0.512)

Setting load kg (lb) 4.8 - 5.8 – –

(10.583 - 12.786)
 1 page 1
S-30 SERVICE SPECIFICATIONS

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method

Free length 20.5 – –

Return spring

(0.807)
Secondary Setting length 12.5 – – Replace
feed valve (0.492)

Setting load kg (lb) 3.6 - 4.4 – –

(7.937 - 9.70)

Installation height 44 - 50 – – Adjust

(1.74 - 1.96)

Angle 18˚ - 20˚ – – Adjust

Depression angle 12.1˚ - 16.1˚ – – Adjust

(Full stroke)
Brake valve

Primary 0.1 - 0.3 – – Adjust

Lever depression (1.422 - 4.267)
Brake pedal

angle 1.1˚ - 3.1˚

kg/cm2 (lb/sq.in.) Secondary 0 - 0.1 – – Adjust
(0 - 1.422)
Discharge pressure

Primary 1.5 - 2.1 – – Adjust

Lever depression (21.330 - 29.862)
angle 5.5˚ - 8.5˚
kg/cm2 (lb/sq.in.) Secondary 1.4 - 2.0 – – Adjust
(19.908 - 28.440)

Primary 4.2 - 5.0 – – Adjust

Lever depression (59.724 - 71.100)
angle 8.8˚ - 11.8˚
kg/cm2 (lb/sq.in.) Secondary 4.4 - 5.2 – – Adjust
(62.568 - 73.944)

Pedal lever rod length 147 - 149 – – Adjust

(5.79 - 5.86)

Secondary feed valve movement 0.8 – – Adjust

(0.0315)

Free length 41.0 – –

(1.614)
Compression
spring Setting length 35.9 – – Replace
(Piston) (1.413)
Pressure regulator

Setting load kg (lb) 29.4 - 33.8 – –

(64.82 - 74.51)

Free length 26.0 – –

(1.024)
Compression
spring Setting length 17.4 – – Replace
(Push rod) (0.685)

Setting load kg (lb) 0.7 - 0.9 – –

(1.55 - 1.98)
 1 page 1
SERVICE SPECIFICATIONS S-31

SERVICE STANDARD (Cont’d) Unit: mm (in.)

Item Assembly standard Repair limit Service limit Corrective method

Free length 17.6 – 16.5 (0.649)

(0.693)
Check valve

Valve spring Setting length 15.4 – – Replace

(0.606)

Setting load kg (lb) 0.08 – –

(0.176)

Free length 34.0 – –

(1.339)
Safety valve

Valve spring Setting length 24.0 – – Replace

(0.945)

Setting load kg (lb) 5.6 - 6.2 – –

(12.346 - 13.668)
60.8
Protection valve

Free length – –
(2.397)

Valve spring Setting length 49.0 – – Replace

(1.929)

Setting load kg (lb) 13.6 - 15.2 – –

(29.983 - 33.509)
 1 page 1
S-32 SERVICE SPECIFICATIONS

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Spring brake release stud nut
(Max. allowable tightening torque) 484 35

Cam shaft bracket (Rear) 1,100 - 1,500 80 - 108

Brake chamber bracket 1,100 - 1,500 80 - 108
Brake spider 1,700 - 2,300 123 - 166
Wheel brake
Anchor pin set screw 200 - 300 15 - 21
Brake drum cover 360 - 530 27 - 38
Brake drum set bolt 200 - 400 15 - 28
* Wheel nut 4,000 - 4,800 290 - 347
Worm gear shaft lock nut 1,000 - 1,200 73 - 86
Slack adjuster
Lock ball plug 40 - 90 2.9 - 6.5
Clamp bolt and nut 250 - 340 19 - 24
Front brake
Clevis lock nut 500 - 700 37 - 50
chamber
Chamber to bracket 1,700 - 2,300 123 - 166
Rear brake chamber to bracket 1,200 - 2,300 87 - 166
Secondary valve body 60 - 75 4.4 - 5.4
Piston spring setting bolt 30 - 50 2.2 - 3.6
Valve cover to valve body 100 - 200 8 - 14
Brake valve
Brake pedal to floor 380 - 500 28 - 36
Valve cover to bracket 380 - 500 28 - 36
Adjusting bolt lock nut 30 - 50 2.2 - 3.6

Quick release Cover to body 50 - 60 3.7 - 4.3

valve Valve assembly to bracket 190 - 260 14 - 18
Filter 5 - 10 0.36 - 0.72

Pressure Regulator installing bolt 190 - 260 14 - 18

regulator Adjusting screw lock nut 24 - 36 1.8 - 2.6
Air pipe 200 - 220 14.5 - 15.9
Body cap 450 - 550 33 - 39
Check valve Air pipe 10.0 (0.394) 400 - 500 29 - 36
Pipe dia. mm (in.) 12.0 (0.472) 600 - 700 44 - 50
Adjusting screw lock nut 200 - 300 15 - 21
Safety valve
Safety valve install 350 - 400 26 - 28

Protection Body cap 400 - 500 29 - 36

valve Adjusting screw lock nut 150 - 250 11 - 18
Front relay
Cover to valve body 90 - 120 6.6 - 8.6
valve
* Apply grease or engine oil to the threads.
 1 page 1
SERVICE SPECIFICATIONS S-33

PARKING BRAKE
Model FD, FE and FF
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method
Moving range of the parking brake lever 3 - 6 clicks 8 clicks – Adjust
(i.e. number of the ratchet teeth)
Clearance between brake lever and cable 1-2 – – Adjust
end joint (0.040 - 0.078)
LF06S Transmission 203.2 (8.0) – 204.2 (8.039)
Inside diameter
Brake drum

LJ06S AT542 and AT545 254 256 Replace

–
Transmission (10.00) (10.07)
LF06S Transmission
0 - 0.1 0.2 –
Runout LJ06S AT542 and AT545 (0 - 0.004) (0.008) Regrind or replace
Transmission

Drum and lining clearance 0.30 - 0.35 0.50 – Adjust

(0.0119 - 0.0137) (0.0196)
LF06S Transmission 5.0 (0.197) – 1.0 (0.039)
Lining thickness LJ06S AT542 and AT545 7.0 4.0 Replace
–
Transmission (0.276) (0.157)
Adjusting spring 58.0 (2.283) – – –
Setting length
(LF06S Transmission) Shoe return spring 66.0 (2.598) – – –
Lever return spring 77.0 (3.031) – – –
Adjusting spring 74.0 (2.913) – – –
Setting length
LJ06S, AT542 and Shoe return spring 75.2 (2.961) – – –
(
AT545 Transmission )
Spring

Lever return spring 137.0 (5.394) – – –

Adjusting spring 8.1±0.8 (17.86±1.76) – – –
Setting load kg (lb)
(LF06S Transmission) Shoe return spring 13.3±1.3 (29.32±2.86) – – –
Lever return spring 12.9±1.3 (28.44±2.86) – – –
Adjusting spring 12±1.2 (26.46±2.64) – – –
Setting load kg (lb)
LJ06S, AT542 and Shoe return spring 18.5±1.9 (40.79±4.18) – – –
(
AT545 Transmission )
Lever return spring 16.4±1.6 (36.16±3.52) – – –

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
LF06S Transmission 150 - 200 11 - 14
Camshaft lever
LJ06S, AT542 and AT545 Transmission 180 - 230 14 - 16
LF06S Transmission 900 - 1,200 66 - 86
Parking brake
LJ06 Transmission 1,500 - 1,700 109 - 122
assembly
AT542 and AT545 Transmission 1,122 - 1,346 82 - 97

Universal joint Manual Transmission 6,000 - 8,000 434 - 578

flange coupling Automatic Transmission 1,150 - 1,380 84 - 99
Cable lock nut 190 - 260 14 - 18
Parking brake lever 380 - 500 28 - 36
Propeller shaft 650 - 870 47 - 62
Brake drum to flange 650 - 870 47 - 62
 1 page 1
S-34 SERVICE SPECIFICATIONS

SPRING BRAKE
Model SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method
Spring brake Clevis setting 267 - 269 – – Adjust
chamber dimension (10.52 - 10.59)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Brake chamber mounting nut Front 1,700 - 2,300 123 - 166
Rear 1,200 - 2,300 87 - 166
Spring brake
chamber Clamp band carriage nut 250 - 340 18 - 24
Push rod clevis lock nut 500 - 700 37 -50
Valve cover fitting bolt 25 - 35 1.8 - 2.5
Quick release
valve Mounting nut 190 - 260 14 - 18
Air line flare nut 600 - 700 44 - 50
Plug 350 - 450 25 - 32
Double check
valve Mounting nut 190 - 260 14 - 18
Air line flare nut 400 - 500 29 - 36
 1 page 1
SERVICE SPECIFICATIONS S-35

WHEEL AND TIRE

Models FD, FE, FF and SG
TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Air valve of wheel for tubeless tires 100 - 130 8-9
 1 page 1
S-36 SERVICE SPECIFICATIONS

SUSPENSION
Model FD
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Front 25.0 – 24.7 Replace

Outside (0.984) (0.973)
diameter
Spring pin of pin Rear 30 – 29.7 Replace
and bushing (1.181) (1.169)

Clearance 0.02 - 0.125 – 0.50 Replace

(0.0008 - 0.0049) (0.0196)

Thrust washer 3.0 – 2.5 Replace

(0.118) (0.098)

Wear of leaf spring – – –15% Replace

Front spring interleaf 1.2 – 0.6 Replace

(0.047) (0.024)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Front center bolt 500 - 630 36 - 45
Rear center bolt 870 - 1,100 63 - 79
Leaf spring
Front U-bolt nut 2,200 - 2,700 160 - 195
Rear U-bolt nut 2,700 - 3,200 196 - 231
Front lock nut 300 - 500 22 - 36
Spring pin
Rear lock bolt 650 - 870 47 - 62
Shock absorber fitting nut 1,100 - 1,500 80 - 108
*Wheel hub nut Front and rear 4,000 - 4,800 290 - 347
* Apply grease or engine oil to the threads.
 1 page 1
SERVICE SPECIFICATIONS S-37

SUSPENSION
Models FE, FF and SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Outside diameter of pin 30 – 29.7 Replace

Spring pin (1.181) (1.169)
and bushing 0.02 - 0.125 0.5
Clearance – Replace
(0.0008 - 0.0049) (0.020)

Thrust washer 3.0 – 2.5 Replace

(0.118) (0.098)

Wear of leaf spring – – –15% Replace

1.2 – 0.6 Replace

Front spring interleaf Model FF only (0.047) (0.024)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Front center bolt 870 - 1,100 63 - 79
Rear center bolt 2,300 - 2,900 167 - 209
Leaf spring
Front U-bolt nut 2,700 - 3,200 196 - 231
Rear U-bolt nut 5,000 - 6,000 362 - 433
Front lock nut 300 - 500 22 - 36
Spring pin
Rear lock bolt 1,100 - 1,500 80 - 108

Models FE Pin fitting nut 1,200 - 2,000 87 - 144

Shock absorber
and SG Fitting nut 1,700 - 2,300 123 - 166
Pin fitting nut 2,400 - 3,300 174 - 238
Shock absorber Model FF
Fitting nut 1,700 - 2,300 123 - 166
*Wheel hub nut 4,000 - 4,800 290 - 347
* Apply grease or engine oil to the threads.
 1 page 1
S-38 SERVICE SPECIFICATIONS

CAB
Models FD, FE, FF and SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Torsion bar free Without optional parts 400 - 700 (15.75 - 27.55)
– – Adjust or replace
operating tension With optional parts 200 - 300 (7.88 - 11.81)
Offset of eye bolt and crank pin 9 - 13 (0.36 - 0.51) – – Adjust
Clearance of latch and pin 1 - 3 (0.04 - 0.11) – – Adjust
Clearance of rear arch and latch 7 - 9 (0.28 - 0.35) – – Adjust
Clearance of hook and eye bolt 5 - 15 (0.20 - 0.59) – – Adjust
Clearance of lock switch and stopper 3 - 4 (0.12 - 0.15) – – Adjust
Lock lever operating strength 20 - 30 kg (44 - 66 lb) – – Adjust

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Cab hinge nut 2,300 - 2,900 167 - 209
Anchor lever set screw 380 - 500 28 - 36
Cab mounting member 870 - 1,100 62 - 80
Eye bolt 1,100 - 1,500 80 - 108
Eye bolt cushion 380 - 500 28 - 36
Cab mounting cushion 380 - 500 28 - 36
Steering shaft yoke and gear box 500 - 600 37 - 43
Seat track to seat leg 200 - 280 15 - 20
Seat height adjuster link 200 - 280 15 - 20
Driver's seat Seat height adjuster stopper 200 - 280 15 - 20
Reclining adjuster 270 - 490 20 - 36
Seat assembly to floor 200 - 320 15 - 23
Height adjuster link to seat track 200 - 280 15 - 20
Air Seat assembly to floor 200 - 320 15 - 23
suspension
Air pipe flare nut 100 - 150 8 - 10
seat (Option)
Seat track to seat
200 - 280 15 - 20
suspension assembly

Assistant's Seat leg to seat 200 - 280 15 - 20

seat Seat assembly to floor 200 - 320 15 - 23
Seat back 200 - 280 15 - 20
Center seat Seat hinge 80 - 120 6-8
Seat assembly to floor 200 - 320 15 - 23
Seat belt 262 - 392 19 - 28
 1 page 1
SERVICE SPECIFICATIONS S-39

POWER STEERING
Models FD, FE, FF and SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Steering wheel play 15 - 35 – – Adjust

(0.60 - 1.37)

Steering wheel turning force Less than 2 kg – – Adjust

(4.41 lb)

Hydraulic pressure 123 - 130 kg/cm2 – – –

(1,750 - 1,849 lb/sq.in.)

Discharge pressure 123 - 130 kg/cm2 – – –

(1,750 - 1,849 lb/sq.in.)
Hydraulic test
Flow-control valve 49 - 50.5 kg/cm2 – – –
(703.89 - 718.11 lb/sq.in.)

Relief valve 125 - 133 kg/cm2 – – –

(1,778 - 1,891 lb/sq.in.)
Starting torque of the worm shaft 6 kg·cm (0.4 lb·ft) or less _ _ Replace
0.05 _
Backlash of the ball nut 0 (0.0019) Replace

Adjusting screw thrust clearance of the 0 - 0.015 _ _ Replace

sector shaft (0 - 0.0059)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.

Piston sub-assembly Model: FD 750 - 1,050 55 - 76

fitting bolt Models: FE, FF and SG 350 - 500 26 - 36

Side cover fitting Model: FD 750 - 1,050 55 - 76

bolt Models: FE, FF and SG 750 - 1,050 55 - 75
Pitman arm Model: FD 3,000 - 4,000 217 - 289
Power steering Model: FD 1,000 72
gear Seal lock nut
Models: FE, FF and SG 800 - 1,200 58 - 86
Pipe connector 600 - 700 44 - 50
*Friction torque Model: FD 3.5 - 10 3.1 - 8.6 lb.in.
Models: FE, FF and SG 5 - 14 4.4 - 12.1 lb.in.
Gear setting nut 850 62
Flow control valve plug 500 - 800 37 - 57
Power steering
pump Rear body fitting bolt 300 - 450 22 - 32
Hose joint bolt 400 - 500 29 - 36
Pump mounting bolt 480 35
Center nut 16 - 24 1.2 - 1.7
Fluid reservoir Inner center nut 10 - 30 0.73 - 2.16
Reservoir mounting bolt 74 - 110 5.4 - 7.9
* : Refer to PRELOAD ADJUSTMENT in chapter 67 power steering.
 1 page 1
S-40 SERVICE SPECIFICATIONS

AUTOMATIC TRANSMISSION
Models FD with Allison AT542
FE and FF with Allison AT545
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Modulator cable tension allowance 1-2 – – Adjust

(0.04 - 0.07)

Fluid normal operating temperature 71 - 93°C – – –

(160 - 200°F)

Shift cable (Transmission side) 200 – – Adjust

(7.87)
71 - 93°C _ _ _
Hot (160 - 200°F)
Fluid level check
16 - 33°C _ _ _
Cold (60 - 100°F)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Spacer coupling, wear plate and flex plate 800 - 900 58 - 65
Torque converter and flex plate 520 - 622 38 - 44
Flywheel and spacer coupling 650 - 870 47 - 62
Torque converter housing and flywheel housing 522 - 622 38 - 44
Modulator retainer 180 - 221 14 - 15
Shift lever 207 - 276 15 - 19
Propeller shaft yoke and transmission flange 650 - 870 47 - 62
Propeller shaft center bearing holder 380 - 500 28 - 36
Shift cable to selector lever 190 - 260 14 - 18
 1 page 1
SERVICE SPECIFICATIONS S-41

AUTOMATIC TRANSMISSION
Model SG
SERVICE STANDARD Unit: mm (in.)
Item Assembly standard Repair limit Service limit Corrective method

Modulator cable tension allowance 1-2 – – Adjust

(0.04 - 0.07)

Fluid normal operating temperature 71 - 93˚C – – –

(160 - 200˚F)

Shift cable (Transmission side) 200 – – Adjust

(7.87)
71 - 93°C _ _ _
Hot (160 - 200°F)
Fluid level check
16 - 33°C _ _ _
Cold (60 - 100°F)

TIGHTENING TORQUE
Tightening position kg·cm lb·ft.
Flex plate, spacer coupling and wear plate 800 - 900 58 - 65
Torque converter and adapter plate 470 - 550 34 - 39
Flex plate and adapter plate 470 - 550 34 - 39
Torque converter housing and flywheel housing 522 - 622 38 - 44
Flywheel and spacer coupling 650 - 870 47 - 62
Modulator retainer 180 - 221 14 - 15
Shift lever 207 - 276 15 - 19
Propeller shaft yoke and transmission flange 1,300 - 1,600 95 - 115
Propeller shaft center bearing holder 650 - 870 47 - 62
Shift cable to selector lever 190 - 260 14 - 18
 1 page 1
S-42 SERVICE SPECIFICATIONS

ANTI-LOCK BRAKE SYSTEM

Models FD, FE, FF and SG
TIGHTENING TORQUE
Tightening position kg·cm lb·ft.

ABS 6.35 (0.25) 200 - 300 14 - 21

Pipe dia. mm (in.)
control valve 10.0 (0.394) 460 - 600 33 - 43
 1 page 1
SERVICE SPECIFICATIONS S-43

METRIC INFORMATION
METRIC FASTENERS
1. Most threaded fasteners on the Hino Models
F and S series are metric.
Be careful not to mix them up with threaded
fasteners using the inch system.
Mismatched or incorrect bolts, nuts and
screws can cause damage or malfunction,
resulting in personal injury and/or property
damage.
2. When bolts, nuts and screws are removed
from the vehicle, they should be kept for re-
use whenever possible.
If they are not re-usable, parts that are equiva-
lent to the original parts in dimensions,
strength, and thread pitch must be selected.
3. Most original bolts are marked with identifi-
cation numbers indicating the strength of the
bolts. The markings are shown below.
4. When replacing bolts, be careful to use bolts
with the same markings as the original bolts.

NOMENCLATURE FOR BOLTS

METRIC SYSTEM BOLT STRENGTH IDENTIFICATION

BOLT M12-1.75 × 25
↑ ↑ ↑
D T L

P
T

8 D 6 7 8 9 10 11

D- Nominal Diameter P- Property Class Metric Bolts – Identification class numbers corre-
(millimeters) (bolt strength) spond to bolt strength – Increasing numbers rep-
L- Length (millimeters) T- Thread Pitch (thread resent increasing strength.
width crest to crest
millimeters)
 1 page 1
S-44 SERVICE SPECIFICATIONS

DECIMAL AND METRIC EQUIVALENTS

Fractions Decimal In. Metric mm. Fractions Decimal In. Metric mm.

1/64 0.015625 0.397 33/64 0.515625 13.097

1/32 0.03125 0.794 17/32 0.53125 13.494
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.09375 2.381 19/32 0.59375 15.081
7/64 0.109375 2.778 39/64 0.609375 15.478
1/8 0.125 3.175 5/8 0.625 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.250 6.35 3/4 0.750 19.05
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.54 51/64 0.796875 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.375 9.525 7/8 0.875 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.500 12.7 1 1.00 25.4
STANDARD TIGHTENING TORQUE
Bolt tightening torque chart – for general purpose Unit: kg·cm (lb·ft)
Bolt
diameter
Bolt
Tightening (mm) 4 6 8 10 12 14 16 18 20 22 24
conditions

Even tightening area. Bolt nut, coating,

10 - 15 36 - 53 88 - 128 174 - 255 304 - 445 486 - 712 758 - 1,110 1,040 - 1,530 1,480 - 2,170 2,030 - 2,980 2,560 - 3,750
naked bolt, lubricant, etc. Optimum
(0.8 - 1.0) (2.7 - 3.8) (7 - 9) (13 - 18) (22 - 32) (36 - 51) (55 - 80) (76 - 110) (108 - 156) (147 - 215) (186 - 271)
conditions.

4
Cast iron or aluminium tightening surface.
14 - 20 48 - 71 117 - 172 232 - 340 405 - 592 647 - 950 1,010 - 1,480 1,390 - 2,040 1,970 - 2,900 2,700 - 3,970 3,410 - 5,000
Washers.
(1.1 - 1.4) (3.5 - 5.1) (9 - 12) (17 - 24) (30 - 42) (47 - 68) (74 - 107) (101 - 147) (143 - 209) (196 - 287) (247 - 361)
Medium conditions.

5
Tightening area having black coarse
17 - 25 60 - 88 146 - 214 290 - 425 506 - 742 809 - 1,180 1,260 - 1,850 1,740 - 2,540 2,460 - 3,620 3,380 - 4,950 4,260 - 6,250
surface. Rusty. Naked bolt or lubricant
(1.3 - 1.8) (4.4 - 6.3) (11 - 15) (21 - 30) (37 - 53) (59 - 85) (92 - 133) (129 - 183) (178 - 261) (245 - 358) (309 - 452)
unavailable. Poor tightening conditions.

Even tightening area. Bolt nut, coating, 16 - 24 58 - 83 138 - 201 273 - 400 477 - 700 764 - 1,120 1,190 - 1,750 1,640 - 2,400 2,320 - 3,410 3,180 - 4,680 4,020 - 5,360
naked bolt, lubricant, etc. (1.2 - 1.7) (4.2 - 6.0) (10 - 14) (20 - 28) (35 - 50) (56 - 81) (87 - 126) (119 - 173) (168 - 246) (231 - 338) (291 - 387)
Optimum conditions.

1 page 1
6
Cast iron or aluminium tightening surface. 22 - 32 75 - 110 183 - 270 364 - 533 636 - 932 1,020 - 1,500 1,590 - 2,320 2,180 - 3,200 3,100 - 4,550 4,250 - 6,210 5,360 - 7,850
Washers. (1.6 - 2.3) (5.5 - 7.9) (14 - 19) (27 - 38) (47 - 67) (74 - 108) (116 - 168) (158 - 231) (225 - 329) (308 - 449) (388 - 567)
Medium conditions.

7
Tightening area having black coarse
27 - 40 94 - 138 229 - 336 455 - 667 795 - 1,165 1,270 - 1,870 1,990 - 2,920 2,730 - 4,000 3,870 - 5,680 5,310 - 7,800 6,700 - 9,850
surface. Rusty. Naked bolt or lubricant
(2.0 - 2.8) (6.8 - 9.9) (17 - 24) (33 - 48) (58 - 84) (92 - 135) (144 - 211) (198 - 289) (280 - 410) (385 - 564) (485 - 712)
unavailable. Poor tightening conditions.

8 Even tightening area. Bolt nut, coating,

naked bolt, lubricant, etc.
24 - 32
(1.8 - 2.3)
82 - 110
(6.0 - 7.9)
200 - 267
(15 - 19)
397 - 574
(29 - 41)
694 - 925
(51 - 66)
1,010 - 1,480 1,730 - 2,310 2,380 - 3,170 3,380 - 4,510 4,630 - 6,170 5,850 - 7,790
(74 - 107) (126 - 167) (173 - 229) (244 - 326) (335 - 446) (424 - 563)
Optimum conditions.

SERVICE SPECIFICATIONS S-45

9 Cast iron or aluminium tightening surface.
32 - 42 110 - 146 267 - 356 529 - 706 925 - 1,230 1,480 - 1,970 2,310 - 3,080 3,170 - 4,230 4,510 - 6,010 6,170 - 8,230 7,790 - 10,390
Washers.
(2.4 - 3.0) (8.0 - 10.5) (19 - 25) (39 - 51) (67 - 88) (108 - 142) (168 - 222) (230 - 305) (327 - 434) (447 - 595) (564 - 751)
Medium conditions.
10
Tightening area having black coarse
40 - 53 137 - 183 334 - 445 662 - 882 1,160 - 1,540 1,850 - 2,470 2,890 - 3,850 3,970 - 5,290 5,640 - 7,510 7,720 - 10,2909,740 - 12,990
surface. Rusty. Naked bolt or lubricant
11 unavailable. Poor tightening conditions.
(2.9 - 3.8) (10.0 - 13.2) (25 - 32) (48 - 63) (84 - 111) (134 - 178) (210 - 278) (288 - 382) (408 - 543) (559 - 744) (705 - 939)

NOTE: The torque values given in this table should be applied where bolt torque is not specified.
 1 page 1
S-46 SERVICE SPECIFICATIONS

RECOMMENDED LUBRICANTS
No. LUBRICANTS POSITIONS ATMOSPHERIC TEMP. S.A.E No.
Below 10W - 30
32°F (0°C)
–10° - 70°F 15W - 40
(–23° - 21°C)
ENGINE OIL
1 (A.P.I. CD) Cylinder Block Above 40
(A.P.I. CE) Injection pump 50°F (10°C)
32° - 100°F 30
(0° - 39°C)
–10° - 70°F 20
(–23° - 21°C)

TRANSMISSION Above 140

LUBRICANT 90°F (32°C)
2 (A.P.I.GL-4) Transmission
90° - 10°F 90 or 80
(MIL-L-2105) (32° - –12°C)
AUTOMATIC
TRANSMISSION ALLISON
Below
LUBRICANT Automatic
86°F (30°C)
(ATF DEXRON) or Transmission
(STF DEXRON II)
3
AUTOMATIC
ALLISON
TRANSMISSION Above
Automatic 30
LUBRICANT 32°F (0°C)
Transmission
TYPE C3.

AXLE LUBRICANT Above 140

(SP TYPE LUBRICANT) 90°F (32°C)
4 Rear Axle
(A.P.I.GL. 5) 90° - 10°F
(MIL-L-2105B) 90
(32° - –12°C)
POWER STEERING
5 FLUID Integral
(DEXRON) or Power Steering Gear
(DEXRON II)
BRAKE AND
6 CLUTCH FLUID Brake and Clutch
(DOT-3) or (DOT-4)
 1 page 1
SERVICE SPECIFICATIONS S-47

No. LUBRICANTS POSITIONS

WHEEL BEARING GREASE Wheel Bearing
7 (MIL-G-10924B/18709A) Propeller Shaft Spider
(NLGI No. 2 LITHIUM-SOAP) Propeller Shaft Sliding Spline
Clutch Disc Hub Spline
HEAT RESISTANCE GREASE T/M Main Drive Shaft Spline
8 (MIL-G-22615/23549/21164) Brake (Adjuster Slit, Anchor Piston)
(NLGI No. 2 or No. 3) Slit, Shoe Hold Washer, Shoe
Parking Brake (Cam, Anchor Pin, Adjuster)

STARTER GREASE Bushing, Clutch, Drive Shaft.

9 (NLGI No. 2 LITHIUM-SOAP) Pinion Shaft Lever and Reduction
Gear
ALTERNATOR and STARTER Alternator Bearing
10 BEARING GREASE Starter Bearing
(NLGI No. 2 LITHIUM-SOAP)
CHASSIS GREASE
11 (MIL-G-17740) Chassis Grease Fitting
(NLGI No. 1 CALCIUM or LITHIUM-SOAP)

No. LUBRICANTS POSITIONS SHELL MOBIL EXXON

LITHIUM BASE Drag Link and Mobil Grease
12 DISULFIDE MOLY- Tie Rod Ball Joint Retinax AM Special Beacon Q2
BDENUM GREASE