1992-1995 Mitsubishi FUSO FE FG Truck Service Manual PDF Download

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Format: PDF
Pages: 1,801
Compatible with: Windows/Mac/Tablet/Phone

Covers: 1992, 1993, 1994, 1995 Mitsubishi FUSO FE FG Series Truck (U.S. models) Service & Repair

  • FE439 w/ 4D34-T3
  • FE449 w/ 4D34-T3
  • FG439 w/ 4D34-T3

Manual Part Number: TWSE9105 plus model year changes

Topics List:

Foreword
Group 00 – General
(1) Change of Model
(2) Change of Engine Stamp Mark Position
Group 11 – Engine
(3) Tension of Air Conditioner Belt
(4) Change of Piston
(5) Change of Connecting Rod
(6) Change of Front Oil Seal
(7) Change of Camshaft
(8) Change of Camshaft Bushing
(9) Change of Timing Gear Case Sealer
(10) Change of Tappet
Group 12 – Lubrication
(11) Change of Oil Pump
(12) Change of Oil Filter
Group 13 – Fuel and Engine Control
(13) Change of Injection Pump
(14) Addition of Inspection Procedure Using the Pre-Stroke Type Injection Pump System MUT
Group 15 – Intake and Exhaust
(15) Employment of Catalyst Converter
(16) Change of Exhaust Manifold
(17) Change of Front Pipe
Group 16 – Engine Electrical
(18) Change of Alternator
(19) Change of Vacuum Pump
Group 22 – Manual Transmission
(20) Change of Special Tool for Main Shaft Removal and Installation
(21) Change of Shift Fork and Jaw Set
(22) Change of Speed Meter Gear
Group 23 – Automatic Transmission
(23) Change of Manual Lever Attaching Nut
(24) Change of Oil Cooler Piping
(25) Change of Oil Temperature
Group 35 – Brake
(26) Modification of Exhaust Brake Circuit Diagram
Group 36 – Parking Brake
(27) Change of Parking Brake Lever
Group 37 – Steering
(28) Change of Power Steering Oil Pump Gear Attaching Nut
(29) Change of Power Steering Oil Pump
Group 42 – Cab and Body
(30) Change of Outside Mirror Stay
Group 55 – Heater and Air Conditioner
(31) Change of Air Conditioner Compressor
1994 Minor Change
Table of Contents
1. Differences of 1994 Model From 1993 Model
2. Change Due to Running Change Made on 1993 Model
1993 Minor Change
1. Differences of 1993 Model From 1992 Model
2. Electrical Wiring Diagram
Group 00 – General
Table of Contents
1. External Views
2. Major Specifications
3. Power Train Table
4. Equipment Model Notation
5. Performance Curves
5.1 Operation Performance Curves
5.2 Engine Performance Curves
6. Servicing Precautions
7. Standard Bolts and Nuts Tightening Torque Table
8. Towing Precautions
9. Chassis and Engine Numbers
10. Vehicle Identification Number
Group 01 – Maintenance Schedule
Table of Contents
1. How To Read the Maintenance Schedule Tables
2. Maintenance Schedule Tables
3. Maintenance Operations
3.1 Replacement of the Engine Oil Filter Element
3.2 Replacement of the Fuel Filter Element
3.3 Water Separator Condensation Drain
3.4 Cleaning the Fuel Feed Pump Gauze Filter
3.5 Bleeding Air From the Fuel Line
3.6 Adjusting V-Belt Tension
3.7 Cleaning and Replacement of the Air Cleaner Element
3.8 Inspecting the Clutch Pedal
3.9 The Tires
3.9.1 Air Pressure
3.9.2 Removing Tires
3.9.3 Putting Tires On
3.9.4 Checking the Wheel Nuts for Looseness
3.9.5 Tire Rotation
3.10 Adjusting the Clearance of the Wheel Brake Shoe (FG Model Only)
3.11 Checking for Wear in the Disk Brake Pads (FE Model Only)
3.12 Adjusting the Clearance of the Parking Brake Shoe
3.13 The Battery
3.13.1 Cleaning the Battery Terminals
3.13.2 Inspecting the Battery
3.14 Fuses
4. Lubrication
4.1 Engine Oil
4.2 Gear Oil for Manual Transmissions
4.3 Transmission Fluid for Automatic Transmissions
4.4 Front Axle <FG Model Only> and Rear Axle Gear Oil
4.5 Transfer Gear Oil <FG Model Only>
4.6 Power Steering Fluid
4.7 Brake Fluid
4.8 Greasing the Various Areas of the Chassis
Group 11 – Engine
Table of Contents
1. Troubleshooting
2. Engine Removal and Installation (Manual Transmission Vehicles)
2.1 Service Standards
2.1.1 Tightening Torque Table
2.1.2 Lubricant Table
2.2 Engine and Transmission Removal
2.2.1 Preparations Before Removal
2.2.2 Harness Removal
2.2.3 Vacuum Hose Removal
2.2.4 Removal of Parts Around Engine
2.2.5 Removal of Each Engine Parts
2.2.6 Removal of Each Transmission Parts
2.2.7 Removing the Engine From the Vehicle
2.2.8 Separating the Engine From the Transmission
2.3 Installation of the Engine and Transmission
2.3.1 Engine and Transmission Installation
2.3.2 Installation the Engine and Transmission in the Vehicle
2.3.3 Installation of Each Transmission Part
2.3.4 Installation of Each Engine Part
2.3.5 Installation of Parts Around the Engine
2.3.6 Vacuum Hose Installation
2.3.7 Harness Installation
2.4 Adjustment After Installation
2.4.1 Operations After Installation
2.4.2 Adjustment
3. Engine Removal and Installation (Automatic Transmission Vehicles)
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 Engine and Transmission Removal
3.2.1 Preparations Before Removal
3.2.2 Harness Removal
3.2.3 Vacuum Hose Removal
3.2.4 Removal of Parts Around Engine
3.2.5 Removal of Each Engine Part
3.2.6 Removal of Each Transmission Part
3.2.7 Removing the Engine From the Vehicle
3.2.8 Separating the Engine and Transmission
3.3 Installation of the Engine and Transmission
3.3.1 Transmission Installation
3.3.2 Installing the Engine and Transmission in the Vehicle
3.3.3 Installation of Each Transmission Part
3.3.4 Installation of Each Engine Part
3.3.5 Installation of Parts Around the Engine
3.3.6 Vacuum Hose Installation
3.3.7 Harness Installation
3.4 Adjustment After Installation
3.4.1 Operations After Installation
3.4.2 Adjustment
4. Engine Assembly
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.2.3 Special Tools Table
4.3 Valve Clearance Inspection and Adjustment
4.4 Compression Pressure Measurement
4.5 Oil Pressure Inspection
4.6 Fuel Injection Timing Inspection and Adjustment
4.7 Bleeding the Fuel System
4.8 Inspection and Adjustment of V-Belt Tension
4.8.1 V-Belt Tension Inspection
4.8.2 V-Belt Tension Adjustment
4.9 Turbocharger Boost Pressure Measurement
5. Cylinder Head and Valve Mechanism
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.1.3 Special Tools Table
5.2 General Description
5.2.1 Cylinder Head
5.2.2 Valve Mechanism
5.3 Removal
5.4 Disassembly
5.4.1 Rocker and Bracket Assembly
5.4.2 Cylinder Head Assembly
5.5 Inspection
5.6 Reassembly
5.6.1 Cylinder Head Assembly
5.6.2 Rocker and Bracket Assembly
5.7 Installation
6. Flywheel and Rear Plate (Manual Transmission Vehicles)
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.1.3 Special Tools Table
6.1.4 Lubricant Table
6.2 General Description
6.3 Disassembly
6.4 Inspection
6.5 Reassembly
7. Flywheel and Flywheel Housing (Automatic Transmission Vehicles)
7.1 Service Standards
7.1.1 Tightening Torque Table
7.1.2 Special Tools Table
7.1.3 Lubricant Table
7.2 General Description
7.3 Disassembly
7.4 Inspection
7.5 Reassembly
8. Timing Gear and Camshaft
8.1 Service Standards
8.1.1 Service Standards Table
8.1.2 Tightening Torque Table
8.1.3 Lubricant Table
8.1.4 Special Tools Table
8.2 General Description
8.3 Disassembly
8.4 Inspection
8.5 Reassembly
9. Crankcase and Main Moving Parts
9.1 Service Standards
9.1.1 Service Standards Table
9.1.2 Tightening Torque Table
9.1.3 Sealant Table
9.1.4 Special Tools Table
9.2 General Description
9.2.1 Crankshaft
9.2.2 Connecting Rod
9.2.3 Piston
9.3 Disassembly
9.4 Inspection
9.5 Reassembly
Group 12 – Lubrication
Table of Contents
1. Troubleshooting
2. Lubrication System
2.1 Specifications
2.2 General Description
2.2.1 System Outline
2.2.2 Lubrication of Main Moving Parts
2.2.3 Camshaft Lubrication
2.2.4 Valve Mechanism Lubrication
2.2.5 Timing Gear Lubrication
2.2.6 Turbocharger Lubrication
2.2.7 Injection Pump Assembly Lubrication
2.2.8 Vacuum Pump Lubrication
2.3 Oil Pressure Check
3. Oil Pan and Oil Strainer
3.1 Service Standards
3.1.1 Tightening Torque Table
3.1.2 Sealant Table
3.2 General Description
3.3 Removal
3.4 Installation
3.5 Post-Installation Inspection
4. Oil Pump
4.1 Service Standards
4.1.1 Service Standards Table
4.2 General Description
4.3 Removal
4.4 Disassembly and Inspection
4.5 Reassembly
4.6 Installation
5. Oil Cooler and Oil Filter
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.1.3 Special Tools Table
5.2 General Description
5.3 Removal
5.4 Disassembly and Inspection
5.5 Reassembly
5.6 Installation
Group 13 – Fuel and Engine Control
Table of Contents
1. Troubleshooting
2. Fuel System
3. Pre-Stroke Control Injection Pump System
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.3.1 Pre-Stroke Control Injection Pump System
3.3.2 Control Unit
3.3.3 Sensors
3.3.4 Injection Pump Unit
3.3.5 Governor
3.3.6 Feed Pump
3.4 Service Procedure
3.4.1 System Inspection
3.4.2 Removing Injection Pump Assembly
3.4.3 Installing Injection Pump Assembly
3.4.4 Bleeding Air From the Fuel System
3.4.5 Fuel Injection Timing Adjustment
3.4.6 Minimum Unloaded Idling Speed and Maximum Speed Adjustment
3.4.7 Idle Up Adjustment <Manual Transmission Equipped Vehicles>
3.4.8 Engine Stop Cable Operational Check
4. Injection Nozzles
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.3 General Description
4.4 Removal
4.5 Disassembly
4.6 Inspection and Cleaning
4.7 Reassembly
4.8 Testing and Adjustment
4.9 Installation
5. Fuel Filter
5.1 Specifications
5.2 Service Standards
5.2.1 Tightening Torque Table
5.2.2 Special Tools Table
5.3 General Description
5.4 Removal and Inspection
5.5 Installation
6. Water Separator
6.1 Specifications
6.2 Service Standards
6.3 General Description
6.4 Removal
6.5 Disassembly and Inspection
6.6 Reassembly
6.7 Installation
6.8 Draining Water
7. Fuel Tank
7.1 Specifications
7.2 Service Standards
7.3 General Description
7.4 Removal
7.5 Inspection
7.6 Installation
8. Engine Control System
8.1 Specifications
8.2 Service Standards
8.3 General Description
8.4 Removal
8.4.1 Disconnecting the Accelerator Control Cable and Engine Stop Cable From the Engine Side
8.4.2 Removing the Throttle Cable and Accelerator Pedal
8.4.3 Disconnecting the Accelerator Control Cable and Accelerator Lever
8.4.4 Removing the Engine Stop Cable
8.5 Inspection
8.6 Installation
8.6.1 Installing the Engine Stop Cable
8.6.2 Installing the Throttle Cable, Accelerator Lever Assembly and Accelerator Pedal
8.6.3 Securing the Accelerator Control Cable
8.6.4 Installing the Accelerator Control Cable and the Engine Stop Cable to Engine Side
8.7 Post-Installation Adjustment
8.7.1 Accelerator Pedal Stopper Adjustment
8.7.2 Engine Stop Cable Operation Check
8.7.3 Accelerator Switch (Exhaust Brake Microswitch) Adjustment
Group 14 – Cooling
Table of Contents
1. Troubleshooting
2. Cooling System
2.1 Specifications
2.2 Service Standards
2.3 General Description
2.4 Removal
2.4.1 Radiator Removal
2.4.2 Cooling Fan and Auto-Cool Fan Coupling Removal
2.4.3 Water Pump Removal
2.4.4 Thermostat Removal
2.5 Installation
2.5.1 Thermostat Installation
2.5.2 Water Pump Installation
2.5.3 Cooling Fan and Auto-Cool Fan Coupling Installation
2.5.4 Radiator Installation
3. Cooling Fan and Auto-Cool Fan Coupling
3.1 General Description
3.1.1 Cooling Fan
3.1.2 Auto-Cool Fan Coupling
3.2 Removal
3.3 Inspection
3.4 Installation
4. Water Pump
4.1 General Description
5. Thermostat
5.1 Service Standards
5.2 General Description
5.3 Inspection
6. Radiator
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.2 General Description
6.2.1 Radiator
6.2.2 Pressure Cap
6.2.3 Radiator Shroud
6.2.4 Condenser Tank
6.3 Inspection and Cleaning
6.3.1 Radiator Cleaning
6.3.2 Radiator Inspection
6.3.3 Pressure Cap Inspection
6.3.4 Radiator (Cooling System) Cleaning
6.3.5 Cooling System Air Bleeding
6.3.6 Gas Leak Test
Group 15 – Intake and Exhaust
Table of Contents
1. Troubleshooting
2. Intake System
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.3 General Description
2.4 Removal
2.5 Disassembly
2.5.1 Air Cleaner Disassembly
2.5.2 Removing the Intake Shutter
2.6 Inspection and Cleaning
2.7 Reassembly
2.7.1 Actuator Installation
2.7.2 Air Cleaner Reassembly
2.8 Installation
2.9 Post-Installation Adjustment
3. Exhaust System
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 General Description
3.3 Removal
3.4 Installation
4. Turbocharger
4.1 Sepcifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.2.3 Lubricants Table
4.3 General Description
4.4 Removal
4.5 Disassembly
4.6 Inspection and Cleaning
4.6.1 Cleaning
4.6.2 Inspection
4.7 Reassembly
4.8 Installation
4.9 Post-Installation Inspection
5. Intercooler
5.1 Specifications
5.2 Service Standard
5.2.1 Service Standards Table
5.2.2 Tightening Torque Table
5.3 Outline
5.4 Removal
5.5 Inspection and Cleaning
5.6 Installation
Group 16 – Engine Electrical
Table of Contents
1. Troubleshooting
2. Electrical System
2.1 Specifications
2.2 General Description
2.2.1 Starting System
2.2.2 Charging System
3. Starter
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Lubrication Table
3.2 General Description
3.3 Removal
3.4 Disassembly
3.5 Inspection
3.6 Reassembly
3.7 Testing
3.8 Installation
4. Alternator
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Lubrication Table
4.2 General Description
4.3 Removal
4.4 Disassembly
4.5 Inspection
4.6 Reassembly
4.7 Testing
4.7.1 Handling Precautions
4.7.2 Performance Testing
4.7.3 Regulator Inspection
4.8 Installation
5. Vacuum Pump
5.1 Service Standards
5.2 General Description
5.3 Removal
5.4 Disassembly
5.5 Inspection
5.6 Reassembly
5.7 Testing
6. Glow Plug System
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Special Tools Table
6.1.3 Tightening Torque Table
6.2 General Description
6.3 Removal
6.4 Inspection
6.4.1 Glow Plug Inspection
6.4.2 Glow Controller Inspection
6.4.3 Water Temperature Gauge Unit Inspection
6.5 Installation
7. Idle Up System and Warning System
7.1 Service Standards
7.1.1 Service Standards Table
7.1.2 Tightening Torque Table
7.1.3 Lubrication Table
7.2 General Description
7.3 Removal
7.4 Inspection
7.5 Installation
7.6 Adjustment
Group 21 – Clutch
Table of Contents
1. Troubleshooting
2. Clutch Proper
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.2.3 Special Tools Table
2.3 General Description
2.4 Removal
2.4.1 Before Removal
2.4.2 Removal
2.5 Inspection and Adjustment
2.5.1 Inspection
2.5.2 Adjustment
2.6 Installation
2.7 Post-Installation Adjustment
3. Clutch Control
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.4 Clutch Hose and Clutch Tube
3.4.1 Removal
3.4.2 Inspection
3.4.3 Installation
3.5 Clutch Pedal
3.5.1 Removal
3.5.2 Disassembly
3.5.3 Inspection
3.5.4 Reassembly
3.5.5 Installation
3.5.6 Post-Installation Adjustment
3.6 Clutch Master Cylinder
3.6.1 Disassembly
3.6.2 Inspection
3.6.3 Reassembly
3.7 Clutch Power Cylinder
3.7.1 Removal
3.7.2 Disassembly
3.7.3 Inspection
3.7.4 Reassembly
3.7.5 Installation
3.8 Clutch Housing Assembly
3.8.1 Removal
3.8.2 Disassembly
3.8.3 Reassembly
3.8.4 Installation
3.9 Fluid Change of Clutch System
3.10 Bleeding the Clutch System
3.11 Post-Installation Adjustment
3.12 Clutch Adjustment
Group 22 – Manual Transmission
Table of Contents
1. Troubleshooting
2. Removing the Transmission
2.1 Service Standards
2.2 Preliminary Operations
2.3 Removal
2.4 Installation
3. Transmission Assembly
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.4 Removal
3.4.1 Clutch Housing Assembly
3.4.2 Gear Shift, Upper and Lower
3.4.3 Rear Cover
3.4.4 Transmission
3.5 Installation
3.5.1 Transmission
3.5.2 Rear Cover
3.5.3 Gear Shift, Upper and Lower
3.5.4 Clutch Housing Assembly
4. Main Shaft Assembly
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Special Tools Table
4.2 Preliminary Inspection
4.3 Disassembly
4.4 Inspection
4.5 Reassembly
5. Gear Shift, Lower
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.2 Disassembly
5.3 Inspection
5.4 Reassembly
6. Gear Shift, Upper
6.1 Service Standards
6.1.1 Service Standards Table
6.1.2 Tightening Torque Table
6.2 Disassembly
6.3 Inspection
6.4 Reassembly
7. Rear Cover
7.1 Service Standards
7.1.1 Service Standards Table
7.1.2 Tightening Torque Table
7.1.3 Special Tools Table
7.2 Disassembly
7.3 Inspection
7.4 Reassembly
8. Transmission Control
8.1 Service Standards
8.2 General Description
8.3 Preliminary Operations
8.4 Removal
8.5 Inspection, Repair and Replacement
8.6 Installation
8.7 Cross-Shaft Assembly
8.7.1 Disassembly
8.7.2 Inspection
8.7.3 Reassembly
8.8 Select Lever Assembly
8.8.1 Disassembly
8.8.2 Inspection and Replacement
8.8.3 Reassembly
8.9 Shift Lever Assembly
8.9.1 Disassembly
8.9.2 Inspection and Replacement
8.9.3 Reassembly
8.10 NO.1 Cross Lever Assembly
8.10.1 Disassembly
8.10.2 Inspection
8.10.3 Reassembly
8.11 Lever Complete
8.11.1 Disassembly
8.11.2 Inspection
8.11.3 Reassembly
8.12 Change Lever Complete
8.12.1 Disassembly
8.12.2 Inspection
8.12.3 Reassembly
8.13 Post-Installation Adjustment
Group 23 – Automatic Transmission
Table of Contents
1. Troubleshooting
2. Specifications
3. Service Standards
3.1 Service Standards Table
3.2 Tightening Torque Table
4. Special Tools
5. Specifications
5.1 Control Mechanisms
5.1.1 Line Pressure Control
5.1.2 Gear Shift Control
5.1.3 Lockup Control
5.1.4 Overrun Clutch Control
5.1.5 Shift Pattern Selector Control
5.1.6 Self Diagnosis Function
5.1.7 Fail Safe Functions
5.2 Electronic Control Devices
5.2.1 Control Unit
5.2.2 Accelerator Sensor
5.2.3 Idle Switch (Accelerator Switch)
5.2.4 Vehicle Speed Sensor 2
5.2.5 Vehicle Speed Sensor 1
5.2.6 Fluid Temperature Sensor
5.2.7 Shift Solenoids A and B
5.2.8 Line Pressure Solenoid and Lock Up Solenoid
5.2.9 Overrun Clutch Solenoid
5.2.10 Engine Speed Sensor
5.2.11 Dropping Register
5.2.12 Power Mode Switch
5.3 Hydraulic Pressure Control Device
5.4 Gear Shift Mechanism
5.4.1 Reverse Clutch (Multi-Plate Clutch)
5.4.2 HIGH Clutch (Multi-Plate Clutch)
5.4.3 Brake Band
5.4.4 Forward Clutch (Multi-Plate Clutch) Overrun Clutch (Multi-Plate Clutch)
5.4.5 Low and Reverse Brake (Multi-Plate Clutch)
5.4.6 Planetary Gear
5.4.7 Forward One Way Clutch
5.4.8 Low One Way Clutch
5.4.9 Torque Transmission Path
5.5 Torque Converter (With Lock Up)
5.6 Oil Pump (Variable Capacity Vane Pump)
6. Service Standards
6.1 Maintenance and Inspection
6.1.1 ATF Inspection
6.1.2 ATF Replacement
6.2 Transmission Removal and Installation
6.2.1 Tasks Prior To Removal
6.2.2 Removal
6.2.3 Installation
6.2.4 Inspection and Adjustment After Installation
6.3 Removal and Installation of Transmission PTO
6.4 Oil Seal Replacement
6.5 Inhibitor Switch
6.5.1 Removal and Installation
6.5.2 Inspection and Adjustment
6.6 Accelerator Sensor Inspection
6.7 Automatic Transmission Control System Inspection
6.7.1 Inspection Preparation Tasks
6.7.2 Sensor Switch and Harness Inspection
6.7.3 Automatic Transmission Control Unit Inspection
6.7.4 Post Inspection Tasks
6.8 Causes of Failure and Prevention
6.8.1 Causes of Automatic Transmission Failure
6.8.2 Self Diagnosis Function
6.8.3 Load Test
6.8.4 Line Pressure Test
6.8.5 Stall Test
6.8.6 Fluid Leakage
6.9 Oil Cooler
6.9.1 Service Standards
6.9.2 General Description
6.9.3 Oil Cooler Fan System
6.9.4 Removal and Installation
6.9.5 Inspection
Group 24 – Transfer
Table of Contents
1. Troubleshooting
2. Removing the Transfer
2.1 Service Standards
2.1.1 Tightening Torque Table
2.1.2 Special Tool Table
2.2 Removal
2.3 Installation
3. Transfer Main Body
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.4 Disassembly
3.5 Inspection and Replacement
3.6 Reassembly
4. Transfer Control
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.3 General Description
4.4 Removal
4.5 Installation
4.6 Adjustment After Installation
4.7 Disassembly
4.8 Inspection
4.9 Reassembly
Group 25 – Propeller Shaft
Table of Contents
1. Troubleshooting
2. Rear Propeller Shaft
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.2.3 Special Tools Table
2.3 General Description
2.4 Removal
2.5 Disassembly
2.6 Inspection
2.7 Reassembly
2.8 Installation
3. Front, Rear Propeller Shaft <Two Joints>
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.4 Removal
3.5 Disassembly
3.6 Inspection
3.7 Reassembly
3.8 Installation
4. Double Cardin Propeller Shaft
4.1 Specifications
4.2 Service Standards
4.2.1 Service Standards Table
4.2.2 Tightening Torque Table
4.2.3 Special Tools Table
4.3 General Description
4.4 Removal
4.5 Disassembly
4.6 Inspection
4.7 Reassembly
4.8 Installation
Group 26 – Front Axle
Group 26A – Front Axle <FE>
Table of Contents
1. Troubleshooting
2. Front Axle Assembly
2.1 Specifications
2.2 Service Standards
2.2.1 Tightening Torque Table
2.3 General Description
2.4 Removal
2.5 Installation
2.6 Post-Installation Adjustment
3. Wheel Hub and Rotor
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Tightening Torque Table
3.1.3 Special Tools Table
3.2 Disassembly
3.3 Inspection
3.4 Reassembly
4. Front Axle Center and Knuckle
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Special Tools Table
4.2 Removal
4.3 Disassembly
4.4 Inspection
4.5 Reassembly
4.6 Installation
Group 26B – Front Axle <FG>
Table of Contents
1. Troubleshooting
2. Front Axle Assembly
2.1 Specifications
2.2 Service Standards
2.2.1 Tightening Torque Table
2.2.2 Special Tools Table
2.3 General Description
2.4 Removal
2.5 Installation
2.6 Post-Installation Adjustment
3. Wheel Hub and Brake Drum
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Tightening Torque Table
3.1.3 Special Tools Table
3.2 Disassembly
3.3 Inspection
3.4 Reassembly
4. Axle, Knuckle and Drive Shaft
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Special Tools Table
4.2 Disassembly
4.3 Inspection and Adjustment
4.4 Reassembly
5. Reduction and Differential
5.1 Service Standards
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.1.3 Special Tools Table
5.2 Removal
5.3 Preliminary Inspection
5.4 Disassembly
5.5 Inspection
5.6 Reassembly
5.7 Installation
Group 27 – Rear Axle
Table of Contents
1. Troubleshooting
2. Rear Axle Assembly
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.3 General Description
2.4 Removal
2.5 Disassembly
2.6 Inspection
2.7 Reassembly
2.8 Installation
3. Wheel Hub and Brake Drum
3.1 Service Standards
3.1.1 Service Standards Table
3.1.2 Tightening Torque Table
3.1.3 Special Tools Table
3.2 Disassembly
3.3 Inspection
3.4 Reassembly
4. Reduction and Differential
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.1.3 Special Tools Table
4.2 Removal
4.3 Preliminary Inspection
4.4 Disassembly
4.5 Inspection
4.6 Reassembly
4.7 Installation
Group 31 – Wheels and Tires
Table of Contents
1. Troubleshooting
2. Wheels and Tires
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.3 General Description
2.4 Removal
2.4.1 Preliminary Operation
2.4.2 Removal
2.4.3 Front Tires
2.4.4 Rear Tires
2.4.5 Inspection of Wheel Bolt and Nut
2.5 Disassembly and Inspection
2.6 Reassembly
2.7 Post-Assembly Inspection and Adjustment
2.8 Installation
Group 33 – Front Suspension
Table of Contents
1. Troubleshooting
2. Front Suspension Assembly
2.1 Service Standards
2.2 General Description
2.3 Removal
2.4 Inspection
2.5 Installation
3. Leaf Springs
3.1 Specifications
3.2 Service Standards
3.3 General Description
3.4 Pre-Disassembly Inspection
3.5 Disassembly
3.6 Inspection
3.7 Reassembly
4. Shock Absorbers
4.1 Specifications
4.2 General Description
4.3 Disassembly
4.4 Inspection
5. Stabilizer <FE Series Only>
5.1 General Description
5.2 Pre-Disassembly Inspection
5.3 Disassembly
5.4 Inspection
5.5 Reassembly
Group 34 – Rear Suspension
Table of Contents
1. Troubleshooting
2. Rear Suspension Assembly
2.1 Service Standards
2.1.1 Service Standard Table
2.1.2 Tightening Torque Table
2.1.3 Special Tools Table
2.2 General Description
2.3 Removal
2.4 Inspection
2.5 Installation
3. Leaf Springs
3.1 Specifications
3.2 Service Standards
3.3 General Description
3.4 Pre-Disassembly Inspection
3.5 Disassembly
3.6 Inspection
3.7 Reassembly
4. Shock Absorbers
4.1 Specifications
4.2 General Description
4.3 Disassembly
4.4 Inspection
5. Stabilizer <FE Series Only>
5.1 General Description
5.2 Pre-Disassembly Inspection
5.3 Disassembly
5.4 Inspection
5.5 Reassembly
Group 35 – Brake
Table of Contents
1. Troubleshooting
2. Brake System
2.1 Specifications
2.2 Service Standards
2.2.1 Tightening Torque Table
2.3 General Description
2.4 Bleeding of Air From the Brake System
2.4.1 Front Brake System
2.4.2 Rear Brake System
2.4.3 Bypass Valve System
2.5 Replacing of Brake Fluid
2.5.1 Draining the Brake Fluid
2.5.2 Changing Front Brake System Brake Fluid
2.5.3 Changing Rear Brake System Brake Fluid
2.5.4 Changing the Brake Fluid of the Bypass Valve System
2.5.5 Bleeding of Brake System
3. Brake Piping
3.1 Service Standards
3.1.1 Tightening Torque Table
3.2 Inspection Before Removal
3.3 Draining Out Brake Fluid
3.4 Removal
3.5 Inspection
3.6 Installation
4. Vacuum Tank
4.1 Service Standards
4.1.1 Service Standards Table
4.2 Vacuum Switch
4.2.1 Inspection
4.2.2 Removal
4.2.3 Installation
4.3 Vacuum Tank
4.3.1 Removal
4.3.2 Inspection
4.3.3 Installation
5. Brake Pedal
5.1 Service Standard
5.1.1 Service Standards Table
5.1.2 Tightening Torque Table
5.2 Brake Fluid Tank
5.2.1 Inspection Before Removal
5.2.2 Removal
5.2.3 Inspection
5.2.4 Installation
5.3 Brake Pedal
5.3.1 Removal
5.3.2 Disassembly
5.3.3 Inspection
5.3.4 Assembly
5.3.5 Installation
5.3.6 Positioning Brake Pedal
5.3.7 Brake Pedal Play
5.3.8 Distance Between Brake Pedal and Floor Board
5.3.9 Adjustment of Stop Lamp Switch
6. Brake Booster (Master Vac)
6.1 Specifications
6.2 Service Standards
6.2.1 Tightening Torque Table
6.2.2 Special Tools Table
6.3 General Description
6.4 Removal
6.5 Disassembly
6.6 Inspection
6.7 Reassembly
6.8 Installation
6.9 Adjustments After Installation
6.10 Inspection After Installation
7. Brake Master Cylinder
7.1 Specifications
7.2 Service Standards
7.2.1 Service Standards Table
7.2.2 Tightening Torque Table
7.3 General Description
7.4 Removal
7.5 Disassembly
7.6 Inspection
7.7 Reassembly
7.8 Installation
8. Proportioning Valve
8.1 Specifications
8.2 Service Standards
8.2.1 Service Standards Table
8.2.2 Tightening Torque Table
8.3 General Description
8.3.1 Valve Unit
8.3.2 Sensor
8.4 Removal
8.5 Disassembly
8.6 Inspection
8.7 Reassembly
8.8 Installation
8.9 Adjustment After Installation and Functional Test
9. Bypass Valve
9.1 General Description
9.2 Functional Inspection
9.3 Removal
9.4 Installation
10. Front Disc Brake <FE Series>
10.1 Specifications
10.2 Service Standards
10.2.1 Service Standards Table
10.2.2 Tightening Torque Table
10.2.3 Special Tools
10.3 General Description
10.4 Replacing the Pads
10.5 Removal
10.6 Disassembly
10.7 Inspection
10.8 Reassembly
10.9 Installation
10.10 Measure Dragging Torque (Tangential Force)
11. Front Drum Brake <FG Series>
11.1 Specifications
11.2 Service Standards
11.2.1 Service Standards Table
11.2.2 Tightening Torque Table
11.3 Outline
11.4 Removal
11.5 Disassembly
11.6 Inspection
11.7 Reassembly
11.8 Wheel Cylinder
11.8.1 Disassembly
11.8.2 Inspection
11.8.3 Reassembly
11.9 Installation
11.10 Shoe Clearance Adjustment
12. Rear Drum Brake
12.1 Specifications
12.2 Service Standards
12.2.1 Service Standards Table
12.2.2 Tightening Torque Table
12.3 General Description
12.4 Removal
12.5 Disassembly
12.6 Inspection
12.7 Reassembly
12.8 Wheel Cylinder <FE Series>
12.8.1 Disassembly
12.8.2 Inspection
12.8.3 Reassembly
12.9 Wheel Cylinder <FG Series>
12.9.1 Disassembly
12.9.2 Inspection
12.9.3 Reassembly
12.10 Installation
12.11 Adjusting Shoe Clearance
13. Exhaust Brake System
13.1 Specifications
13.2 Service Standards
13.2.1 Service Standards Table
13.2.2 Tightening Torque Table
13.3 General Description
13.4 Removal
13.5 Disassembly
13.6 Inspection
13.7 Reassembly
13.8 Installation
13.9 Inspection After Installation
Group 36 – Parking Brake
Table of Contents
1. Troubleshooting
2. Parking Brake Control
2.1 Specifications
2.2 Service Standards
2.2.1 Service Standards Table
2.2.2 Tightening Torque Table
2.3 General Description
2.4 Removal
2.4.1 Preliminary Operations
2.4.2 Parking Brake Lever Assembly
2.4.3 Parking Brake Cable
2.4.4 Inspection
2.5 Disassembly and Inspection
2.5.1 Disassembly
2.5.2 Inspection
2.6 Assembly and Repair
2.7 Installation
2.7.1 Parking Brake Lever Assembly
2.7.2 Parking Brake Cable
2.8 Post-Installation Adjustments
3. Parking Brake Drum and Brake Shoe
3.1 Specifications
3.2 Service Standards
3.2.1 Service Standards Table
3.2.2 Tightening Torque Table
3.2.3 Special Tools Table
3.3 General Description
3.4 Removal
3.4.1 Preliminary Operations
3.4.2 Removal
3.5 Disassembly and Inspection
3.5.1 Disassembly
3.5.2 Inspection
3.6 Reassembly
3.7 Installation
Group 37 – Steering
Table of Contents
1. Troubleshooting
2. Steering System
2.1 Service Standards
2.1.1 Service Standards Table
2.1.2 Tightening Torque Table
2.2 General Description
2.2.1 Steering System
2.2.2 Power Steering System
2.3 Power Steering Oil Change
2.4 Performance Verification Tests
2.5 Overall Power Steering Inspection
3. Steering Wheel and Shaft
3.1 Specifications
3.2 Service Standards
3.2.1 Tightening Torque Table
3.3 General Description
3.4 Removal
3.5 Disassembly
3.6 Assembly
3.7 Installation
3.8 Post-Installation Inspection
4. Steering Linkage
4.1 Service Standards
4.1.1 Service Standards Table
4.1.2 Tightening Torque Table
4.2 General Description
4.3 Drag Link
4.3.1 Removal
4.3.2 Installation
4.3.3 Greasing
4.4 Tie Rod
4.4.1 Removal
4.4.2 Disassembly
4.4.3 Inspection
4.4.4 Assembly
4.4.5 Installation
4.4.6 Greasing
4.5 Post-Installation Inspection and Adjustment
5. Power Steering Booster
5.1 Specifications
5.2 Service Standards
5.2.1 Service Standards Table
5.2.2 Tightening Torque Table
5.2.3 Special Tools Table
5.3 General Description
5.3.1 Structure
5.3.2 Operation
5.4 Removal
5.5 Pre-Disassembly Work and Inspection
5.6 Disassembly
5.7 Inspection
5.8 Assembly
5.9 Post-Assembly Work and Inspection
5.10 Installation
5.11 Post-Installation Inspection
6. Power Steering Oil Pump
6.1 Specifications
6.2 Service Standards
6.2.1 Service Standards Table
6.2.2 Tightening Torque Table
6.3 General Description
6.4 Removal
6.5 Disassembly
6.6 Inspection
6.7 Assembly
6.8 Installation
6.9 Post-Installation Inspection and Adjustment
Group 41 – Frame
Table of Contents
1. Frame Assembly
1.1 Specifications
1.2 General Description
1.3 Inspection and Repair
1.3.1 Frame
1.3.2 Rivets
1.3.3 Nuts and Bolts
1.4 Frame Shape
Group 42 – Cab
Table of Contents
1. Troubleshooting
2. Cab
2.1 Specifications
2.2 Service Standards
2.3 General Description
2.4 Cab Tilting Method
2.5 Removal
2.5.1 Operations Before Removal
2.5.2 Operations Inside the Cab
2.5.3 Operations In Front of the Cab
2.5.4 Cab Tilting Operations
2.5.5 Lifting the Cab
2.6 Installing the Cab
2.6.1 Lifting the Cab
2.6.2 Operations for Tilting the Cab
2.6.3 Operations In Front of the Cab
2.6.4 Operations Inside the Cab
2.6.5 Operations After Installation
3. Cab Mounting
3.1 Specifications
3.2 Service Standards
3.3 General Description
3.3.1 Cab Mounting
3.3.2 Cab Hinge
3.3.3 Cab Stay
3.3.4 Cab Tilt Link
3.4 Removal
3.4.1 Operations Before Removal
3.4.2 Removing the Cab Tilt Link
3.4.3 Removing the Rear Cab Mounting
3.4.4 Removing the Cab Hinge
3.5 Installation
3.5.1 Cab Hinge Installation
3.5.2 Rear Cab Mounting Installation
3.5.3 Cab Tilt Link Installation
3.5.4 Operations After Installation
4. Front Windshield Glass and Rear Window Glass
4.1 Specifications
4.2 Service Standards
4.3 Removal
4.3.1 Operations Before Removal
4.3.2 Removal Operations
4.4 Installation
4.4.1 Installation Operations
4.4.2 Operations After Installation
5. Door Assembly
5.1 Specifications
5.2 Service Standards
5.3 General Description
5.4 Removal
5.4.1 Operations Before Removal
5.4.2 Removing the Door Trim
5.4.3 Removing the Front Door Window Glass
5.4.4 Removing the Front Door Window Regulator
5.4.5 Removing the Front Door Locking System
5.4.6 Removing the Outside Mirror Stay Assembly
5.4.7 Removing the Front Door Panel
5.5 Installation
5.5.1 Front Door Panel Installation
5.5.2 Outside Mirror Stay Assembly Installation
5.5.3 Front Door Locking System Installation
5.5.4 Inspection and Adjustment After Installing the Front Door Locking System
5.5.5 Front Door Window Regulator Installation
5.5.6 Front Door Window Glass Installation
5.5.7 Door Trim Installation
6. Seat and Seat Belts
6.1 Specifications
6.2 Service Standards
6.3 Removal
6.3.1 Removing the Driver’s Seat
6.3.2 Removing the Passenger Seat
6.3.3 Removing the Seat Belts
6.4 Inspection
6.4.1 Seat Belt Installation
6.4.2 Driver’s Seat Installation
6.4.3 Passenger Seat Installation
7. Trim
7.1 Service Standards
7.2 Removal
7.3 Installation
8. Floor Mats
8.1 Removal
8.2 Installation
9. Instrument Panel
9.1 Service Standards
9.2 Removal
9.3 Installation
10. Cab and Associated Parts
10.1 Service Standards
10.2 Removal
10.3 Installation
11. Silencer
11.1 Service Standards
11.2 Removal
11.3 Installation
Group 54 – Chassis Electrical
Table of Contents
1. Troubleshooting
2. Chassis Electrical System
2.1 Specifications
2.2 General Description
2.3 Wiring Harness
2.4 Central Ground Connections
3. Battery
3.1 Specifications
3.2 General Description
3.3 Inspection
4. Fuses and Relays
4.1 Specifications
4.2 Service Standards
4.3 General Description
4.4 Installation Locations
4.5 Inspection
5. Fusible Link
5.1 Specifications
5.2 General Description
5.3 Installation Locations
5.4 Inspection
6. Starting System
6.1 Specifications
6.2 General Description
6.3 Installation Locations
6.4 Inspection
7. Column Switches
7.1 Specifications
7.2 General Description
7.3 Installation Locations
7.4 Inspection
8. Lighting System
8.1 Specifications
8.2 Wiring Diagram
8.3 General Description
8.4 Installation Locations
8.5 Inspection
9. Meters and Gauges
9.1 Specifications
9.2 Service Standards
9.3 Wiring Diagram
9.4 General Description
9.5 Installation Locations
9.6 Inspection
10. Indicators and Warning Lamps
10.1 Specifications
10.2 Service Standards
10.3 Wiring Diagram
10.4 General Description
10.5 Installation Locations
10.6 Inspection
11. Exhaust Brake System
11.1 Specifications
11.2 Wiring Diagram
11.3 General Description
11.4 Installation Locations
11.5 Inspection
12. Wipers and Washer
12.1 Specifications
12.2 Wiring Diagram
12.3 Installation Locations
12.4 Inspection
13. Sub-Starting System
13.1 Specifications
13.2 Wiring Diagram
13.3 General Description
13.4 Installation Locations
13.5 Inspection
14. Horn
14.1 Specifications
14.2 Wiring Diagram
14.3 Installation Locations
14.4 Inspection
15. Radio (Option), Cassette Stereo (Option), Speakers and Antenna
15.1 Specifications
15.2 General Description
15.3 Installation Locations
15.4 Inspection
16. Cigarette Lighter
16.1 Specifications
16.2 Wiring Diagram
16.3 General Description
16.4 Installation Locations
16.5 Inspection
Group 55A – Air Conditioner
Group 55A (9401) – Air Conditioner
Foreword/Table of Contents
1. Specifications
2. Outlines of Refrigeration System
3. Construction
4. Troubleshooting
5. Removal and Installation
6. Treatment After Installation
7. Cooling Unit
8. Maintenance
9. Compressor
Group 55A (9105) – Air Conditioner
Table of Contents
1. Specifications
2. Outlines of Refrigeration System
3. Construction
4. Troubleshooting
5. Removal and Installation
6. Treatment After Installation
7. Cooling Unit
8. Maintenance
9. Compressor
Group 55B – Heater
Table of Contents
1. Troubleshooting
2. Heater
2.1 Specifications
2.2 Service Standards
2.3 General Description
2.4 Wiring Diagram
2.5 Pre-Removal Inspection
2.5.1 Heater Switch Inspection
2.5.2 Mode Selector Lever Inspection
2.5.3 Temperature Control Lever Inspection
2.5.4 Air Selector Lever Inspection
2.5.5 Side Ventilator Inspection
2.6 Removal
2.7 Disassembly
2.8 Reassembly
2.9 Installation
2.10 Post-Installation Adjustments
2.11 Water Hoses
2.11.1 Inspection
2.11.2 Removal
2.11.3 Connection
3. Ventilation
3.1 Service Standards
3.2 Removal
3.3 Installation
3.4 Post-Installation Adjustments

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