SUPPLEMENT CHASSIS & BODY DR053E.pdf

2000 TOYOTA MOTOR CORPORATION
All rights reserved. This CD may not be repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
FOREWORD
This SUPPLEMENT has been prepared to provide information covering general service repairs for the
CHASSIS and BODY of the TOYOTA HILUX which underwent changes in June, 2000.
Applicable models: KZN165, 190 series
Forthe service specifications and repair procedures of the above modelother than those listed in this supple-
ment, refer to the following manuals.
Manual Name Pub. No.
S HILUX Chassis and Body Repair Manual RM585E
S HILUX Chassis and Body Repair Manual Supplement (May, 1998) RM651E
S HILUX Chassis and Body Repair Manual Supplement (Aug., 1999) RM706E
S 1KZ-
-TE Engine Repair Manual RM710E
S HILUX Electrical Wiring Diagram DR030W
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non--specialized or uncertified technicians perform repair or service only using this manu-
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damages to your customer’s vehicle, be sure to follow
the instruction shown below.
S Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of ”IN” section.
S The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use toolsspe-
cified and recommended. If using non--specified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customer’s vehicle before starting the operation.
S If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
S It is important to note that this manual contains various ”Cautions” and ”Notices” that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ”Cautions” and ”Notices” are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
THE MAIN INDEX
DR053E Pages From Supplement
TOYOTA MOTOR CORPORATION
Back To Chassis & Body Index
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PREPARATION
SERVICE SPECIFICATIONS
CLUTCH
R151, R151F MANUAL TRANSMISSION
SUSPENSION AND AXLE
BRAKE
STEERING
BODY ELECTRICAL
AIR CONDITIONING
ALPHABETICAL INDEX
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SUPPLEMENT: CHASSIS & BODY:
Pages From Supplement
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DR053E
MAIN INDEX: HILUX
June 2000

PREPARATION
CLUTCH PP--1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSMISSION
(R151, R151F) PP--4
. . . . . . . . . . . . . . . . . . . . . . . . .
STEERING PP--10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REFER TO FOLLOWING REPAIR MANUALS:
HILUX Chassis and Body Repair Manual RM585E
HILUX Chassis and Body Repair Manual Supplement
(May, 1998)
RM651E
(Aug., 1999)
RM706E
NOTE: The above pages contain only the points which differ
from the above listed manuals.
BACK TO MAIN INDEX Pages From Supplement
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DR053E
CHAS. & BODY:

PP0KV-
-02
-
-
PREPARATION CLUTCH
PP-
-1
CLUTCH
SST (Special Service Tools)
09023-
-00100 Union Nut Wrench 10 mm Clutch line
09301-
-00110 Clutch Guide Tool
09303-
-35011 Input Shaft Front Bearing Puller
09304-
-30012 Input Shaft Front Bearing
Replacer
09333-
-00013 Clutch Diaphragm Spring Aligner
09922-
-10010 Variable Open Wrench Clutch accumulator
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DR053E
CHAS. & BODY:

PP0KW-
-02
PP-
-2
-
-
PREPARATION CLUTCH
RECOMMENDED TOOLS
09031-
-00030 Pin Punch . Reservoir tank
09905-
-00013 Snap Ring Pliers .
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DR053E
CHAS. & BODY:

PP0KX-
-01
-
-
PREPARATION CLUTCH
PP-
-3
EQUIPMENT
Calipers
Torque wrench
Dial indicator with magnetic base
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DR053E
CHAS. & BODY:

PP0A2-
-03
PP-
-4
-
-
PREPARATION MANUAL TRANSMISSION (R151, R151F)
MANUAL TRANSMISSION (R151, R151F)
09309-
-35010 Transmission Rear Bearing
Replacer
2WD:
Output shaft rear bearing
Output shaft center bearing
09316-
-60011 Transmission & Transfer Bearing
Replacer
(09316-
-00011) Replacer Pipe Output shaft rear bearing
Gear spline piece No.5
(09316-
-00031) Replacer ”B” 5th gear
(09316-
-00071) Replacer ”F” 4WD:
Output shaft rear bearing
Output shaft center bearing
09506-
-35010 Differential Drive Pinion Rear
Bearing Replacer
Input shaft bearing
09950-
-00020 Bearing Remover
09950-
-40011 Puller B Set Output shaft rear bearing
09950-
-50012 Puller C Set Gear spline piece No.5
09950-
-60010 Replacer Set
(09951-
-00510) Replacer 51 Front bearing retainer oil seal
(09951-
-00570) Replacer 57 Extension housing oil seal
Transfer adaptor oil seal
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DR053E
CONTINUED
CHAS. & BODY:

-
-
PP-
-5
(09951-
-00620) Replacer 62 Counter rear bearing
09950-
-70010 Handle Set
(09951-
-07150) Handle 150
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DR053E
CHAS. & BODY:

PP0A3-
-03
PP-
-6
-
-
RECOMMENDED TOOLS
09031-
-00030 Pin Punch .
09040-
-00011 Hexagon Wrench Set .
09042-
-00020 Torx Socket T40 .
09905-
-00012 Snap Ring No.1 Expander .
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DR053E
CHAS. & BODY:

PP0A4-
-01
-
-
PP-
-7
EQUIPMENT
Dial indicator
Micrometer
Torque wrench
Feeler gauge
Magnetic finger
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DR053E
CHAS. & BODY:

PP0A5-
-02
PP-
-8
-
-
LUBRICANT
Item Capacity Classification
Manual transmission oil 2WD
4WD
2.6 liters (2.7 US qts, 2.3 Imp. qts)
2.2 liters (2.3 US qts, 1.9 Imp. qts)
API GL-
-4 or GL-
-5
SAE 75W-
-90
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DR053E
CHAS. & BODY:

PP3AH-
-01
-
-
PP-
-9
SSM (Special Service Materials)
08826-
-00090 Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)
Transmission case x
Intermediate plate
Front bearing retainer x
Transmission case
08833-
-00080 Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent
Straight screw plug
Front bearing retainer bolt
Control shift lever retainer set bolt
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DR053E
CHAS. & BODY:

PP3AI-
-01
PP-
-10
-
-
PREPARATION STEERING
STEERING
09631-
-12031 Oil Seal ”A” Remover-
-
09640-
-10010 Power Steering Pressure Gauge
Set
(09641-
-01010) Gauge Assy Power steering fluid
(09641-
-01030) Attachment B Power steering fluid
(09641-
-01040) Attachment C Power steering fluid
09950-
-00020 Bearing Remover PS vane pump
09950-
-60010 Replacer Set
(09951-
-00230) Replacer 23 PS vane pump
09950-
-70010 Handle Set
(09951-
-07100) Handle 100 PS vane pump
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DR053E
CHAS. & BODY:

PP3AJ-
-01
-
-
PP-
-11
RECOMMENDED TOOLS
09025-
-00010 Torque Wrench (30 kgf-
-cm) PS vane pump
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DR053E
CHAS. & BODY:

PP3AK-
-01
PP-
-12
-
-
EQUIPMENT
Caliper gauge PS vane pump
Vernier calipers PS vane pump
Feeler gauge PS vane pump
Micrometer PS vane pump
Torque wrench
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DR053E
CHAS. & BODY:

PP3AL-
-01
-
-
PP-
-13
LUBRICANT
Item Capacity Classification
Power steering fluid Total 0.8 liters (0.8 US qts, 0.7 lmp.qts) ATF DEXRON II or III
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DR053E
CHAS. & BODY:

SERVICE SPECIFICATIONS
STANDARD BOLT SS--1
. . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH SS--4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSMISSION (R151, R151F) SS--6
. .
SUSPENSION AND AXLE SS--9
. . . . . . . . . . . . . . . .
BRAKE SS--12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING SS--14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING SS--16
. . . . . . . . . . . . . . . . . . . . .
(May, 1998)
RM651E
(Aug., 1999)
RM706E
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DR053E
CHAS. & BODY:

SS0ZS-
-01
4
5
6
7
8
9
10
11
B06431
Bolt Type
Hexagon Head Bolt
Normal Recess Bolt Deep Recess Bolt
Stud Bolt Weld Bolt
Class
4T
5T
6T
7T
8T
9T
10T
11T
No Mark
w/ Washer
No Mark No Mark
w/ Washer
-
-
SERVICE SPECIFICATIONS STANDARD BOLT
SS-
-1
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH
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DR053E
CHAS. & BODY:

SS0ZT-
-01
SS-
-2
-
-
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
Class
Diameter
mm
Pitch
mm
Hexagon head bolt Hexagon flange bolt
Class
mm mm
N∙m kgf∙cm ft∙lbf N∙m kgf∙cm ft∙lbf
4T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
5
12.5
26
47
74
115
55
130
260
480
760
1,150
48 in.∙lbf
9
19
35
55
83
6
14
29
53
84
-
-
60
145
290
540
850
-
-
52 in.∙lbf
10
21
39
61
-
-
5T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
6.5
15.5
32
59
91
140
65
160
330
600
930
1,400
56 in.∙lbf
12
24
43
67
101
7.5
17.5
36
65
100
-
-
75
175
360
670
1,050
-
-
65 in.∙lbf
13
26
48
76
-
-
6T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
8
19
39
71
110
170
80
195
400
730
1,100
1,750
69 in.∙lbf
14
29
53
80
127
9
21
44
80
125
-
-
90
210
440
810
1,250
-
-
78 in.∙lbf
15
32
59
90
-
-
7T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
10.5
25
52
95
145
230
110
260
530
970
1,500
2,300
8
19
38
70
108
166
12
28
58
105
165
-
-
120
290
590
1,050
1,700
-
-
9
21
43
76
123
-
-
8T
8
10
12
1.25
1.25
1.25
29
61
110
300
620
1,100
22
45
80
33
68
120
330
690
1,250
24
50
90
9T
8
10
12
1.25
1.25
1.25
34
70
125
340
710
1,300
25
51
94
37
78
140
380
790
1,450
27
57
105
10T
8
10
12
1.25
1.25
1.25
38
78
140
390
800
1,450
28
58
105
42
88
155
430
890
1,600
31
64
116
11T
8
10
12
1.25
1.25
1.25
42
87
155
430
890
1,600
31
64
116
47
97
175
480
990
1,800
35
72
130
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DR053E
CHAS. & BODY:

SS0ZU-
-01
6N
8N
10N
11N
12N
B06432
Nut Type
Present Standard
Hexagon Nut Cold Forging Nut Cutting Processed Nut
Class
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11N
12N
Old Standard Hexagon Nut
No Mark (w/ Washer)
No Mark
*
No Mark (w/ Washer) No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
-
-
SS-
-3
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
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DR053E
CHAS. & BODY:

SS0AY-
-02
SS-
-4
-
-
SERVICE SPECIFICATIONS CLUTCH
CLUTCH
SERVICE DATA
Pedal height from dash panel 172.0 -
- 182.0 mm (6.772 -
- 7.165 in.)
Pedal freeplay 5.0 -
- 15.0 mm (0.197 -
- 0.591 in.)
Push rod play at pedal top 1.0 -
- 5.0 mm (0.039 -
- 0.197 in.)
Clutch release point from pedal full stroke end position 25 mm (0.98 in.) or more
Slotted spring pin protrusion 1.5 -
- 3.5 mm (0.059 -
- 0.138 in.)
Disc rivet head depth Min. 0.3 mm (0.012 in.)
Disc runout Max. 0.8 mm (0.031 in.)
Flywheel runout Max. 0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth A 0.6 mm (0.024 in.)
Diaphragm spring finger wear Max. width B 5.0 mm (0.197 in.)
Diaphragm spring tip non-
-alignment Max. 0.5 mm (0.020 in.)
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DR053E
CHAS. & BODY:

SS0AZ-
-02
-
-
SERVICE SPECIFICATIONS CLUTCH
SS-
-5
TORQUE SPECIFICATION
Part tightened N∙m kgf∙cm ft∙lbf
Clutch line union 15 155 11
Master cylinder installation nut 14 143 10
Clutch accumulator (For use with SST)
(For use without SST)
48
63
485
640
35
46
Bleeder plug 11 110 8
Release cylinder installation bolt 12 120 9
Clutch cover x Flywheel 19 195 14
Release fork support 39 400 29
Flywheel set bolt 178 1.817 131
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DR053E
CHAS. & BODY:

SS05E-
-03
SS-
-6
-
-
SERVICE SPECIFICATIONS MANUAL TRANSMISSION (R151, R151F)
SERVICE DATA
Output shaft 1st gear journal diameter Min. 38.979 mm (1.5346 in.)
Output shaft 2nd gear journal diameter Min. 46.984 mm (1.8498 in.)
Output shaft 3rd gear journal diameter Min. 37.984 mm (1.4954 in.)
Output shaft flange thickness Min. 4.8 mm (0.1890 in.)
Output shaft runout Max. 0.03 mm (0.0012 in.)
Gear thrust clearance 1st STD
Max.
0.20-
-0.45 mm (0.0079-
-0.0177 in.)
0.45 mm (0.0177 in.)
Gear thrust clearance 2nd and 3rd STD
Max.
0.10-
-0.25 mm (0.0039-
-0.0098 in.)
0.25 mm (0.0098 in.)
Gear radial clearance 1st STD
Max.
0.020-
-0.073 mm (0.0008-
-0.0029 in.)
0.073 mm (0.0029 in.)
Gear radial clearance 2nd and 3rd STD
Max.
0.015-
-0.068 mm (0.0006-
-0.0027 in.)
0.068 mm (0.0063 in.)
Shift fork No. 1 to reverse gear clearance Max. 0.41 mm (0.016 in.)
Shift fork No. 2 to hub sleeve No. 2 clearance Max. 0.35 mm (0.014 in.)
Synchronizer ring to gear clearance 1st Min. 0.75 mm (0.030 in.)
Synchronizer ring to gear clearance 2nd Min. 0.65 mm (0.026 in.)
Synchronizer ring to gear clearance 3rd Min. 0.75 mm (0.030 in.)
Synchronizer ring to gear clearance 4th Min. 0.7 mm (0.028 in.)
Input shaft snap ring thickness
Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.10-
-2.15 mm (0.0827-
-0.0846 in.)
2.15-
-2.20 mm (0.0846-
-0.0866 in.)
2.20-
-2.25 mm (0.0866-
-0.0886 in.)
2.25-
-2.30 mm (0.0886-
-0.0906 in.)
2.30-
-2.35 mm (0.0906-
-0.0925 in.)
2.35-
-2.40 mm (0.0925-
-0.0945 in.)
2.40-
-2.45 mm (0.0945-
-0.0965 in.)
Output shaft snap ring thickness
Clutch hub No. 1 Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.30-
-2.35 mm (0.0906-
-0.0925 in.)
2.35-
-2.40 mm (0.0925-
-0.0945 in.)
2.40-
-2.45 mm (0.0945-
-0.0965 in.)
2.45-
-2.50 mm (0.0965-
-0.0984 in.)
2.50-
-2.55 mm (0.0984-
-0.1004 in.)
2.55-
-2.60 mm (0.1004-
-0.1024 in.)
2.60-
-2.65 mm (0.1024-
-0.1043 in.)
Clutch hub No. 2 Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
1.80-
-1.85 mm (0.0709-
-0.0728 in.)
1.85-
-1.90 mm (0.0728-
-0.0748 in.)
1.90-
-1.95 mm (0.0748-
-0.0768 in.)
1.95-
-2.00 mm (0.0768-
-0.0787 in.)
2.00-
-2.05 mm (0.0787-
-0.0807 in.)
2.05-
-2.10 mm (0.0807-
-0.0827 in.)
2.10-
-2.15 mm (0.0827-
-0.0846 in.)
TO MODEL INDEX
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DR053E
CONTINUED
CHAS. & BODY:

-
-
SS-
-7
Rear Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
Mark H
Mark J
Mark K
Mark L
Mark M
Mark N
Mark P
Mark Q
Mark R
Mark S
2.65-
-2.70 mm (0.1043-
-0.1063 in.)
2.70-
-2.75 mm (0.1063-
-0.1083 in.)
2.75-
-2.80 mm (0.1083-
-0.1102 in.)
2.80-
-2.85 mm (0.1102-
-0.1122 in.)
2.85-
-2.90 mm (0.1122-
-0.1142 in.)
2.90-
-2.95 mm (0.1142-
-0.1161 in.)
2.95-
-3.00 mm (0.1161-
-0.1181 in.)
3.00-
-3.05 mm (0.1181-
-0.1201 in.)
3.05-
-3.10 mm (0.1201-
-0.1220 in.)
3.10-
-3.15 mm (0.1220-
-0.1240 in.)
3.15-
-3.20 mm (0.1240-
-0.1260 in.)
3.20-
-3.25 mm (0.1260-
-0.1280 in.)
3.25-
-3.30 mm (0.1280-
-0.1299 in.)
3.30-
-3.35 mm (0.1299-
-0.1319 in.)
3.35-
-3.40 mm (0.1319-
-0.1339 in.)
3.40-
-3.45 mm (0.1339-
-0.1358 in.)
3.45-
-3.50 mm (0.1358-
-0.1378 in.)
Counter gear roller bearing journal diameter Min. 29.984 mm (1.1805 in.)
Counter 5th gear thrust clearance STD
Max.
0-
-0.25 mm (0-
-0.0098 in.)
0.25 mm (0.0098 in.)
Counter 5th radial clearance STD
Max.
0.015-
-0.068 mm (0.0006-
-0.0027 in.)
0.068 mm (0.0027 in.)
Shift fork No. 3 to hub sleeve No. 3 clearance Max. 0.84 mm (0.033 in.)
Reverse idler gear radial clearance STD
Max.
0.040-
-0.082 mm (0.0016-
-0.0032 in.)
0.082 mm (0.0032 in.)
Reverse idler gear to shift arm clearance STD
Max.
0.05-
-0.35 mm (0.0020-
-0.0138 in.)
0.35 mm (0.0138 in.)
Counter gear snap ring thickness
Front Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
2.05-
-2.10 mm (0.0807-
-0.0827 in.)
2.10-
-2.15 mm (0.0827-
-0.0846 in.)
2.15-
-2.20 mm (0.0846-
-0.0866 in.)
2.20-
-2.25 mm (0.0866-
-0.0886 in.)
2.25-
-2.30 mm (0.0886-
-0.0906 in.)
2.30-
-2.35 mm (0.0906-
-0.0925 in.)
Counter gear snap ring thickness
Rear Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.80-
-2.85 mm (0.1102-
-0.1122 in.)
2.85-
-2.90 mm (0.1122-
-0.1142 in.)
2.90-
-2.95 mm (0.1142-
-0.1161 in.)
2.95-
-3.00 mm (0.1161-
-0.1181 in.)
3.00-
-3.05 mm (0.1181-
-0.1201 in.)
3.05-
-3.10 mm (0.1201-
-0.1220 in.)
3.10-
-3.15 mm (0.1220-
-0.1240 in.)
Oil seal drive in depth
Front bearing retainer (from retainer end)
Extension housing
Transfer adaptor
11.7 ± 0.5 mm (0.461 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
45.9 ± 0.5 mm (1.807 ± 0.020 in.)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS05F-
-02
SS-
-8
-
-
Transmission x Engine 72 730 53
Starter x Transmission 39 400 29
Engine rear mounting x Transmission 65 660 48
Rear end plate x Transmission 18 185 13
Clutch release cylinder x Clutch housing 12 120 9
Clutch release cylinder line x Clutch housing 12 120 9
Front exhaust pipe support bracket 44 450 33
Front exhaust pipe x Exhaust manifold 62 630 46
No. 2 Frame crossmember x Engine rear mounting 13 130 9
No. 2 Frame crossmember x Frame 95 970 70
Transmission x Transfer (4WD) 38 390 28
Reverse shift arm bracket set bolt 18 185 13
Rear bearing retainer x Intermediate plate 18 185 13
Shift fork x Shift fork shaft 20 200 14
Straight screw plug 19 190 14
Front bearing retainer x Transmission case 17 170 12
Transmission case x Transfer adaptor 37 380 27
Transmission case x Extension housing 37 380 27
Shift lever housing set bolt 38 390 28
Clutch housing x Transmission case 36 370 27
Oil receiver pipe x Extension housing (2WD) 11 115 8
Back-
-up light switch 44 450 32
Shift position switch 39 400 29
Restrict pin 37 380 27
Control shift lever retainer x Extension housing (2WD) 18 185 13
Control shift lever retainer x Transfer adaptor (4WD) 18 185 13
Transfer control shift lever retainer x Transfer adaptor (4WD) 18 185 13
Filler and drain plug 37 380 27
Vehicle speedometer driven gear set bolt (2WD) 11 115 8
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS1H7-
-01
-
-
SERVICE SPECIFICATIONS SUSPENSION AND AXLE
SS-
-9
SUSPENSION AND AXLE
SERVICE DATA
Wheel alignment (2WD)
Cold tire inflation
215R15C-
-6PR Front 180 kPa (1.8 kgf/cm2 or bar, 26 psi)
Rear 280 kPa (2.8 kgf/cm2 or bar, 41 psi)
pressure
(Loaded)
245/75R15 Front 180 kPa (1.8 kgf/cm2 or bar, 26 psi)
Cold tire inflation
215R15C-
-6PR Front 180 kPa (1.8 kgf/cm2 or bar, 26 psi)
pressure
(Unloaded)
245/75R15 Front 180 kPa (1.8 kgf/cm2 or bar, 26 psi)
KZN190R-
-TRMDTN 215R15C-
-6PR Front *1 69 mm (2.72 in.)
Rear *2 45 mm (1.77 in.)
Vehicle height
(Loaded)
KZN190R-
-TRMDTN 245/75R15 Front *1 69 mm (2.72 in.)
Rear *2 46 mm (1.81 in.)
(Loaded)
KZN190R-
-PRMDTN Front *1 68 mm (2.68 in.)
Rear *2 43 mm (1.69 in.)
KZN190R-
-TRMDTN 215R15C-
-6PR Front *1 62 mm (2.56 in.)
Rear *2 103 mm (4.06 in.)
Vehicle height
(Unloaded)
KZN190R-
-TRMDTN 245/75R15 Front *1 62 mm (2.44 in.)
Rear *2 104 mm (4.09 in.)
(Unloaded)
KZN190R-
-PRMDTN Front *1 64 mm (2.52 in.)
Rear *2 98 mm (3.86 in.)
KZN190R-
-TRMDTN 215R15C-
-6PR -
-0˚15’ ± 30’ (-
-0.25˚ ± 0.50˚)
Camber KZN190R-
-TRMDTN 245/75R15 -
-0˚15’ ± 30’ (-
-0.25˚ ± 0.50˚)
Camber
(Loaded) KZN190R-
-PRMDTN -
-0˚15’ ± 30’ (-
-0.25˚ ± 0.50˚)
Right-
-left error: 30’ (0.5˚) or less
KZN190R-
-TRMDTN 215R15C-
-6PR -
-0˚17’ ± 30’ (-
-0.28˚ ± 0.50˚)
Camber KZN190R-
-TRMDTN 245/75R15 -
-0˚17’ ± 30’ (-
-0.28˚ ± 0.50˚)
Camber
(Unloaded) KZN190R-
-PRMDTN -
-0˚17’ ± 30’ (-
-0.28˚ ± 0.50˚)
Right-
KZN190R-
-TRMDTN 215R15C-
-6PR 2˚52’ ± 30’ (2.87˚ ± 0.50˚)
Caster KZN190R-
-TRMDTN 245/75R15 2˚58’ ± 30’ (2.97˚ ± 0.50˚)
Caster
(Loaded) KZN190R-
-PRMDTN 3˚3’ ± 30’ (3.50˚ ± 0.50˚)
Right-
KZN190R-
-TRMDTN 215R15C-
-6PR 1˚10’ ± 30’ (1.17˚ ± 0.50˚)
Caster KZN190R-
-TRMDTN 245/75R15 1˚14’ ± 30’ (1.23˚ ± 0.50˚)
Caster
(Unloaded) KZN190R-
-PRMDTN 1˚21’ ± 45’ (1.35˚ ± 0.50˚)
Right-
Front*1: A --B
Rear*2: C -- D
Measuring points:
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

SS-
-10
-
-
KZN190R-
-TRMDTN 215R15C-
-6PR 12˚18’ ± 30’ (12.30˚ ± 0.50˚)
Steering axis
i li ti
KZN190R-
-TRMDTN 245/75R15 12˚18’ ± 30’ (12.30˚ ± 0.50˚)
inclination
(Loaded)
KZN190R-
-PRMDTN 12˚18’ ± 30’ (12.30˚ ± 0.50˚)
(Loaded)
Right-
KZN190R-
-TRMDTN 215R15C-
-6PR 12˚16’ ± 30’ (12.27˚ ± 0.50˚)
Steering axis
i li ti
KZN190R-
-TRMDTN 245/75R15 12˚16’ ± 30’ (12.27˚ ± 0.50˚)
inclination
(Unloaded)
KZN190R-
-PRMDTN 12˚16’ ± 30’ (12.27˚ ± 0.50˚)
(Unloaded)
Right-
KZN190R-
-TRMDTN 215R15C-
-6PR 1 ± 1 mm, 0.04 ± 0.04 in.
Toe-
-in (total) KZN190R-
-TRMDTN 245/75R15 1 ± 1 mm, 0.04 ± 0.04 in.
Toe in (total)
(Loaded) KZN190R-
-PRMDTN 1 ± 1 mm, 0.04 ± 0.04 in.
Tie rod end length difference: 3.0 mm (0.118 in.) or less
KZN190R-
-TRMDTN 215R15C-
-6PR 2.4 ± 1 mm, 0.09 ± 0.04 in.
Toe-
-TRMDTN 245/75R15 2.4 ± 1 mm, 0.09 ± 0.04 in.
Toe in (total)
(Unloaded) KZN190R-
-PRMDTN 2.4 ± 1 mm, 0.09 ± 0.04 in.
Tie rod end length difference: 3.0 mm (0.118 in.) or less
Wheel angle
(Manual steering)
Inside wheel
Outside wheel: Reference
36˚ (34˚ --- 37˚)
32˚
Wheel angle
(Power steering)
Inside wheel
38˚ (36˚ --- 39˚)
34˚
Wheel alignment (4WD)
Cold tire inflation
pressure
(Loaded)
KZN165R-
-PRMSTN
Front 180 kPa (1.8 kgf/cm2 or bar, 26 psi)
Cold tire inflation
pressure
(Unloaded)
KZN165R-
-PRMSTN
Front 180 kPa (1.8 kgf/cm2 or bar, 26 psi)
Vehicle height
(Loaded)
KZN165R-
-PRMSTN Front *3 70 mm (2.76 in.)
Rear *4 45 mm (1.77 in.)
Vehicle height
(Unloaded)
KZN165R-
-PRMSTN Front *3 63 mm (2.48 in.)
Rear *4 98 mm (3.86 in.)
Camber KZN165R-
-PRMSTN 0˚15’ ± 30’ (0.25˚ ± 0.50˚)
Camber
(Loaded) Right-
Camber KZN165R-
-PRMSTN 0˚17’ ± 30’ (0.28˚ ± 0.50˚)
Camber
(Unloaded) Right-
Caster KZN165R-
-PRMSTN 2˚55’ ± 30’ (2.92˚ ± 0.50˚)
Caster
(Loaded) Right-
Caster KZN165R-
-PRMSTN 1˚20’ ± 30’ (1.33˚ ± 0.50˚)
Caster
(Unloaded) Right-
Front*3: A --B
Rear*4: C -- D
Measuring points:
A: Ground clearance of spindle center.
B: Ground clearance of lower suspension arm bolt center.
C: Ground clearance of rear axle shaft center.
D: Ground clearance of leaf spring front hanger pin center.
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

-
-
SS-
-11
Steering axis
i li ti
KZN165R-
-PRMSTN 12˚18’ ± 45’ (12.27˚ ± 0.75˚)
inclination
(Loaded) Right-
Steering axis
i li ti
KZN165R-
-PRMSTN 12˚16’ ± 45’ (12.27˚ ± 0.75˚)
inclination
(Unloaded) Right-
Toe-
-PRMSTN 1 ± 1 mm, 0.04 ± 0.04 in.
Toe in (total)
(Loaded) Tie rod end length difference: 3.0 mm (0.118 in.) or less
Toe-
-PRMSTN 2.3 ± 1 mm, 0.09 ± 0.04 in.
Toe in (total)
(Unloaded) Tie rod end length difference: 3.0 mm (0.118 in.) or less
Wheel angle
Inside wheel
33˚ (31˚ --- 34˚)
32˚
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS0W2-
-03
SS-
-12
-
-
SERVICE SPECIFICATIONS BRAKE
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) 156.7 -
- 166.7 mm (6.169 -
- 6.563 in.)
Brake pedal freeplay 1 -
- 6 mm (0.039 -
- 0.236 in.)
Brake pedal reserve distance at 490 N (50 kgf, 110.1 lbf) 2WD More than 85 mm (3.35 in.)
4WD More than 80 mm (3.15 in.)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS0W3-
-03
-
-
SERVICE SPECIFICATIONS BRAKE
SS-
-13
Push rod lock nut 25 260 19
Vacuum pump x Check valve 74 750 54
Vacuum pump x engine nut 21 210 15
Vacuum pump gear lock nut 110 1,125 81
Vacuum pump end cover bolt 7.8 80 69 in.∙lbf
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS1HC-
-01
SS-
-14
-
-
SERVICE SPECIFICATIONS STEERING
STEERING
SERVICE DATA
POWER STEERING FLUID
Oil level rise Maximum 5 mm (0.20 in.)
Oil pressure at idle speed with valve closed Minimum 8,336 kPa (85 kgf/cm2, 1,209 psi)
PS VANE PUMP
Pump rotating torque Maximum 0.3 N∙m (2.8 kgf∙cm, 2.4 in.∙lbf)
Pump shaft and front housing bushing oil clearance STD
Maximum
0.03 -
- 0.05 mm (0.0012 -
- 0.0020 in.)
0.07 mm (0.0028 in.)
Vane plate height Minimum 8.6 mm (0.339 in.)
Vane plate thickness Minimum 1.397 mm (0.0550 in.)
Vane plate length Minimum 14.991 mm (0.5902 in.)
Vane plate and pump rotor groove clearance Maximum 0.035 mm (0.0014 in.)
Vane plate length Pump rotor and cam ring mark
None 14.999 -
- 15.001 mm (0.59001 -
- 0.59059 in.)
1 14.997 -
- 14.999 mm (0.59043 -
- 0.59051 in.)
2 14.995 -
- 14.997 mm (0.59035 -
- 0.59043 in.)
3 14.993 -
- 14.995 mm (0.59027 -
- 0.59035 in.)
4 14.991 -
- 14.993 mm (0.59020 -
- 0.59027 in.)
Flow control valve spring length Minimum 36.9 mm (1.453 in.)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS1HD-
-01
-
-
SERVICE SPECIFICATIONS STEERING
SS-
-15
PS VANE PUMP
Union bolt x Pressure feed tube 46 475 34
PS vane pump assembly set nut 39 400 29
Suction port union set bolt 13 130 9
Pressure port union x Front housing 69 700 51
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS0YJ-
-02
SS-
-16
-
-
SERVICE SPECIFICATIONS AIR CONDITIONING
AIR CONDITIONING
SERVICE DATA
Refrigerant volume 550 ± 50 g (19.40 ± 1.76 oz.)
Drive belt deflection (Apply load of 98 N) -
-
New belt 13.0 -
- 15.0 mm (0.51 -
- 0.59 in.)
Used belt 15.0 -
- 21.0 mm (0.59 -
- 0.83 in.)
Drive belt tension -
-
New belt 372 -
- 608 N (38 -
- 62 kgf)
Used belt 196 -
- 392 N (20 -
- 40 kgf)
Idle-
-up speed (Magnetic clutch engaged) 800 ± 50 rpm
Magnetic clutch clearance 0.5 ± 0.15 mm (0.020 ± 0.0059 in.)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SS050-
-06
-
-
SERVICE SPECIFICATIONS AIR CONDITIONING
SS-
-17
Idle pulley lock nut 39 400 29
Compressor x Discharge hose 10 100 7
Compressor x Suction hose 10 100 7
Front housing x Cylinder block 25 250 18
Discharge cover x Cylinder block 25 250 18
Cooling unit x Suction tube 32 330 24
Cooling unit x Liquid tube 14 140 10
Receiver x Liquied tube 5.4 55 48 in.∙lbf
Condenser x Liquid tube 10 100 7
Condenser x Discharge hose 5.4 55 48 in.∙lbf
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CLUTCH
TROUBLESHOOTING CL--1
. . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL CL--2
. . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER CL--4
. . . . . . . . . . . .
CLUTCH RELEASE CYLINDER CL--9
. . . . . . . . . . . .
CLUTCH UNIT CL--14
. . . . . . . . . . . . . . . . . . . . . . . . . . .
REFER TO HILUX REPAIR MANUAL FOR CHASSIS AND
BODY (Pub. No. RM585E)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0B4-
-01
-
-
CLUTCH TROUBLESHOOTING
CL-
-1
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
1. Engine mounting (Loosen) -
-
1. Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
-
-
CL-
-14
3. Clutch disc (Oily) CL-
-14
Clutch grabs/chatters
3. Clutch disc (Oily)
4. Clutch disc (Worn out) CL-
-14
Clutch grabs/chatters 4. Clutch disc (Worn out)
5. Clutch disc torsion rubber (Damaged) CL-
-14
5. Clutch disc torsion rubber (Damaged)
6. Clutch disc (Glazed) CL-
-14
6. Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment) CL-
-18
1. Clutch line (Air in line) -
-
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
-
-
CL-
-4
Clutch pedal spongy 2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged) CL-
-9
1. Release bearing (Worn, dirty, or damaged) CL-
-14
Clutch noisy
1. Release bearing (Worn, dirty, or damaged)
2. Input shaft bearing (Worn or Damaged) MT-
-23
Clutch noisy 2. Input shaft bearing (Worn or Damaged)
3. Clutch disc torsion rubber (Damaged) CL-
-14
1. Clutch pedal (Freeplay out of adjustment) CL-
-2
1. Clutch pedal (Freeplay out of adjustment)
2. Clutch disc (Oily) CL-
-14
Cl t h li
2. Clutch disc (Oily)
3. Clutch disc (Worn out) CL-
-14
Clutch slips
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged) CL-
-14
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion) CL-
-14
5. Pressure plate (Distortion)
6. Flywheel (Distortion) CL-
-14
1 Clutch pedal (Freeplay out of adjustment)
1. Clutch pedal (Freeplay out of adjustment)
2 Clutch line (Air in line)
CL-
-2
-
-
2. Clutch line (Air in line)
3 Master cylinder cup (Damaged)
-
-
CL-
-4
3. Master cylinder cup (Damaged)
4 Release cylinder cup (Damaged)
CL-
-4
CL-
-9
4. Release cylinder cup (Damaged)
5. Input shaft bearing (Worn or Damaged)
CL-
-9
MT-
-23
5. Input shaft bearing (Worn or Damaged)
6. Clutch disc (Out of true) CL-
-14
Cl t h d t di
6. Clutch disc (Out of true)
7. Clutch disc (Runout is excessive) CL-
-14
Clutch does not disengage
8. Clutch disc (Lining broken) CL-
-14
8. Clutch disc (Lining broken)
9. Clutch disc (Dirty or burned) CL-
-14
9. Clutch disc (Dirty or burned)
10.Clutch disc (Oily) CL-
-14
10.Clutch disc (Oily)
11.Clutch disc (Lack of spline grease) CL-
-14
11.Clutch disc (Lack of spline grease)
12.Diaphragm spring (Damaged)
CL 14
CL-
-17
p g p g ( g )
13.Diaphragm spring (Out of tip alignment) CL-
-18
p g p g ( p g )
14.Pressure plate (Distortion) CL-
-14
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

D00555
Push Rod Play Adjust Point
Pedal Height
Adjust Point
Push Rod
Play
Pedal Height
CL0B5-
-01
D00556
Pedal Freeplay
CL-
-2
-
-
CLUTCH CLUTCH PEDAL
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from dash panel:
172.0 -
- 182.0 mm (6.772 -
- 7.165 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD
PLAY ARE CORRECT
(a) Depress the pedal until the clutch resistance begins to be
felt.
Pedal freeplay: 5.0 -
- 15.0 mm (0.197 -
- 0.591 in.)
(b) Gently depress the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0 -
- 5.0 mm (0.039 -
- 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

D00557
25 mm (0.98 in.) or more
Full Stroke
End Position
Release
Point
-
-
CLUTCH CLUTCH PEDAL
CL-
-3
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point that the gear noise stops
(release point) up to the full stroke end position.
Standard distance: 25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following opera-
tions.
S Check pedal height.
S Check push rod play and pedal freeplay.
S Bleed the clutch line.
S Check the clutch cover and disc.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CLUTCH MASTER CYLINDER:
1. Components CL-4
2. Removal CL-5
3. Disassembly CL-6
4. Reassembly CL-7
5. Installation CL-8
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0B6-
-01
D09817
Filler Cap
Snap Ring
Push Rod
Lock Nut
Master Cylinder
Body
Reservoir Tank
z Grommet
Float
Clevis
Clip
Pin
Boot
Washer
Piston
Spring
Slotted Spring
Pin
Clutch accumulator
Clutch Line
z Gasket
63 (640, 46)
*48 (485,35)
14 (143, 10)
z Non--reusable part
N∙m (kgf∙cm, ft∙lbf) : Specified torque
*For use withSST
15 (155, 11)
CL-
-4
-
-
CLUTCH CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0B7-
-01
Q09026
SST
-
-
CL-
-5
REMOVAL
1. DRAW OUT FLUID WITH SYRINGE
2. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023--00100
Torque: 15 N∙m (155 kgf∙cm, 11 ft∙lbf)
3. REMOVE CLIP AND CLEVIS PIN
4. REMOVE MOUNTING NUTS AND PULL OUT MASTER
CYLINDER
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

Q02469
CL0B8-
-01
Q02470
D00569
SST
CL-
-6
-
-
DISASSEMBLY
1. REMOVE RESERVOIR TANK
(a) Using a pin punch and hammer, drive out the slotted
spring pin.
(b) Remove the reservoir tank and grommet.
2. REMOVE PUSH ROD
Pull back the boot, and using snap ring pliers, remove the snap
ring.
3. REMOVE PISTON
4. REMOVE CLUTCH ACCUMULATOR
Using SST, remove the accumulator and gasket.
SST 09922--10010
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0B9-
-01
D00570
SST
Fulcrum Length
CL0528
Q02471
Protrusion
1.5 -- 3.5 mm
(0.059 -- 0.138 in.)
-
-
CL-
-7
REASSEMBLY
1. INSTALL CLUTCH ACCUMULATOR
Using SST, install the accumulator with a new gasket.
SST 09922--10010
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
2. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
3. INSERT PISTON INTO CYLINDER
4. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING
5. INSTALL RESERVOIR TANK
(a) Install the reservoir tank and a new grommet.
(b) Using a pin punch and hammer, drive in the slotted spring
pin.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BA-
-01
CL-
-8
-
-
INSTALLATION
Installation is in the reverse order of removal (See page CL-
-5).
HINT:
After installation, bleed the system and adjust the clutch pedal.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CLUTCH RELEASE CYLINDER:
1. Components CL-9
2. Removal CL-10
3. Disassembly CL-11
4. Reassembly CL-12
5. Installation CL-13
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BB-
-01
D09818
Bleeder Plug
11 (110, 8)
Release Cylinder Body
Spring
12 (120, 9)
Push Rod
Boot
Piston
Clutch Line
15 (155, 11)
-
-
CLUTCH CLUTCH RELEASE CYLINDER
CL-
-9
CLUTCH RELEASE CYLINDER
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BC-
-01
D00564
SST
D00565
CL-
-10
-
-
REMOVAL
1. DISCONNECT CLUTCH LINE
Using SST, disconnect the line. Use a container to catch the
fluid.
SST 09023--00100
2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYL-
INDER
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BD-
-01
D00566
-
-
CL-
-11
DISASSEMBLY
1. PULL OUT BOOT WITH PUSH ROD
2. REMOVE PISTON
Using compressed air, remove the piston with the spring from
the cylinder.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BE-
-01
CL0672
CL-
-12
-
-
REASSEMBLY
1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL
GREASE, AS SHOWN
2. INSTALL PISTON WITH SPRING INTO CYLINDER
3. INSTALL BOOT WITH PUSH ROD TO CYLINDER
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BF-
-01
-
-
CL-
-13
INSTALLATION
Installation is in the reverse order of removal (See page CL-
-10).
HINT:
After installation, bleed clutch system.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CLUTCH UNIT:
1. Components CL-14
2. Removal CL-15
3. Inspection CL-16 / 17
4. Installation CL- 18 /19
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BG-
-01
D09814
Flywheel
z Pilot Bearing
Clutch Disc
Clutch Cover
Clutch Release Bearing
Clutch Release Fork
Boot
Flywheel set bolt
39(400,29)
Clutch Release Fork Support
178 (1,817, 131)
Clip
19(195,14)
CL-
-14
-
-
CLUTCH CLUTCH UNIT
CLUTCH UNIT
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BH-
-01
Q07148
Matchmarks
D09115
-
-
CLUTCH CLUTCH UNIT
CL-
-15
REMOVAL
1. REMOVE TRANSMISSION FROM ENGINE
2WD: (See page MT-
-4)
4WD: (See page MT-
-8)
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE BOOT, RELEASE BEARING AND FORK
FROM TRANSMISSION
Remove the boot and release bearing together with the fork and
then separate them.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BI-
-01
CL0239
CL0373
Q07250
Q02481
Q07150
SST
CL-
-16
-
-
CLUTCH CLUTCH UNIT
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If necessary, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
If necessary, replace the flywheel.
4. INSPECT PILOT BEARING
Turn the bearing by hand while applying force in the rotation
direction.
If the bearing sticks or has much resistance, replace the pilot
bearing.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
5. IF NECESSARY, REPLACE PILOT BEARING
(a) Remove the 2 bolts at diametrically opposite points.
(b) Using SST, remove the pilot bearing.
SST 09303--35011
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Q07151
SST
D00881
B
A
D00882
-
-
CLUTCH CLUTCH UNIT
CL-
-17
(c) Using SST and a hammer, install the pilot bearing.
SST 09304--30012
HINT:
After assembling the pilot bearing to the hub, make sure that it
rotates smoothly.
(d) Install 2 new bolts.
Torque: 178 N∙m (1,817 kgf∙cm, 131 ft∙lbf)
6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum depth A: 0.6 mm (0.024 in.)
Maximum width B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

CL0BJ-
-01
D09819
Flywheel
Side
SST
Q06958
7
3
6
1,4
8
2,5
Matchmarks
Q07153
SST
D09116
Q06642
CL-
-18
-
-
CLUTCH CLUTCH UNIT
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert the SST in the clutch disc, and then set them.
SST 09301--00110
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Torque the 6 bolts on the clutch cover in the order shown.
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non-
-alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333--00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO. 2)
(a) Apply release hub grease to these parts:
S Release fork and hub contact point
S Release fork and push rod contact point
S Release fork pivot point
(b) Apply clutch spline grease.
S Clutch disc spline
HINT:
Recommended grease part number 08887--01706 (100 g).
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

-
-
CLUTCH CLUTCH UNIT
CL-
-19
4. INSTALL BOOT, RELEASE BEARING AND FORK TO
TRANSMISSION
Install the boot and bearing to the release fork, and then install
them to the transmission.
5. INSTALL TRANSMISSION TO ENGINE
2WD: (See page MT-
-6)
4WD: (See Page MT-
-11)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MANUAL TRANSMISSION SYSTEM MT--1
. . . . . . .
TROUBLESHOOTING MT--2
. . . . . . . . . . . . . . . . . . . .
MANUAL TRANSMISSION UNIT (2WD) MT--3
. . . .
MANUAL TRANSMISSION UNIT (4WD) MT--7
. . . .
MANUAL TRANSMISSION ASSEMBLY MT--12
. . . . .
INPUT SHAFT MT--23
. . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT MT--26
. . . . . . . . . . . . . . . . . . . . . . . . .
COUNTER GEAR AND
REVERSE IDLER GEAR MT--36
. . . . . . . . . . . . . . . .
FRONT BEARING RETAINER OIL SEAL MT--42
. . . .
EXTENSION HOUSING AND
TRANSFER ADAPTOR MT--44
. . . . . . . . . . . . . . . . .
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT02P-
-02
-
-
MANUAL TRANSMISSION (R151, R151F) MANUAL TRANSMISSION SYSTEM
MT-
-1
MANUAL TRANSMISSION SYSTEM
PRECAUTION
When working with FIPG material, you must observe the following items.
S Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur-
faces.
S Thoroughly clean all components to remove all the loose material.
S Clean both sealing surfaces with a non-
-residue solvent.
S Apply FIPG in an approx. 1.2 mm (0.05 in.) wide bead along the sealing surface.
S Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT02Q-
-03
MT-
-2
-
-
MANUAL TRANSMISSION (R151, R151F) TROUBLESHOOTING
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
Noise
1. Oil (Level low)
2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
MT-
-4
MT-
-8
MT-
-4
MT-
-8
MT-
-12
MT-
-12
Oil leakage
1. Oil (Level too high)
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O-
-Ring (Worn or damaged)
MT-
-4
MT-
-8
MT-
-12
MT-
-12
MT-
-12
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)
MT-
-23
MT-
-26
MT-
-36
MT-
-26
MT-
-36
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
MT-
-12
MT-
-12
MT-
-12
MT-
-12
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MANUAL TRANSMISSION UNIT (2WD)
1. Components MT-3
2. Removal MT-4 / 5
3. Installation MT-6
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT02R-
-03
D09816
Rear Console Box
Front Console Box
Propeller Shaft
Transmission Shift Lever Knob
Transmission Shift Lever
Shift Lever Boot Retainer
Shift Lever Boot
Speedometer Cable
Back--Up Light Switch Connector
39 (400, 29)
72 (730, 53)
Transmission
72 (730, 53)
Starter
Stabilizer Bar
Front Exhaust Pipe
z Gasket
Bracket
29 (300, 22)
48 (490, 35)
72 (730, 53)
71 (720, 52)
Engine Under Cover
95 (970, 70)
13 (130, 9)
Clutch
Release
Cylinder
12 (120, 9)
No. 2 Frame Crossmember
40 (410, 30)
74 (750, 54)
36 (370, 27)
w/ Front and Rear Console Box
62 (490, 46)
19 (190, 14)
37 (380, 27)
z Gasket
No. 2 Rear End Plate
Engine Rear Mounting
-
-
MANUAL TRANSMISSION (R151, R151F) MANUAL TRANSMISSION UNIT (2WD)
MT-
-3
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT05L-
-02
MT0501
Counterclockwise
Down
Cloth
D00823
Drain Plug
Filler Plug
Oil Level
0 -- 5 mm
Q09380
D00534
A
B
MT-
-4
-
-
REMOVAL
1. REMOVE TRANSMISSION SHIFT LEVER
(a) w/ Front and Rear Console Box:
Remove the front and rear console box.
(b) Remove the 4 screws, shift lever boot and retainer.
(c) Cover the shift lever cap with a cloth.
(d) Pressing down on the shift lever cap and rotate it counter-
clockwise to remove.
(e) Pull out the shift lever.
HINT:
At the time of installation, please refer to the following item.
Apply MP grease to the tip of the shift lever.
2. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL-
-4 or GL-
-5
Viscosity: SAE 75W-
-90
Capacity: 2.6 liters (2.7 US qts, 2.3 lmp. qts)
3. REMOVE ENGINE UNDER COVER
4. REMOVE PROPELLER SHAFT
5. DISCONNECT BACK-
-UP LIGHT SWITCH CONNEC-
TOR
6. DISCONNECT SPEEDOMETER CABLE
7. DISCONNECT CLUTCH RELEASE CYLINDER
Remove the 4 bolts, disconnect the release cylinder and line.
8. REMOVE FRONT EXHAUST PIPE
(a) Remove the set bolt of the clamp.
(b) Remove the 2 bolts and support bracket.
Torque:
Bolt A: 71 N∙m (720 kgf∙cm, 52 ft∙lbf)
Bolt B: 72 N∙m (730 kgf∙cm, 53 ft∙lbf)
(c) Remove the bolt, 2 nuts and gasket from the exhaust
manifold.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

D00533
D00824
D00797
Q09001
Starter Set Bolt
-
-
MT-
-5
(d) Remove the 2 bolts, nuts, gasket and pipe.
9. REMOVE No. 2 REAR END PLATES
Remove the 4 bolts and No. 2 rear end plate.
10. REMOVE No. 2 FRAME CROSSMEMBER
(a) Support the transmission rear side.
(b) Remove the 4 set bolts of the engine rear mounting.
(c) Remove the 8 bolts and No. 2 frame crossmember.
11. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-
mission.
12. DISCONNECT STABILIZER BAR
(a) Remove the 4 set bolts of the stabilizer bar bracket.
(b) Disconnect the stabilizer bar.
13. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.
14. REMOVE STARTER
(a) Remove the set bolt of the starter lower side with the
clutch line bracket.
(b) Disconnect the connector and wire, and remove the set
bolt of the starter upper side and starter.
15. REMOVE TRANSMISSION
(a) Disconnect the wire harness from the transmission.
(b) Remove the 3 transmission mounting bolts from the en-
gine.
(c) Pull out the transmission down and toward the rear.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT05M-
-02
MT-
-6
-
-
INSTALLATION
Installation is in the reverse order of removal (See page MT-
-4).
HINT:
After installation, do the road test.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

1. Components MT-7
2. Removal MT-8 / 9 / 10
3. Installation MT-11
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT02U-
-03
D09815
Front Console Box
Rear Console Box
Transmission Shift Lever Knob
Transfer Shift Lever Knob
Shift Lever Boot Retainer
Shift Lever Boot
Transmission Shift Lever
Transfer Shift Lever
Snap Ring
Rear Propeller Shaft
Speedometer Cable
4WD Position Switch Connector
Back--Up Light Switch Connector
Transmission with Transfer
Starter
Stabilizer Bar
Front Exhaust Pipe
Engine Under Cover
No. 2 Frame Crossmember
Bracket
Clutch
Release
Cylinder
Engine Rear Mounting
74 (750, 54)
74 (750, 54)
39 (400, 29)
72 (730, 53)
72 (730, 53)
29 (300, 22)
95 (970, 70)
13 (130, 9)
48 (490, 35)
71 (720, 52)
12 (120, 9)
40 (410, 30)
Front Propeller Shaft
74 (750, 54)
74 (750, 54)
Propeller Shaft Dust Cover
Propeller Shaft No. 2 Dust Cover
13 (135, 10)
17 (175, 13)
23 (230, 17)
38 (390, 28)
37 (380, 27)
z Gasket
19 (190, 14)
72 (730, 53)
62 (490, 46)
z Gasket
No. 2 Rear End Plate
-
-
MT-
-7
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT0DG-
-01
D00822
Installation
Select Return
Spring Tip of Shift Lever
MT0501
Counterclockwise
Down
Cloth
D00823
Drain Plug
Filler Plug
Oil Level
0 -- 5 mm
Q09380
MT-
-8
-
-
REMOVAL
1. REMOVE TRANSFER SHIFT LEVER
Using snap ring pliers, remove the snap ring and pull out the
shift lever.
HINT:
S Shift the transfer shift lever to the ”H4” position.
S At the time of installation, apply MP grease to the tip of the
shift lever.
2. REMOVE TRANSMISSION SHIFT LEVER
(a) Remove the front and rear console box.
(b) Remove the 4 screws, shift lever boot and retainer.
(c) Cover the shift lever cap with a cloth.
(d) Pressing down on the shift lever cap and rotate it counter-
clockwise to remove.
(e) Pull out the shift lever.
HINT:
Apply MP grease to the tip of the shift lever.
3. RAISE VEHICLE AND DRAIN TRANSMISSION OIL
Oil grade: API GL-
-4 or GL-
-5
Viscosity: SAE 75W-
-90
Capacity: 2.2 liters (2.3 US qts, 1.9 lmp. qts)
4. REMOVE ENGINE UNDER COVER
5. REMOVE PROPELLER SHAFT NO. 2 DUST COVER
Remove the 4 bolts and No.2 dust cover.
6. REMOVE PROPELLER SHAFT DUST COVER
Remove the bolt, 2 transfer mounting bolts and dust cover.
Torque:
Bolt: 23 N∙m (230 kgf∙cm, 17 ft∙lbf)
Transfer mounting Bolt: 37 N∙m (380 kgf∙cm, 27 ft∙lbf)
7. REMOVE FRONT AND REAR PROPELLER SHAFTS
8. DISCONNECT 4WD POSITION SWITCH AND BACK-
-
UP LIGHT SWITCH CONNECTORS
9. DISCONNECT SPEEDOMETER CABLE
10. DISCONNECT CLUTCH RELEASE CYLINDER
Remove the 4 bolts, disconnect the release cylinder and line.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

D00534
A
B
D00533
D00824
D00797
Q09001
Starter Set Bolt
-
-
MT-
-9
11. REMOVE FRONT EXHAUST PIPE
(a) Remove the set bolt of the clamp.
(b) Remove the 2 bolts and support bracket.
Torque:
Bolt A: 71 N∙m (720 kgf∙cm, 52 ft∙lbf)
Bolt B: 72 N∙m (730 kgf∙cm, 53 ft∙lbf)
(c) Remove the bolt, 2 nuts and gasket from the exhaust
manifold.
(d) Remove the 2 bolts, nuts, gasket and pipe.
12. REMOVE No. 2 REAR END PLATES
Remove the No. 2 rear end plate.
13. REMOVE No. 2 FRAME CROSSMEMBER
(a) Support the transmission rear side.
(b) Remove the 4 set bolts of the engine rear mounting.
(c) Remove the 8 bolts and No. 2 frame crossmember.
14. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-
mission.
15. DISCONNECT STABILIZER BAR
(a) Remove the 4 set bolts of the stabilizer bar bracket.
(b) Disconnect the stabilizer bar.
16. JACK UP TRANSMISSION SLIGHTLY
Using a transmission jack, support the transmission.
17. REMOVE STARTER
(a) Remove the set bolt of the starter lower side with the
clutch line bracket.
(b) Disconnect the connector and wire, and remove the set
bolt of the starter upper side and starter.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

D00827
MT-
-10
-
-
18. REMOVE TRANSMISSION WITH TRANSFER
(a) Disconnect the wire harness from the transmission.
(b) Remove the 3 transmission mounting bolts from the en-
gine.
(c) Pull out the transmission with the transfer down and to-
ward the rear.
19. REMOVE TRANSFER FROM TRANSMISSION
(a) Disconnect the breather hose and remove the transfer
adaptor rear mounting bolts.
(b) Pull the transfer straight up and remove it from the trans-
mission.
HINT:
Take care not to damage the transfer adaptor rear oil seal with
the transfer input gear spline.
HINT:
Apply MP grease to the transfer adaptor oil seal.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT05M-
-03
-
-
MT-
-11
INSTALLATION
Installation is in the reverse order of removal (See page MT-
-8).
HINT:
After installation, do the road test.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MANUAL TRANSMISSION (R151, R151F) – MANUAL TRANSMISSION ASSEMBLY
MANUAL TRANSMISSION ASSEMBLY – COMPONENTS MT-12/13
DISASSEMBLY
1. REMOVE BACK-UP LIGHT SWITCH MT-14
2. REMOVE SHIFT POSITION SWITCH MT-14
3. 2WD: REMOVE SPEEDOMETER DRIVEN GEAR MT-14
4. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE MT-14
5. REMOVE CONTROL SHIFT LEVER RETAINER MT-14
6. 4WD: REMOVE TRANSFER CONTROL SHIFT LEVER MT-14
7. REMOVE 2 RESTRICT PINS MT-14
8. 2WD: REMOVE EXTENSION HOUSING MT-14
9. 4WD: REMOVE TRANSFER ADAPTOR MT-15
10.REMOVE FRONT BEARING RETAINER MT-15
11.REMOVE BEARING SNAP RING MT-15
12.SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE MT-15
13.REMOVE MAGNET FROM INTERMEDIATE PLATE MT-16
14.MOUNT INTERMEDIATE PLATE IN VISE MT-16
15.REMOVE STRAIGHT SCREW PLUG, LOCKING BALL AND SPRING MT-16
16.REMOVE SHIFT FORK SET BOLT MT-16
17.REMOVE SLOTTED SPRING PIN MT-16
18.REMOVE SNAP RING MT-16
19.REMOVE SHIFT FORK SHAFT NO.2 AND SHIFT FORK NO.2 MT-17
22.REMOVE SHIFT FORK SHAFT NO.4 MT-17
23.REMOVE REVERSE SHIFT FORK AND ARM MT-17
24.REMOVE REVERSE SHIFT ARM BRACKET MT-18
25.2WD: REMOVE SPEEDOMETER DRIVE GEAR MT-18
26.REMOVE OUTPUT SHAFT REAR BEARING MT-18/19
27.REMOVE SPACER MT-19
28.INSPECT COUNTER 5TH
GEAR THRUST CLEARANCE MT-19
29.REMOVE GEAR SPLINE PIECE NO.5, SYNCRONIZER RING, NEEDLE ROLLER
BEARING AND COUNTER 5TH
GEAR WITH HUB SLEEVE NO.3 MT-20
30.REMOVE THRUST WASHER AND BALL FROM COUNTER GEAR MT-20
31.REMOVE REAR BEARING RETAINER MT-20
32.REMOVE REVERSE IDLER GEAR AND SHAFT MT-21
33.REMOVE OUTPUT SHAFT CENTER BEARING SNAP RING MT-21
34.REMOVE OUTPUT SHAFT AND COUNTER GEAR FROM INTERMEDIATE PLATE
MT-21
35.REMOVE COUNTER REAR BEARING FROM INTERMEDIATE PLATE MT-21
REASSEMBLY MT-22
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT02X-
-03
D09820
Clutch Housing
Drain Plug
Back--Up Light Switch
Straight Screw Plug
L
Spring
Ball
z Gasket
Filler Plug
Transmission Case
Snap Ring
Front Bearing Retainer
x 8
x 9
z Gasket
L
L
Control Shift Lever
Retainer
x 6
x 10
z Gasket
z Gasket
Restrict Pin
Straight Screw Plug
x 10
Restrict Pin
Extension Housing
L Precoated part
L
Restrict Pin
Restrict Pin
Transfer Adaptor
2WD: 4WD:
Transfer Control
Shift Lever
Retainer
19 (190, 14)
37 (380, 27)
37 (380, 27)
37 (380, 27)
18 (185, 13)
37 (380, 27)
37 (380, 27)
18 (185, 13)
37 (380, 27)
36 (370, 27)
17 (170, 12)
37 (380, 27)
19 (190, 14)
19 (190, 14)
44 (450, 32)
37 (380, 27)
11 (115, 8)
Spring
Control Shift Lever Retainer
z Oil Deflector
Shift Position Switch
39 (400, 29)
18 (185, 13)
Speedometer
Driven Gear
MT-
-12
-
-
MANUAL TRANSMISSION (R151, R151F) MANUAL TRANSMISSION ASSEMBLY
MANUAL TRANSMISSION ASSEMBLY
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

D10038
Output Shaft Assembly
Vehicle Speedometer Drive Gear
Snap Ring
Ball
Bearing
Spacer
z Bearing
Input Shaft
Synchronizer Ring
Rear Bearing Retainer
Gear Spline Piece No.5
Synchronizer Cone Ring
Hub Sleeve No.3
Reverse Idler Gear
Shaft
Shifting Key Spring
Ball
Shifting Key
Counter 5th Gear
Reverse Synchronizer
Pull Ring
5th Synchronizer Ring
Reverse Synchronizer Ring
Thrust Washer
Counter Gear Rear Bearing
Shift Fork Shaft No.2
Needle Roller Bearing
Straight Pin
Intermediate Plate
Counter Gear
z Counter Gear
Front Bearing
Interlock Pin
Straight Pin
Slotted Spring Pin
Shift Fork No.3
2WD:
2WD:
Shift Fork No.1
Reverse Idler Gear
Magnet
Shift Lever Housing
Shift and Select Lever
Shift Lever Housing
Shift and Select Lever
4WD:
Reverse Shift Arm Bracket
Reverse Shift Arm
E--Ring
Reverse Shift Fork
Shift Fork Shaft
No.4
z Bearing
Snap Ring
Snap Ring
Snap Ring
Snap Ring
Snap Ring
Snap Ring
Snap Ring
z
z
Spring
Shift Fork No.2
z
18 (185, 13)
38 (390, 28)
20 (200, 14)
20 (200, 14)
18 (185, 13)
18 (185, 13)
Snap Ring
Snap Ring
Snap Ring
Inter Lock Pin
Inter Lock Pin
Straight Pin
-
-
MT-
-13
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT02Y-
-03
Q06902
FIPG
MT-
-14
-
-
DISASSEMBLY
1. REMOVE BACK-
-UP LIGHT SWITCH
2. REMOVE SHIFT POSITION SWITCH
3. 2WD:
REMOVE SPEEDOMETER DRIVEN GEAR
Remove the bolt and speedometer driven gear.
4. REMOVE CLUTCH HOUSING FROM TRANSMISSION
CASE
Remove the 9 bolts and clutch housing from the transmission
case.
5. REMOVE CONTROL SHIFT LEVER RETAINER
(a) Remove the 6 (2WD) or 4 (4WD) bolts.
(b) Remove the retainer and gasket (2WD) or oil deflector
(4WD).
6. 4WD:
REMOVE TRANSFER CONTROL SHIFT LEVER
(a) Remove the 4 bolts.
(b) Remove the retainer and gasket.
(c) Remove the select return spring from the retainer.
7. REMOVE 2 RESTRICT PINS
8. 2WD:
REMOVE EXTENSION HOUSING
(a) Remove the shift lever housing set bolt.
(b) Remove the 10 bolts.
(c) Using a plastic hammer, tap the extension housing, re-
move the shift lever housing and shift and select lever.
FIPG:
Part No. 08826-
-00090, THREE BOND 1281 or equiva-
lent
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DR053E
CLICK HERE TO VIEW CHAPTER INDEX
CONTINUED
CHAS. & BODY:

Q06901
FIPG
Q08462
FIPG
Q06903
FIPG
-
-
MT-
-15
9. 4WD:
REMOVE TRANSFER ADAPTOR
(a) Remove the slotted spring pin and shift lever housing.
(b) Remove the 10 bolts.
(c) Using a plastic hammer, tap the transfer adaptor, remove
the shift lever housing and the shift and select lever.
FIPG:
Part No. 08826-
lent
10. REMOVE FRONT BEARING RETAINER
(a) Remove the 8 bolts.
Sealant:
Part No. 08833-
-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(b) Using a plastic hammer, tap the front bearing retainer.
FIPG:
Part No. 08826-
lent
11. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
12. SEPARATE INTERMEDIATE PLATE FROM TRANS-
MISSION CASE
(a) Using a brass bar and hammer, carefully tap the transmis-
sion case.
(b) Remove the transmission case from the intermediate
plate.
HINT:
At the time of reassembly, please refer to the following item.
Align the each bearing outer race, each fork shaft end and re-
verse idler gear shaft end with the case installation holes.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Q06785
Q06905
Q06764
MT-
-16
-
-
FIPG:
Part No. 08826-
lent
13. REMOVE MAGNET FROM INTERMEDIATE PLATE
14. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use the 2 clutch housing bolts, plate washers and suit-
able nuts, as shown.
HINT:
Increase or decrease plate washers so that the bolt tip does not
protrude from the nut.
(b) Mount the intermediate plate in a vise.
15. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench, remove the 4 plugs.
Sealant:
Part No.08833-
242 or equivalent
(b) Using a magnetic finger, remove the 3 springs and balls.
16. REMOVE SHIFT FORK SET BOLT
Remove the 2 bolts from the shift forks No. 1 and No. 2.
17. REMOVE SLOTTED SPRING PIN
Using a pin punch and hammer, drive out the pin from the shift
fork No. 3.
18. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the 4 snap rings
from each shift fork shaft.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Q06766
Q06763
Q06768
Q06904
Q06771
-
-
MT-
-17
19. REMOVE SHIFT FORK SHAFT NO. 2 AND SHIFT
FORK NO. 2
(a) Pull out the shift fork shaft No. 2 from the shift forks No.
1, No. 2 and intermediate plate.
(b) Remove the shift fork No. 2 from the groove of hub sleeve
No. 2.
(c) Using a magnetic finger, remove the interlock pin from the
intermediate plate.
FORK NO. 1
(a) Pull out the shift fork shaft No. 1 with the straight pin from
the shift fork No. 1 and intermediate plate.
(b) Remove the shift fork No. 1 from the groove of reverse
gear.
intermediate plate.
FORK NO. 3
(a) Pull out the shift fork shaft No. 3 from the shift fork No. 3,
reverse shift fork and intermediate plate.
(b) Remove the shift fork No. 3 from the groove of hub sleeve
No. 3.
intermediate plate.
22. REMOVE SHIFT FORK SHAFT NO. 4
(a) Using a magnetic finger, remove the ball.
(b) Pull out the shift fork shaft No. 4 from the reverse shift fork
and intermediate plate.
NOTICE:
Take care of the ball in the reverse shift fork. It will spring
out when you pull out the shift fork shaft No. 4.
(c) Using a magnetic finger, remove the spring from the re-
verse shift fork.
23. REMOVE REVERSE SHIFT FORK AND ARM
(a) Remove the reverse shift fork and arm.
HINT:
Align the reverse shift arm to the pivot of the reverse shift arm
bracket.
(b) Using a screwdriver, remove the E--ring.
(c) Separate the reverse shift fork and arm.
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TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

RM0063
RM0072
MT-
-18
-
-
24. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and reverse shift arm bracket.
25. 2WD:
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using 2 screwdrivers and a hammer, tap out the rear snap
ring, and remove the drive gear and ball.
(b) Using 2 screwdrivers and a hammer, tap out the front
snap ring, and remove the speedometer drive gear.
26. REMOVE OUTPUT SHAFT REAR BEARING
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Select a snap ring that allows the minimum axial play.
Mark Thickness mm (in.)
A 2.65 -
- 2.70 (0.1043 -
- 0.1063)
B 2.70 -
- 2.75 (0.1063 -
- 0.1083)
C 2.75 -
- 2.80 (0.1083 -
- 0.1102)
D 2.80 -
- 2.85 (0.1102 -
- 0.1122)
E 2.85 -
- 2.90 (0.1122 -
- 0.1142)
F 2.90 -
- 2.95 (0.1142 -
- 0.1161)
G 2.95 -
- 3.00 (0.1161 -
- 0.1181)
H 3.00 -
- 3.05 (0.1181 -
- 0.1201)
J 3.05 -
- 3.10 (0.1201 -
- 0.1220)
K 3.10 -
- 3.15 (0.1220 -
- 0.1240)
L 3.15 -
- 3.20 (0.1240 -
- 0.1260)
M 3.20 -
- 3.25 (0.1260 -
- 0.1280)
N 3.25 -
- 3.30 (0.1280 -
- 0.1299)
P 3.30 -
- 3.35 (0.1299 -
- 0.1319)
Q 3.35 -
- 3.40 (0.1319 -
- 0.1339)
R 3.40 -
- 3.45 (0.1339 -
- 0.1358)
S 3.45 -
- 3.50 (0.1358 -
- 0.1378)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Z14821
4WD:
SST
Z14820
2WD:
SST
RM0070
2WD:
SST
RM0071
4WD:
SST
Q06786
-
-
MT-
-19
(b) Using SST, remove the rear bearing.
SST 09950--40011
HINT:
At the time of reassembly, please refer to the following items.
S 2WD:
Using SST and a hammer, drive in a new bearing.
SST 09309--35010
S 4WD:
Using SST and a hammer, drive in a new bearing.
SST 09316--60011 (09316--00011, 09316--00071)
27. REMOVE SPACER
28. INSPECT COUNTER 5TH GEAR THRUST CLEAR-
ANCE
Using a feeler gauge, measure the counter 5th gear thrust
clearance.
Standard clearance:
0 -
- 0.25 mm (0 -
- 0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Q06688
Q06605
SST
RM0024
SST
MT-
-20
-
-
29. REMOVE GEAR SPLINE PIECE NO. 5, SYNCHRONIZ-
ER RING, NEEDLE ROLLER BEARING AND COUNT-
ER 5TH GEAR WITH HUB SLEEVE NO. 3
ring.
HINT:
Select a snap ring that allows the minimum axial play.
A 2.80 -
- 2.85 (0.1102 -
- 0.1122)
B 2.85 -
- 2.90 (0.1122 -
- 0.1142)
C 2.90 -
- 2.95 (0.1142 -
- 0.1161)
D 2.95 -
- 3.00 (0.1161 -
- 0.1181)
E 3.00 -
- 3.05 (0.1181 -
- 0.1201)
F 3.05 -
- 3.10 (0.1201 -
- 0.1220)
G 3.10 -
- 3.15 (0.1220 -
- 0.1240)
(b) Using SST, remove the gear spline piece No. 5.
SST 09950--50012
(c) Remove the counter 5th gear with the hub sleeve No.3.
HINT:
At the time of reassembly, please refer to the following items.
S Using SST and a hammer, drive in the gear spline piece
No. 5 with the synchronizer ring slots aligned with the
shifting keys.
SST 09316--60011 (09316--00011)
S When installing the gear spline piece No. 5, support the
counter gear in front with a 1.4 -- 2.3 kg (3 -- 5 lb) hammer
or equivalent.
30. REMOVE THRUST WASHER AND BALL FROM
COUNTER GEAR
31. REMOVE REAR BEARING RETAINER
Remove the 4 bolts and rear bearing retainer.
HINT:
Align the rear bearing retainer to the reverse idler gear shaft
groove.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Z03540
RM0010
Q07393
SST
-
-
MT-
-21
32. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft toward the rear.
HINT:
Align the reverse shift arm to the reverse idler gear shaft.
33. REMOVE OUTPUT SHAFT CENTER BEARING SNAP
RING
Using a snap ring expander, remove the snap ring.
34. REMOVE OUTPUT SHAFT AND COUNTER GEAR
FROM INTERMEDIATE PLATE
(a) Remove the output shaft, counter gear and input shaft as
a unit from the intermediate plate by pulling on the counter
gear and tapping on the intermediate plate with a plastic
hammer.
(b) Remove the input shaft with the needle roller bearing from
the output shaft.
35. REMOVE COUNTER REAR BEARING FROM INTER-
MEDIATE PLATE
Using SST and a hammer, remove the counter rear bearing.
SST 09950--60010 (09951--00620), 09950--70010
(09951--07150)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT02Z-
-02
MT-
-22
-
-
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MT-
-14).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

INPUT SHAFT:
1. Components MT-23
2. Inspection MT-24
3. Replacement MT-25
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT030-
-02
WM0301
z Bearing
Snap Ring
Input Shaft
Bearing
Synchronizer Ring
Snap Ring
-
-
MANUAL TRANSMISSION (R151, R151F) INPUT SHAFT
MT-
-23
INPUT SHAFT
COMPONENTS
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DR053E
CHAS. & BODY:

Q00550
MT031-
-02
Z03541
MT-
-24
-
-
INSPECTION
INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
off after rubbing.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT032-
-02
Z03543
Z03544
SST
Z03545
-
-
MT-
-25
REPLACEMENT
IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing.
(c) Using SST and a press, install a new bearing.
SST 09506--35010
(d) Select a snap ring that allows the minimum axial play.
A 2.10 -
- 2.15 (0.0827 -
- 0.0846)
B 2.15 -
- 2.20 (0.0846 -
- 0.0866)
C 2.20 -
- 2.25 (0.0866 -
- 0.0886)
D 2.25 -
- 2.30 (0.0886 -
- 0.0906)
E 2.30 -
- 2.35 (0.0906 -
- 0.0925)
F 2.35 -
- 2.40 (0.0925 -
- 0.0945)
G 2.40 -
- 2.45 (0.0945 -
- 0.0965)
(e) Using a snap ring expander, install the snap ring.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MANUAL TRANSMISSION (R151, R151F) – OUTPUT SHAFT
OUTPUT SHAFT – COMPONENTS MT-26
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE MT-27
2. INSPECT EACH GEAR RADIAL CLEARANCE MT-27
3. REMOVE 5TH
GEAR, OUTPUT SHAFT CENTER BEARING AND 1ST
GEAR ASSEMBLY
MT-27
4. REMOVE REVERSE GEAR ASSEMBLY AND 2ND
GEAR ASSEMBLY MT-28
5. REMOVE REVERSE GEAR, SHIFTING KEY AND SPRING FROM CLUTCH HUB NO.1
MT-28
6. REMOVE HUB SLEEVE NO.2 ASSEMBLY AND 3RD
GEAR ASSEMBLY MT-28
7. REMOVE SHIFTING KEY AND SPRING FROM HUB SLEEVE NO.2 ASSEMBLY MT-28
INSPECTION
1. INSPECT OUTPUT SHAFT MT-29
2. INSPECT 1ST
AND 3RD
GEARS SYNCRONIZER RING MT-29/30
3. INSPECT 2ND
GEAR SYNCRONIZER RING MT-30
4. INSPECT SHIFT FORK NO.2 AND HUB SLEEVE NO.2 CLEARANCE MT-30
5. INSPECT SHIFT FORK NO.1 AND REVERSE GEAR CLEARANCE MT-31
REASSEMBLY
1. INSTALL CLUTCH HUB NO.2 INTO HUB SLEEVE NO.2 MT-32
2. INSTALL CLUTCH HUB NO.1 INTO REVERSE GEAR MT-32
3. INSTALL 3RD
GEAR AND HUB SLEEVE NO.2 ON OUTPUT SHAFT MT-32/33
4. INSTALL SNAP RING MT-33
5. INSPECT 3RD
6. INSTALL 2ND
GEAR AND REVERSE GEAR MT-33
7. INSTALL SNAP RING MT-34
8. INSTALL SPACER AND 1ST
GEAR ASSEMBLY MT-34
9. INSTALL STRAIGHT PIN AND 1ST
GEAR THRUST WASHER MT-34
10.INSTALL OUTPUT SHAFT CENTER BEARING MT-34
11.INSPECT 1ST
12.INSPECT 2ND
13.INSTALL 5TH
GEAR MT-35
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT033-
-02
Q09921
Synchronizer Ring
3rd Gear
Shifting Key Spring
Shifting
Key Spring
Hub Sleeve No. 2
Clutch Hub No. 2
Snap Ring
Output Shaft
2WD:
4WD: Output Shaft
Shifting Key Spring
Synchronizer Middle Ring
2nd Gear
Shifting Key
Clutch Hub No.1
Synchronizer Ring Straight Pin
5th Gear
Center
Bearing
Thrust
Washer
Spacer
1st Gear
Reverse
Gear
Spacer
Ball
Snap Ring
2WD:
zRear Bearing
Snap Ring
Rear Bearing Retainer
Synchronizer Outer Ring
Synchronizer Inner Ring
Shifting Key
Snap Ring
Snap Ring
18 (185, 13)
Speedometer
Driven Gear
MT-
-26
-
-
MANUAL TRANSMISSION (R151, R151F) OUTPUT SHAFT
OUTPUT SHAFT
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT034-
-02
Q06818
3rd 1st
Z03552
2nd
Z03553
RM0012
-
-
MT-
-27
DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.
Standard clearance:
1st gear:
0.20 -
- 0.45 mm (0.0079 -
- 0.0177 in.)
2nd and 3rd gears:
0.10 -
- 0.25 mm (0.0039 -
- 0.0098 in.)
Maximum clearance:
1st gear: 0.45 mm (0.0177 in.)
2nd and 3rd gears: 0.25 mm (0.0098 in.)
2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each
gear.
Standard clearance:
1st gear:
0.020 -
- 0.073 mm (0.0008 -
- 0.0029 in.)
2nd and 3rd gears:
0.015 -
- 0.068 mm (0.0006 -
- 0.0027 in.)
Maximum clearance:
1st gear: 0.073 mm (0.0029 in.)
2nd and 3rd gears: 0.068 mm (0.0027 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE 5TH GEAR, OUTPUT SHAFT CENTER
BEARING AND 1ST GEAR ASSEMBLY
(a) Using a press, remove the 5th gear, center bearing, thrust
washer and 1st gear.
(b) Remove the synchronizer ring.
(c) Remove the straight pin and needle roller bearing.
(d) Remove the spacer.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CONTINUED
CHAS. & BODY:

Z03548
Q00888
Z03550
MT-
-28
-
-
4. REMOVE REVERSE GEAR ASSEMBLY AND 2ND
GEAR ASSEMBLY
ring.
(b) Using a press, remove the reverse gear assembly and
2nd gear assembly.
(c) Remove the needle roller bearing.
5. REMOVE REVERSE GEAR, SHIFTING KEY AND
SPRING FROM CLUTCH HUB NO. 1
(a) Remove the reverse gear from the clutch hub No. 1.
(b) Push the shifting key spring with a screwdriver, remove
the 3 shifting keys and key springs.
6. REMOVE HUB SLEEVE NO. 2 ASSEMBLY AND 3RD
GEAR ASSEMBLY
(b) Using a press, remove the hub sleeve No. 2 assembly
and 3rd gear assembly.
(c) Remove the needle roller bearing.
7. REMOVE SHIFTING KEY AND SPRING FROM HUB
SLEEVE NO. 2 ASSEMBLY
Using a screwdriver, remove the 3 shifting keys and 2 springs.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

Z03554
MT0DH-
-01
Z03555
A B C
Z03556
WM0064
-
-
MT-
-29
INSPECTION
1. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the output shaft flange
thickness.
Minimum thickness: 4.8 mm (0.1890 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
A 1st gear: 38.979 mm (1.5346 in.)
B 2nd gear: 46.984 mm (1.8498 in.)
C 3rd gear: 37.984 mm (1.4954 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
(c) Using a dial indicator, check the shaft runout.
If the runout exceeds the maximum, replace the output shaft.
2. INSPECT 1ST AND 3RD GEARS SYNCHRONIZER
RING
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

WM0065
Q09913
Q09914
Q09915
WM0066
MT-
-30
-
-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
off after rubbing.
3. INSPECT 2ND GEAR SYNCHRONIZER RING
(b) Install the synchronizer inner ring, middle ring and outer
ring to each gear.
(c) Check the braking effect of the synchronizerring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
nizer ring.
4. INSPECT SHIFT FORK NO. 2 AND HUB SLEEVE NO.2
CLEARANCE
Using a feeler gauge, measure the clearance between the hub
sleeve No. 2 and shift fork No. 2.
Maximum clearance: 0.35 mm (0.014 in.)
If the clearance exceeds the maximum, replace the shift fork
No. 2 or hub sleeve No. 2.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

WM0066
-
-
MT-
-31
5. INSPECT SHIFT FORK NO. 1 AND REVERSE GEAR
CLEARANCE
Using a feeler gauge, measure the clearance between the re-
verse gear and shift fork No.1.
No.1 or reverse gear.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT036-
-02
Q06699
Front
Q00888
Q06700
Front
Z03558
MT-
-32
-
-
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL CLUTCH HUB NO. 2 INTO HUB SLEEVE NO.
2
(a) Install the clutch hub No. 2 and shifting keys to the hub
sleeve No. 2.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not
aligned.
2. INSTALL CLUTCH HUB NO. 1 INTO REVERSE GEAR
(a) Install the 3 shifting key springs to the clutch hub No. 1.
(b) While pushing the shifting key spring with a screwdriver,
install the 3 shifting keys.
(c) While pushing the 3 shifting keys, install the clutch hub
No. 1 to the reverse gear, as shown.
3. INSTALL 3RD GEAR AND HUB SLEEVE NO. 2 ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Install the needle roller bearing in the 3rd gear.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

GM0060
WM0116
RM0023
-
-
MT-
-33
(d) Using a press, install the 3rd gear and hub sleeve No. 2.
4. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
A 1.80 -
- 1.85 (0.0709 -
- 0.0728)
B 1.85 -
- 1.90 (0.0728 -
- 0.0748)
C 1.90 -
- 1.95 (0.0748 -
- 0.0768)
D 1.95 -
- 2.00 (0.0768 -
- 0.0787)
E 2.00 -
- 2.05 (0.0787 -
- 0.0807)
F 2.05 -
- 2.10 (0.0807 -
- 0.0827)
G 2.10 -
- 2.15 (0.0827 -
- 0.0846)
(b) Using a snap ring expander, install the snap ring.
5. INSPECT 3RD GEAR THRUST CLEARANCE (See
page MT-
-27)
6. INSTALL 2ND GEAR AND REVERSE GEAR
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Align the projection of the synchronizer inner ring with the
slots of the clutch hub No. 1.
(d) Install the needle roller bearing in the 2nd gear.
(e) Using a press, install the 2nd gear assembly and reverse
gear assembly.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Z03560
Z03563
Z03564
Z03565
2WD: 4WD:
SST SST
MT-
-34
-
-
7. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
A 2.30 -
- 2.35 (0.0906 -
- 0.0925)
B 2.35 -
- 2.40 (0.0925 -
- 0.0945)
C 2.40 -
- 2.45 (0.0945 -
- 0.0965)
D 2.45 -
- 2.50 (0.0965 -
- 0.0984)
E 2.50 -
- 2.55 (0.0984 -
- 0.1004)
F 2.55 -
- 2.60 (0.1004 -
- 0.1024)
G 2.60 -
- 2.65 (0.1024 -
- 0.1043)
(b) Using a screwdriver and hammer, install the snap ring.
8. INSTALL SPACER AND 1ST GEAR ASSEMBLY
(a) Install the spacer on the output shaft.
(b) Apply gear oil to the needle roller bearing.
(c) Assemble the 1st gear, synchronizer ring and needle roll-
er bearing.
(d) Install the assembly on the output shaft with the synchro-
nizer ring slots aligned with the shifting keys.
9. INSTALL STRAIGHT PIN AND 1ST GEAR THRUST
WASHER
Install the 1st gear thrust washer onto the output shaft with the
straight pin aligned with the 1st gear thrust washer.
10. INSTALL OUTPUT SHAFT CENTER BEARING
(a) 2WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09309--35010
(b) 4WD:
Using SST and a hammer, drive in the bearing with the
outer race snap ring groove toward the rear.
SST 09316--60011 (09316--00011, 09316--00071)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Z03568
SST
-
-
MT-
-35
11. INSPECT 1ST GEAR THRUST CLEARANCE
(See page MT-
-27)
12. INSPECT 2ND GEAR THRUST CLEARANCE
(See page MT-
-27)
13. INSTALL 5TH GEAR
Using SST and a press, install the 5th gear.
SST 09316--60011 (09316--00031)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

COUNTER GEAR & REVERSE IDLER GEAR
1. Components MT-36
2. Disassembly MT-37
3. Inspection MT-38 / 39
4. Replacement MT-40
5. Reassembly MT-41
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT037-
-02
D10039
Snap Ring
Counter Gear
Reverse Idler Gear Shaft
z Counter Gear Front Bearing
Reverse Idler Gear
Gear Spline Piece No. 5
Synchronizer Cone Ring
Hub Sleeve No. 3
Counter 5th Gear
Straight Pin
Thrust Washer
Counter Gear Rear Bearing
Reverse Synchronizer Ring
Shifting Key
Shifting Key Spring
5th Synchronizer Ring
Reverse Synchronizer Pull Ring
Snap Ring
Snap Ring
MT-
-36
-
-
MANUAL TRANSMISSION (R151, R151F) COUNTER GEAR AND REVERSE IDLER GEAR
COUNTER GEAR AND REVERSE IDLER GEAR
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT038-
-02
Q07459
Q06828
Q06829
-
-
MT-
-37
DISASSEMBLY
REMOVE HUB SLEEVE NO. 3, SHIFTING KEY AND SPRING
FROM SYNCHRONIZER RING
(a) Remove the synchronizer ring assembly from the hub
sleeve No. 3.
(b) Turn the reverse synchronizer pull ring.
(c) Remove the reverse synchronizer ring and 5th synchro-
nizer ring from the synchronizer pull ring and cone ring.
(d) Turn the reverse synchronizer pull ring, separate the pull
ring and cone ring.
(e) Push the shifting key and spring, and remove the 3 shift-
ing keys and springs to the reverse synchronizer ring.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT039-
-02
Z03569
Q06689
Q06831
Q06832
MT-
-38
-
-
INSPECTION
1. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Installthe spacer, counter 5th gear and needle rollerbear-
ings.
(b) Using a dial indicator, measure the counter 5th gearradial
clearance.
Standard clearance:
0.015 -
- 0.068 mm (0.0006 -
- 0.0027 in.)
Maximum clearance:
0.68 mm (0.0268 in.)
If the clearance exceeds the maximum, replace the gear bear-
ing or shaft.
2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter
gear journal.
Minimum diameter: 29.984 mm (1.1805 in.)
If the outer diameter is less than the minimum, replace the
counter gear.
3. INSPECT 5TH SYNCHRONIZER RING
(b) Install the synchronizer pull ring, cone ring and outer ring
to the gear spline piece No. 5.
(c) Check the braking effect of the synchronizerring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

WM0066
Q01803
Q06775
-
-
MT-
-39
4. INSPECT SHIFT FORK NO. 3 AND HUB SLEEVE NO.3
CLEARANCE
Using a feeler gauge, measure the clearance between the hub
sleeve No. 3 and shift fork No. 3.
No. 3 or hub sleeve No. 3.
5. INSPECT REVERSE IDLER GEAR RADIAL CLEAR-
ANCE
Using a dial indicator, measure the reverse idler gear radial
clearance.
Standard clearance:
0.040 -
- 0.082 mm (0.0016 -
- 0.0032 in.)
Maximum clearance:
0.082 mm (0.0032 in.)
If the clearance exceeds the maximum, replace the reverse
idler gear or reverse idler gear shaft.
6. INSPECT REVERSE IDLER GEAR AND SHIFT ARM
CLEARANCE
Using a feeler gauge, measure the clearance between the re-
verse idler gear and shift arm.
Standard clearance:
0.05 -
- 0.35 mm (0.0020 -
- 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replace the shift arm or
reverse idler gear.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT03A-
-02
Z03575
SST
RM0013
Socket Wrench
Z03576
MT-
-40
-
-
REPLACEMENT
IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING
(b) Using SST and a press, remove the bearing.
SST 09950--00020
(c) Replace the side race.
(d) Using a socket wrench and press, install a new bearing
and side race.
(e) Select a snap ring that allows the minimum axial play.
A 2.05 -
- 2.10 (0.0807 -
- 0.0827)
B 2.10 -
- 2.15 (0.0827 -
- 0.0846)
C 2.15 -
- 2.20 (0.0846 -
- 0.0866)
D 2.20 -
- 2.25 (0.0866 -
- 0.0886)
E 2.25 -
- 2.30 (0.0886 -
- 0.0906)
F 2.30 -
- 2.35 (0.0906 -
- 0.0925)
(f) Using a snap ring expander, install the snap ring.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT03B-
-02
Q06830
Q06828
Q07460
Q06819
Front
-
-
MT-
-41
REASSEMBLY
INSTALL SYNCHRONIZER RING ASSEMBLY TO HUB
SLEEVE NO. 3
(a) Put the key spring to the hole of the shifting key.
(b) Push the 3 shifting keys with the 3 key springs to the re-
verse synchronizer ring.
(c) Install the synchronizer cone ring to the reverse synchro-
nizer pull ring and turn the pull ring.
(d) Install the 5th synchronizer ring.
(e) Install the reverse synchronizer ring.
(f) Turn the reverse synchronizer pull ring.
(g) While pushing the 3 shifting keys, install the synchronizer
ring assembly to the hub sleeve No. 3.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT03C-
-02
RM0322
Front Bearing Retainer
z Oil Seal
MT-
-42
-
-
MANUAL TRANSMISSION (R151, R151F) FRONT BEARING RETAINER OIL SEAL
FRONT BEARING RETAINER OIL SEAL
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT03D-
-02
Z03583
Q07394
SST
-
-
MANUAL TRANSMISSION (R151, R151F) FRONT BEARING RETAINER OIL SEAL
MT-
-43
REPLACEMENT
IF NECESSARY, REPLACE FRONT BEARING RETAINER
OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950--60010 (09951--00510), 09950--70010
(09951--07150)
Drive in depth: 11.7 ± 0.5 mm (0.461 ± 0.020 in.)
from retainer end
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT03E-
-03
D09821
4WD: Transfer Adaptor
Dust Deflector
z Oil Seal
Straight Screw Plug
L
2WD:
Straight Screw Plug
Oil Receiver Pipe
Oil Receiver
Reverse Restrict Pin
Extension Housing
: Specified torque
Slotted Spring Pin
L
19 (190, 14)
z Oil Seal
19 (190, 14)
11 (115, 8)
N∙m (kgf∙cm, ft∙lbf)
L Precoated part
Oil Receiver
Reverse Restrict Pin
Slotted Spring Pin
L
MT-
-44
-
-
MANUAL TRANSMISSION (R151, R151F) EXTENSION HOUSING AND TRANSFER ADAPTOR
EXTENSION HOUSING AND TRANSFER ADAPTOR
COMPONENTS
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

MT03F-
-02
Q04410
Z03582
Q07365
SST
-
-
MT-
-45
REPLACEMENT
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Remove the reverse restrict pin.
(1) Using a torx socket wrench (T40), remove the screw
plug.
(2) Using a pin punch and hammer, drive out the slotted
spring pin.
(3) Remove the reverse restrict pin.
(b) Inspect the reverse restrict pin.
Turn and push the reverse restrict pin by hand. Check for
smooth operation.
(c) Install the reverse restrict pin.
(1) Install the reverse restrict pin to the extension hous-
ing or transfer adaptor.
(2) Using a pin punch and hammer, drive in the slotted
spring pin, as shown.
(3) Apply sealant to the plug threads.
Sealant:
Part No.08833-
242 or equivalent
(4) Using a torx socket wrench (T40), install and torque
the screw plug.
2. 2WD:
IF NECESSARY, REPLACE EXTENSION HOUSING
OIL SEAL
(a) Remove the dust deflector.
(b) Using a screwdriver, pry out the oil seal.
(c) Using SST and a hammer, drive in a new oil seal.
SST 09950--60010 (09951--00570), 09950--70010
(09951--07150)
Drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(d) Install the deflector.
TO MODEL INDEX
TO MODEL INDEX
DR053E
CONTINUED
CHAS. & BODY:

Q07366
SST
MT-
-46
-
-
3. 4WD:
IFNECESSARY, REPLACE TRANSFER ADAPTOROIL
SEAL
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09950--60010 (09951--00570), 09950--70010
(09951--07150)
Drive in depth: 45.9 ± 0.5 mm (1.807 ± 0.020 in.)
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SUSPENSION AND AXLE
TIRE AND WHEEL (2WD) SA--1
. . . . . . . . . . . . . . . . .
TIRE AND WHEEL (4WD) SA--3
. . . . . . . . . . . . . . . . .
FRONT WHEEL ALIGNMENT (2WD) SA--5
. . . . . . .
FRONT WHEEL ALIGNMENT (4WD) SA--9
. . . . . . .
(May, 1998)
RM651E
(Aug., 1999)
RM706E
TO MODEL INDEX
TO MODEL INDEX
DR053E
CHAS. & BODY:

SUPPLEMENT CHASSIS & BODY DR053E.pdf

SUPPLEMENT CHASSIS & BODY DR053E.pdf

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