Assembly of transmission

ASSEMBLE EACH CLUTCH HUB AND SLEEVE (al Install the clutch hub and shilling keys to the hub sleeve. NOTE Be careful not to install them backwards. (b) Install the shifting key springs under the keys. NOTE Install the key springs positioned so that their ends overlap. 2. INSTALL SECOND GEAR AND CLUTCH HUB NO. 1 (a) Apply MP grease to the shaft. (b) Install the needle roller bearing. (c) Place the synchronizer ring on the gear and align the ring slots with the shifting keys. (d) Using a press,...

Disassembly Of Propeller Shaft Joint Type

SEPARATE PROPELLER SHAFT AND INTERMEDIATE SHAFT (a) Place matchmarks on the flanges. (b) Remove the four bolts and nuts. 2. REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT (a) Using a hammer and chisel, loosen the staked part of the nut. (b) Using SST to hold the flange, remove the nut. SST 09330 00020 (c) Place matchmarks on the flange and shaft. (d) Clamp the flange in a vise and tap off the shaft.

Disassembly of transmission

SPEEDOMETER DRIVEN GEAR. SHIFT LEVER RETAINER, RESTRICT PINS, CLUTCH RELEASE BEARING AND FORK 2. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE (a) Remove the front bearing retainer. Remove the six bolts and pull off the extension housing. 4. REMOVE LOCKING BALLS AND SPRINGS (b) Using a magnetic finger, remove the three locking balls and springs. 5. REMOVE LEFT CASE FROM RIGHT CASE Separate the left case from the right case by tapping the projection with a plastic...

If Necessary Replace Rear Bearing Fifth Gear Reverse Gear And Center Bearing

(a) Using snap ring pliers, remove the snap ring, lb) Using a press and 12-mm socket wrench, press out the rear bearing and 5th gear. (c) Remove the reverse gear and center bearing. (d) Install the center bearing and reverse gear. (e) Using a press and SST, install the rear bearing and 5th gear. NOTE Lift the reverse gear to the upper side, and press in the bearing and 5th gear. (f) Select a snap ring that will allow minimum axial play and install it on the shaft.

Inspection of transmission components

INSPECT OUTPUT SHAFT AND INNER RACES (a) Inspect the output shaft and inner races for wear or damage. (b) Using calipers, measure the thickness of the output shaft flange. Minimum thickness 4.0 mm (0.157 in.) (c) Using a micrometer, measure the outer diameter of the shaft bushing surface. Minimum diameter 37.8 mm (1.488 in.) (d) Using calipers, measure the thickness of each race flange. Minimum all gear race 3.8 mm (0.150 in.) (e) Using a micrometer, measure the outer diameter of each race....

Installation Of Front Shock Absorber Assembly

INSTALL BUMPER, COIL SPRING AND SPRING SEAT (a) Mount the front shock absorber on a stand. (b) Install the bumper to the shock absorber. (c) Align the coil spring end with the lower seat hollow and install. (d) Align the spring seat with the piston rod and install. (e) Install the dust seal on the spring seat. (f) Using SST, compress the coil spring. SST 09727 22031 (a) Using SST to hold the support, install the support with a new nut. Torque the nut. (b) Pack MP grease into the suspension...

Installation of master cylinder

INSTALL MASTER CYLINDER WITH MOUNTING NUTS Using SST, connect the tube. SST 09751 36011 3. CONNECT CLEVIS, AND INSTALL CLEVIS PIN AND CLIP Secure the clevis pin with the clip. 5. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM (See page CL-3) 7. CHECK AND ADJUST CLUTCH PEDAL (See page CL-3) 8. INSTALL INSTRUMENT LOWER FINISH PANEL AND AIR DUCT

Installation of transmission

PLACE TRANSMISSION AT INSTALLATION POSITION, AND INSTALL TRANSMISSION MOUNT BOLTS (a) Align the input shaft spline with the clutch disc, and push the transmission fully into position. (b) Install the two set bolts of the upper transmission, and troque the bolts. 2. INSTALL ENGINE REAR MOUNTING Install and torque the eight bolts. Torque 530 kg-cm (38 ft-lb) 3. INSTALL TRANSMISSION BOLTS AND STIFFENER PLATE Install and torque the bolts. Torque 375 kg-cm (27 ft-lb) 4. INSTALL EXHAUST PIPE BRACKET...

Removal Of Front Shock Absorber Assembly

Using SST and an open end wrench, disconnect the brake tube from the flexible hose. Drain the brake fluid into a container. SST 09751-36011 Remove the two bolts mounting the shock absorber assembly to the steering knuckle arm. 4. REMOVE FRONT SHOCK ABSORBER, FRONT AXLE HUB AND BRAKE CALIPER NOTE Collars extend into the steering knuckle bolt holes about 5 mm (0.20 in.) deep. Push the suspension lower arm down and remove the front shock absorber, front axle hub and brake caliper. 5. MOUNT FRONT...

Removal of transmission

REMOVE NEGATIVE BATTERY TERMINAL WIRE (b) Turn the distributor so it does not strike against the dash panel. 4. REMOVE SHIFT LEVER FROM INSIDE OF VEHICLE 5. RAISE VEHICLE AND DRAIN TRANSMISSION OIL CAUTION Be sure the vehicle is securely supported. 6. DISCONNECT PROPELLER SHAFT FLANGE FROM FLANGE ON DIFFERENTIAL (a) Place matchmarks on the flanges. (b) Remove the four bolts and nuts. 7. REMOVE CENTER SUPPORT BEARING FROM BODY (3-Joint Type) (a) Pull the yoke from the transmission. (b) Insert...

Remove Spider Bearings

(a) Using SST, push out the bearing from the propeller NOTE Sufficiently raise the part indicated by A so that it does not come into contact with the bearing. (b) Clamp the bearing outer race in a vise and tap off the propeller shaft with a hammer. NOTE Remove the bearing on the opposite side in the same procedure. (c) Install the two removed bearing outer races to the spider. (d) Using SST, push out the bearing from the yoke. SST 09332 25010 (e) Clamp the bearing outer race in a vise and tap...

Front Wheel Alignment

MAKE FOLLOWING CHECKS AND CORRECT ANY PROBLEMS (a) Check the tires for size, wear, and proper inflation. Correct tire pressure 1.7 kg cm2 (24 psi) Lateral runout Less than 1.0 mm (0.039 in.) (c) Check the front wheel bearings for looseness. (d) Check the front suspension for looseness. (e) Check the steering linkage for looseness. (f) Check that the front absorbers work properly by using the standard bounce test. If height of the vehicle is not as specified, try to level the vehicle by shaking...

Install Fifth Gear And Spacer

Output Shaft Needle Bearing Toyota Hilux

a Install the spacer for the needle roller bearing. b Place the synchronizer ring on the gear, c Place the roller bearing in the gear. Id Install the 5th gear on the output shaft with the synchronizer ring slots aligned with the shifting keys. e Install the locking ball in the shaft. f Fit the spacer groove securely over the locking ball when installing the spacer on the shaft. Using a press and SST, install the rear bearing on the out CAUTION Support the 5th gear and inner race by hand. NOTE...

Bleeding Of Clutch System

NOTE If any work is done on the clutch system or if air is suspected in the clutch lines, bleed the system of air. CAUTION DO NOT let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID Check the reservoir frequently. Add fluid if necessary. 2. CONNECT VINYL TUBE TO BLEEDER PLUG Insert the other end of the tube in a half full container of brake fluid. a Slowly pump the clutch pedal several times. b While depressing the pedal, loosen the...

Check And Adjustment Of Clutch Pedal

CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet LHD 161-171 mm 6.34-6.73 in. RHD 162 - 172 mm 6.38 - 6.77 in. 2. IF NECESSARY, ADJUST PEDAL HEIGHT a Remove the instrument lower finish panel and air duct. b 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 Push in on the pedal until the beginning of clutch resis tance is felt. Pedal freeplay 13 - 23 mm 0.51 - 0.91 in....

Install Wheel Alignment Equipment

Follow the specific instructions of the equipment manufacturer. INSPECT CAMBER AND STEERING AXIS INCLINATION INSPECT CAMBER AND STEERING AXIS INCLINATION If camber or steering axis inclination checks are out of tolerance, inspect and replace damaged or worn front suspension parts. If caster is out of tolerance, adjust the caster with the staked nuts of the strut bar. Torque 925 kg-cm 67 ft-lb NOTE Decrease caster by lengthening the strut bar. Increase caster by shortening the strut bar. One...

Inspection Of Ball Joints

INSPECT BALL JOINTS FOR EXCESSIVE LOOSENESS a Jack up the front of the vehicle and place wooden blocks with a height of 180 200 mm 7.09-7.87 in.l under one front tire. b Lower the jack until there is about half a load on the front coil springs. Place stands under the vehicle for safety. c Make sure the front wheels arc in a straight forward position and block them with chocks. d Move the lower arm up and down and check that the ball joint has no excessive play. Maximum ball joint vertical...