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Toyota 7FD 10, Repair Manual, Page: 32 / 111

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Toyota 7FD 10 Repair Manual Download Page 32

Functions

Functions

  

II

  

+

+

-

-

  

+

+

-

-

  

+

+

-

-

Loos

Loosening 

ening  and  dam

and  damage 

age  at 

at senso

sensor 

r  moun

mounting

ting

II

  

4

4

-

-

 

+

 

+

-

 

-

 

+

+

-

-

portion

portion

Dama

Damage, 

ge,  defo

deformat

rmation, 

ion,  oil 

oil leaka

leakage 

ge  and

and

II

  

4

4

-

-

 

+

 

+

-

 

-

 

+

+

-

-

SAS

SAS

loose

loosening 

ning  of  th

of  the  mountin

e  mounting 

g  of  fu

of  functio

nctional 

nal  part

parts

s

Loos

Loosenin

ening 

g  and  damag

and  damage 

e  of 

of wire 

wire  harn

harnesses

esses

  

II

 

4

 

4

-

 

-

 

4

4

-

-

  

+

+

-

-

Lock  cylin

Lock  cylinder 

der  accum

accumulato

ulator 

r  perf

performa

ormance

nce

  

II

R

Ru

us

sttiin

ng  

g  a

an

nd  

d  c

co

orrrro

os

siio

on  

n  o

of  

f  llo

oa

ad  

d  s

se

en

ns

so

or  

r  

II

Others

Others

  

Grea

Grease 

se  up

up

  

L

L

 

4

 

4

-

 

-

 

4

4

-

-

  

+

+

-

-

  

0-28

0-28

PE

PERIO

RIODI

DIC 

C  RE

REPLACEM

PLACEMEN

ENT 

T  OF  PART

OF  PARTS 

S  AND  L

AND  L UBRI

UBRICANTS

CANTS

• 

•  : 

:  Rep

Replac

laceme

ement

nt

Interval

Interval

 

Every

 

Every

 

Every

 

Every

 

Every

 

Every

 

Every

 

Every

1 month

1 month

  

3  

3  m o

m on t

n th s  

h s  

6  

6  m o

m on t

n th s

h s    12 

12 months

months

Every

Every

 

E

 

Evveerry  

y  

E

Evveerry  

y  

E

Evveerryy

Item

Item

  

170 

170 hours

hours    500 

500  hours

hours    1000 

1000 hours

hours    2000 

2000  hours

hours

Engine  oil

Engine  oil

•

•

  

+

+

-

-

  

+

+

-

-

  

+

+

-

-

Engine oil filter 

Engine oil filter 

• •  * * 11

   ••

  

+

+

-

-

  

+

+

-

-

Engin

Engine 

e  cool

coolant 

ant  (ever

(every 2 years for LLC)

y 2 years for LLC)

•

•

 

+

 

+

-

 

-

 

+

+

-

-

Fuel filter 

Fuel filter 

••

  

+

+

-

-

Torque  converter  oil

Torque  converter  oil

••

  

+

+

-

-

Torque  converter 

Torque  converter  oil 

oil filter 

filter 

••

  

+

+

-

-

Manual 

Manual  tran

transmissi

smission 

on  oil

oil

••

Differenti

Differential 

al  oil

oil

•

•

Hydraul

Hydraulic 

ic  oil

oil

••

  

+

+

-

-

Hydraulic 

Hydraulic  oil 

oil filt

filter 

er 

. . * * 11

  

••

  

+

+

-

-

Wheel  bearing  grease

Wheel  bearing  grease

•

•

Spark  plugs

Spark  plugs

••

  

+

+

-

-

Air  clea

Air  cleaner 

ner  element

element

••

Cups  and  seals  for  brake  master  and  wheel  cylinders

Cups  and  seals  for  brake  master  and  wheel  cylinders

•

•

Brake  fluid

Brake  fluid

••

  

+

+

-

-

Power  stee

Power  steerin

ring 

g  hoses

hoses

. . * * 22

Power  steer

Power  steering 

ing  rubbe

rubbers 

rs  part

partss

. . * * 22

Hydrau

Hydraulic 

lic  hoses

hoses

. . * * 22

Brake fluid reservoir tank hose

Brake fluid reservoir tank hose

. . * * 22

Fuel hoses

Fuel hoses

. . * * 22

Torque conv

Torque converte

erter 

r  rubbe

rubber 

r  hoses

hoses

. . * * 22

** 33

https://www.besttruckmanuals.com/

Summary of Contents for 7FD 10

Page 1: ...https www besttruckmanuals com...

Page 2: ...CG CG 1 1b b https www besttruckmanuals com...

Page 3: ...e ures s of t of the moun he mounted ted eng engine ine rea read the d the rep repair air man manual uals s lis listed below ted below as ref as refere erence nce tog togeth ether er wit with this h t...

Page 4: ...SECT CTIO ION N IN INDE DEX X II E E II GENERAL GENERAL F FE EA AT T E ES S II MAN MANUAL UAL TRA TRANSM NSMISS ISSION ION II DIFFERENTIAL DIFFERENTIAL II APPENDIX APPENDIX https www besttruckmanuals...

Page 5: ...CATION ON MET METHOD HOD 0 0 13 13 T TI IG GH HT TE EN NI IN NG G T TO OR RQ QU UE E T TA AB BL LE E 0 0 1 14 4 P PR RE EC CO OAT AT BO BO LT LTS S 0 15 0 15 HI HIGH GH PR PRES ESSU SURE RE HO HOSE SE...

Page 6: ...0 2 0 2 EXTE EXTERIO RIOR R VIE VIEWS WS https www besttruckmanuals com...

Page 7: ...soline 42 7FG18 42 7FG18 1 75 ton 1 75 ton mode model l T I C T I C 10Z 11 10Z 11 Diesel Diesel 02 7FD18 02 7FD18 7FG20 7FG20 Mff Mff 5K 5K Gasoline Gasoline 02 7FG20 02 7FG20 T I C T I C 4O 7FG20 4O...

Page 8: ...MI IT T 1DZ II 1DZ II Diesel Diesel 02 7FDK20 02 7FDK20 T I C T I C K2 ton series K2 ton series 7 7F FG GK K2 25 5 M MI IT T 5K 5K Gasoline Gasoline 02 7FGK25 02 7FGK25 T I C T I C 4 40 0 7 7F FG GK K...

Page 9: ...G18 42 7FG18 7FD10 7FD10 02 7FD10 02 7FD10 10Z 11 10Z 11 7FD15 7FD15 7F018 10011 7F018 10011 02 7FD15 02 7FD15 02 7FD18 02 7FD18 7FG20 7FG20 02 7FG20 02 7FG20 5 5K K 7 7F FG G2 25 5 1 1 0 00 01 11 1 7...

Page 10: ...011 62 7FD30 62 7FD30 7FGK20 7FGK20 02 7FGK20 02 7FGK20 5K 5K 7FGK25 10011 7FGK25 10011 7FGK25 7FGK25 02 7FGK25 02 7FGK25 4Q 7FGK20 4Q 7FGK20 K2ton K2ton 42 7FGK20 42 7FGK20 series series 4Y 4Y 7FGK3Q...

Page 11: ...r are e pa part rtia iall lly y so some meti time mes s omitt omitted ed in in illus illustratio trations ns Wh When en a a pa part rt re requ quir irin ing g ti tigh ghte teni ning ng tor torque que...

Page 12: ...use ac accide cidents nts Be Be sure t sure to obser o observe ve the them m Note Note Importa Important nt ite items of which ms of which negli negligence gence may ca may cause accide use accidents...

Page 13: ...y Tig Tighte hten n to th to the e cen center ter of t of the spec he specifi ified ed tig tighte htenin ning g tor torque que ran range ge If If no no tight tightenin ening g torqu torque e is is sp...

Page 14: ...oles and the rear side of the head guard hook holes and the rear side of the head guard Sli Slinging nging at t at the he head guard head guard is is done done in in two ways two ways Method A Method...

Page 15: ...y be may be dif differ ferent ent bet betwee ween n mea measur sureme ements nts wit with the a h the anal nalog og typ type and digi e and digital tal typ type e Always Always use use a a circuit cir...

Page 16: ...g g diffe different rent powe power r supp supply ly volta voltages ges are diffe are different rent Thi This s man manual desc ual describ ribes es the res the result ults s of mea of measur sureme e...

Page 17: ...ific ification ation by by part part No No Sha Shape pe and and cla class ss Class Class Hexago Hexagonhead nhead bolt bolt 4 4T 4 4T 5 5T 5 5T Bol Bolt t hea head No d No 6 6T 6 6T Parts Parts No No...

Page 18: ...I I 1600 1600 I I 116 116 6 6 1 0 1 0 7 8 7 8 I I 80 80 II 69 i 69 in Ib n Ibf f 8 8 8 8 II 90 90 I I 78 78 in Ib in Ibf f 8 8 1 25 1 25 19 19 II 195 195 II 14 14 21 21 I I 215 215 I I 16 16 10 10 1...

Page 19: ...a ean n cl clot oth h to to re remo move ve fo fore reig ign n ma matt tter ers s an and d di dirt rt Al Also so ch chec eck k no de no dent or oth nt or other er da dama mage ge on th on the e co con...

Page 20: ...uspension nsion suspension suspension d di ia am me et te er r l lo oa ad d 0 0 0 0 0 0 0 0 30 30 0 0 60 60 0 0 90 90 0 0 0 0 0 0 30 30 0 0 60 60 0 0 90 90 0 0 6mm 6mm 21380 21380 3040 3040 6080 6080...

Page 21: ...1 5 ton n mode model l Ap Appro prox x 745 745 16 1640 40 1 75 to 1 75 ton n mode model l Ap Appro prox x 880 880 19 1940 40 2 0 ton model 2 0 ton model Appr Approx ox 1150 1150 2535 2535 Coun Counte...

Page 22: ...TIC TIC 2 speeds 2 speeds 10 5 10 5 2 77 2 77 1 ton series 1 ton series 6 3 6 3 1 66 1 66 2 ton series 2 ton series Differential Differential K2 K2 ton ton series series 7 1 7 1 1 87 1 87 AP API I Hyp...

Page 23: ...7 9 7 9 1DZ II engine models 1DZ II engine models 27 27 7 1 7 1 34 34 9 0 9 0 36 36 9 5 9 5 2Z engi 2Z engine ne mode models ls 39 39 10 3 10 3 41 41 10 10 8 8 Note Note Si Since the hydr nce the hyd...

Page 24: ...Hypo Hypoid id gear gear oil oil Hydr Hydraulic aulic oil oil Hypo Hypoid id gear gear oil oil Brake Brake fluid fluid j j Molybdenum Molybdenum disulfide disulfide grease grease L L In Insp spec ect...

Page 25: ...in in 18 18 Ti Tie e ro rod d en end d p pin in 19 19 Re Rear ar ax axle le cy cylin linde der r en end d pi pin n 20 20 Ge Gear ar sh shif ift t le leve ver r 0 21 0 21 To Torque Conv rque Conver ert...

Page 26: ...u Lubr brica icati tion on Fo For r ne new w ve vehi hicl cle e 1 1 F Fla law w d det etec ecto tor r Inspection Period Inspection Period Every Every Every Every Every Every Every Every 1 month 1 mont...

Page 27: ...and and leak leak I I Fluid level Fluid level I I Oil cl Oil clutc utch h mec mechan hanism ism fun functi ction on and lea and leak k I I OPT OPT Leak Leak I I Fluid level Fluid level I I Manual Manu...

Page 28: ...rmal mal sound and loos sound and looseness eness of r of rear ear I I wheel bearing wheel bearing Front axle Front axle Cracks Cracks damage damage and and defor deformatio mation n of of housi housi...

Page 29: ...ic Automatic adjuster adjuster function function I I Defor Deformati mation on crack cracks s and da and damage mage I I Backi Backing ng plate plate Loose mounting Loose mounting T T MATER MATERIAL I...

Page 30: ...earing Cytinder Cytinder Lifting speed Lifting speed M M Uneven movement Uneven movement I I Oil pump Oil pump Oil Oil leak leak and and abnor abnormal mal sound sound I I Oil level and contamination...

Page 31: ...for back ck pres pressure sure sens sensor or I I SAF SAFETY ETY DEVI DEVICES CES ETC ETC Crac Cracks ks at at weld welded ed port portion ion I I Head guard Head guard Defor Deformatio mation n and...

Page 32: ...ry E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y Item Item 170 170 hours hours 500 500 hours hours 1000 1000 hours hours 2000 2000 hours hours Engine oil Engine oil Engine oil filter Engine oil filt...

Page 33: ...v de upon arrival al of th of the operat e operation ion hou hours rs or mo or month nths s whi whiche chever ver is is ear earlie lier r FEATURES FEATURES Page Page C C L LUTC H UTC H 1 2 1 2 MANUAL...

Page 34: ...ylinder to t nder to the clutch he clutch cover through the release fork and release hub after the modi cover through the release fork and release hub after the modi fi ficati cation on made made thi...

Page 35: ...4 N Note ote P Powe ower r a assi ssist st typ type e clu clutch tch is a is adop dopte ted d on v on ve ehic hicle les s ins insta talle lled d wit with h the op the optio tiona nal l oil cl oil clu...

Page 36: ...draulic Size Size mm mm 27 278 8 Clutch cover Clutch cover Installati Installation on load load N N kg kg 5 070 5 070 517 517 6865 6865 700 700 0 0 0 0 x x 1 0 1 0 mm mm 27 275 5 x x 17 175 5 Clutc Cl...

Page 37: ...S CATIONS Tran Transmiss smission ion type type Synchromesh Synchromesh Oper Operating ating meth method od Floor Floor shift shift link link Tran Transmiss smission ion case oil case oil capa capacit...

Page 38: ...Z 3 3 3 37 79 9 1 1 3 35 55 5 3 3 3 38 85 5 1 1 3 35 58 8 Th The e gea gear r rat ratios of the 4 ios of the 4Y EC Y ECS S eng engine ine veh vehicl icles es are th are the same e same as as tho thos...

Page 39: ...idl idle e gea gear r Outp Output ut gea gear r POWER POWER TRANSMIS TRANSMISSION SION CHARTS CHARTS For Forwar ward d 1s 1st spe t speed ed Forw Forward ard 2nd speed 2nd speed 1 7 1 7 https www bes...

Page 40: ...SMI MANUAL TRANSMISSI SSION ON SECT SECTIO IONAL NAL VI VIEW Oil EW Oil CLUTC CLUTCH VEHI H VEHICLE CLE Countershaft gear 2nd Countershaft gear 2nd Speed gear shaft Speed gear shaft Forward reverse sy...

Page 41: ...t axl axle e hou housin sing g bol bolts ts has be has been en cha change nged d fro from m 16 16 to to 12 12 pcs pcs v vehi ehicle cle Old Old New New F F RO RONT NT AX AXLE LE BRA BRACK CKET ET The...

Page 42: ...LT RCE BOLT The reac The reactio tion n for force ce bol bolt used for fix t used for fixing the front axle brac ing the front axle bracket ket on t on the diffe he differen rentia tial l hou housin s...

Page 43: ...dri the drive pini ve pinion on and redu and reducti ction on gea gear r mou mounti nting ng por portio tion n has b has been disc een discont ontinu inued ed and the and the dif differ ferent ential...

Page 44: ...Not provided provided 21 21 x x 8 9 8 9 MfTVehicle MfTVehicle 1 642 1 642 4 4 5 50 0 1 12 2 1 1 s sp pe ee ed d TIC TIC vehicle vehicle 2 2 3 36 63 3 1 1 5 58 86 6 2 2 2 21 17 7 1 1 5 58 86 6 6 00 9 6...

Page 45: ...Sol Solid id Ti Tire re Rim Rim J Lug J Lug Soft Soft White White Green Green Type Type Tir Tire e Siz Size e J J Lu Lug g Ti Tire re Si Size ze Non Non N No on n N No on n N No on n Puncture Puncture...

Page 46: ...h 5K 5K 1 14 1 14 K2 K2 0 0 Ton Ton K2 5 K2 5 Ton Ton Veh Vehicl icle e Pneumatic Tire Pneumatic Tire Pneumat Pneumatic ic Type Type Soli Solid d Tir Tire e Component Component R Rim im J Lug J Lug S...

Page 47: ...vehi ehicle cle onl only y K3 K3 0 0 Ton Ton Veh Vehicl icle e 1 15 1 15 Pneu Pneumatic matic Tire Tire Pneu Pneumatic matic Type Type Soli Solid d Tire Tire Component Component Rim Rim J Lug J Lug S...

Page 48: ...ial ial Doub Double le 28x8 15 12 28x8 15 12 6 6 7 00 15 7 00 15 Rear Tires Rear Tires 6 50 10 12 6 50 10 12 6 50 10 6 50 10 l l 1 16 1 16 CH CHANGE ANGE LEVE LEVER R GENERAL GENERAL Th The e sh shif...

Page 49: ...K LOCK MECHANI MECHANISM SM The The str struct ucture ure of t of the til he tilt steer t steering ing loc lock k mec mechan hanism ism has been cha has been change nged d as sh as shown own bel below...

Page 50: ...locati ation on a roo a roof hole is f hole is pro provid vided ed in in the head guard the head guard roo roof f A A roo roof f cap is al cap is also provided so provided for oper for operation atio...

Page 51: ...5 2 25 1 360 1 360 2 5 2 5 1 500 1 500 2 75 2 75 1 650 1 650 3 ton 3 ton serie series s 3 0 3 0 1 800 1 800 3 5 3 5 2 135 2 135 V V M MAST AST LIFT BRACKET LIFT BRACKET The V mast The V mast lif lift...

Page 52: ...elow ow Bush Bush Collar Collar rt l T rt l T I I I I a ring a ring Grea Grease se groo groove ve Oil Oil groove groove 1 20 1 20 LIFT CYLINDER LIFT CYLINDER LIFT CYUNDER LIFT CYUNDER The The pis pist...

Page 53: ...sam the same e als also for th o for the e LH LH FSV FSV FV FV FRO FRONT NT CYLIND CYLINDER ER FRONT CYUNDER FRONT CYUNDER The fron The front t cy cylin linder der str struct ucture ure has bee has b...

Page 54: ...ch itch Le Leve ver r The switch The switch lev lever er rol roller str ler structu ucture re has been changed has been changed in in the lif the lifti ting ng hei height ght swi switch for durabi tch...

Page 55: ...The The lif liftin ting g hei height ght swi switch tch cas case e set bol set bolt has been t has been cha change nged d fro from m an ord an ordina inary ry to a t to a tapp apping ing bol bolt t 1...

Page 56: ...s s MAN MANUAL UAL TRA TRANSM NSMISSI ISSION ON Page Page G EN ERAL G EN ERAL 2 2 2 2 SPE SPECI CIFIC FICATIO ATION NS S 2 3 2 3 CO COM M PO PON NEN ENTS TS 2 4 2 4 MAN MANUAL UAL TRA TRANSM NSMISS IS...

Page 57: ...ASSY SY 2 22 2 22 DI A DI A E E BLY I BLY I SPE C SPE C c c EA SE EA SE BLY BLY 2 22 2 22 SHI SHIFT FT LEV LEVER ER WIR WIRE E CAB CABLE LE 2 23 2 23 E C E C 1 S 1 S1r T 1r Tlc lc 2 23 2 23 2 2 2 2 GE...

Page 58: ...ar ratio ratio Gear ratio Gear ratio Vehi Vehicle cle mode model l Engine Engine Forward Forward Reverse Reverse 1st speed 1st speed 2nd 2nd speed speed 1 1st st sp spe eed ed 2 2nd nd s spe peed ed...

Page 59: ...3 3 5 54 41 1 1 1 5 56 64 4 3_548 3_548 1 567 1 567 4Y 1DZ 1I 4Y 1DZ 1I f f f f f f f f 3 ton series 3 ton series 2Z 2Z 3 379 3 379 1 355 1 355 3 3 3 38 85 5 1 1 3 35 58 8 4Y 4Y 3 3 5 54 41 1 1 1 5 5...

Page 60: ...54 54 3301 064A 3301 064A https www besttruckmanuals com...

Page 61: ...2 6 2 6 MANU MANUAL AL TR TRANSM ANSMISS ISSIO ION N ASSY ASSY REMOVAL INSTALLATION REMOVAL INSTALLATION T T N m kgf c N m kgf cm m ft I ft Ibf bf https www besttruckmanuals com...

Page 62: ...use e bo box an x and el d elec ectr tric ical al pa part rts plat s plate e se set bo t bolt lts fo s for fre r freei eing ng 8 8 Di Disc scon onne nect ct co conn nnec ecto tors rs an and wir d wir...

Page 63: ...e e he eng ngin ine e mo moun unt nut t nuts s 26 26 Rem Remove t ove the e he engi ngine W tr ne W trans ansmis missio sion n P Point 4 oint 4 27 27 Re Remo move t ve the c he clu lutc tch h ho hous...

Page 64: ...et et be betw twee een n th the e FI FIR R an and d 1 1st st 2 2nd nd le leve ver r kno knobs bs wit with h shi shift ft lev levers ers in t in the he neu neutra tral l pos positi itions ons Kno Knob...

Page 65: ...e fro front nt sid side e 0 00 0 not cross the TCM not cross the TCM arran arrangemen gement t 2 10 2 10 DI DISASS SASSEMBLY EMBLY I INSP NSPECT ECTI ION ON RE REASSE ASSEMBLY MBLY T T N N m m kgf cm...

Page 66: ...emo move ve th the e co coun unte ters rsha haft ft be bear arin ing g sn snap ap ri ring ng Point Point 2 2 5 5 Re Rem mov ove e th the e lo loc ck k nu nut t P Point oint 3 3 6 6 Re Remo move ve th...

Page 67: ...trat ations ions be below low Seal Seal pack packing ing 08826 08826 0009 00090 0 Cou Counte ntersh rshaft aft cov cover er Out Output put sh shaft aft cov cover er Tran Transmis smission sion cas cas...

Page 68: ...the rubber boot on the link side beforehand rubber boot on the link side beforehand 2 13 2 13 Po Point int 6 6 Inspection Inspection In Insp spec ect t th the e ou outp tput ut sh shaf aft t oi oil s...

Page 69: ...9950 7001 7001 0 0 09950 60010 09950 60010 Apply Apply MP MP grease grease on on the the outer outer periphery periphery and and lip lip of of the the oil oil seal seal befor before e reass reassembly...

Page 70: ...haf aft t P Point oint 6 6 Rea Reassembly ssembly Procedure Procedure The The reass reassembly embly proce procedure is dure is the reverse the reverseof the disassem of the disassembly procedu bly pr...

Page 71: ...e the input input shaft shaft and and spacer spacer use use the the SST SST and and insta install ll the tight the tight plug plug SST 0 SST 0995 9950 6 0 6001 0010 0 C D C D 099 09950 50 700 70010 10...

Page 72: ...y Disassembly SST 0995 SST 09950 4 0 4001 0011 1 G G 099 09950 50 600 60010 10 P Poi oint nt 6 6 Inspection Inspection Measure the outside diameter Measure the outside diameter of of the speed the spe...

Page 73: ...e er bear arin ing g Point Point 5 5 8 8 In Insp spec ect the t the fo forw rwar ard d ge gear ar th thru rust c st cle lear aran ance ce Point Point 6 6 9 9 Rem Remove the c ove the clut lutch hub ch...

Page 74: ...2 2 mm 0 mm 0 00 0007 071 1 0 0 00 0024 244 4 in in SST SST Point 2 Point 2 Disassembly Reassembly Disassembly Reassembly SST 09905 00012 SST 09905 00012 Reassembly Reassembly Select and install the t...

Page 75: ...s mm or less Mark Mark T Th hi ic ck kn ne es ss s m mm m i in n A A 1 8 1 85 5 1 9 1 90 0 0 0 072 0728 8 0 0 0 0748 748 B B 1 9 1 95 5 2 0 2 00 0 0 0 076 0768 8 0 0 0 0787 787 C C 2 0 2 05 5 2 1 2 10...

Page 76: ...Point oint 8 8 Inspection Inspection Measu Measure re the c the counte ountersha rshaft ft journ journal al outsi outside de diame diameter ter 1st gea 1st gear r re reve verse rse ge gear ar Limit 29...

Page 77: ...brough ught t int into clos o close e con contac tact t and ro and ro tat tated ed it s it shal hall l not s not slip lip Inspection Inspection Mea Measur sure e the c the clea learan rance ce bet be...

Page 78: ...e Reasse assembly mbly Proce Procedure dure Switch position Switch position Standard Standard Free Free No No continuity continuity Pressed Pressed Continui Continuity ty shall shall exist exist o o o...

Page 79: ...amp o p on n th the l e low ower er si side de of of th the e ve vehi hicl cle e 6 6 Dis Discon connec nect t the the cab cable le fro from th m the e tra transm nsmiss ission s ion side ide 7 7 Re R...

Page 80: ...s ton series J3 5 J3 5 ton ton 3 16 3 16 DI DIFF FFERE ERENTI NTIAL AL CASE CASE ASSY ASSY 3 19 3 19 D DI IS SA S A SS SE EM MB l B lY Y I IN NS SP PE EC CT TllO ON N R RE EA S A SS SE EM MB l B lY Y...

Page 81: ...Differential Differential 2 2 K2 K2 K3 K3 Ton Se Ton Series ries Dif Differ ferent ential ial 3 3e e J3 J3 5 5 Ton Ser Ton Series ies 3 3 3 3 https www besttruckmanuals com...

Page 82: ...Red Reduct uction ion Gea Gear r 1 1 Ton Ser Ton Series ies 3 4 3 4 Red Reduct uction ion Gea Gear 2 K r 2 K2 K 2 K3 3 Ton Ser Ton Series ies https www besttruckmanuals com...

Page 83: ...S 3 5 3 5 I I 1 ton series 1 ton series 2 K 2 K2 K 2 K3 3 ton se ton serie ries s 1 0 ton 1 0 ton 1 5 1 1 5 1 75 75 ton ton 3 J3 3 J3 5 5 ton series ton series Item Item models models models models Di...

Page 84: ...Number of Pinion Pinion gear gear 10 10 x x 4 4 10 10 x x 4 4 teeth teeth x x quantity quantity Mrr Mrr models with models with 1DZ II engine 1DZ II engine All T C models All T C models Side gear Side...

Page 85: ...K3 J3 5 K3 J3 5 ton serie ton series s 2 3 K2 2 3 K2 4101 4101 3 7 3 7 https www besttruckmanuals com...

Page 86: ...1 146 3 8 3 8 DIF DIFFER FERENT ENTIAL IAL ASSY ASSY REMOVAL INSTALLATION REMOVAL INSTALLATION Note Note Ne Never ver apply impact apply impact to the f to the frame rame at at the time of remova the...

Page 87: ...8 0 07 7 12 127 7 5 5 1 100 000 0 13 1300 00 7 72 2 35 35 94 94 0 06 6 T T 68 68 6 6 88 88 3 3 7 700 00 90 900 0 5 50 0 6 6 65 65 1 1 T 107 T 107 9 9 13 137 7 3 3 1 110 100 0 14 1400 00 7 79 9 59 59 1...

Page 88: ...he conn e connec ecto tor r 12 12 Re Remo move ve th the fro e front axle nt axle br brac acke ket t th thro roug ugh h bo bolt lt 13 13 Re Remo move the fr ve the fron ont t ax axle b le bra rack cke...

Page 89: ...oint 4 Point 4 Removal Removal SST 0931 SST 0931 0 23320 0 23320 71 71 Point 5 Point 5 Removal lnstallation Removal lnstallation Operat Operate e caref carefull ully y so as not t so as not to bring t...

Page 90: ...i tion on an and d re reas asse semb mbly ly 7 7 Re Remo move veth the e dr driv ive e pi pinio nion n W W be bear arin ing g P Point oint 5 5 8 8 Re Remo move veth the e dr driv ive e pin pinio ion n...

Page 91: ...r backl backlash ash Sta Standard ndard 0 0 2 2 0 0 3 mm 3 mm 0 0 0 008 08 0 0 01 012 2 in in Point 4 Point 4 Disassembly Disassembly pro provid vide e mat match ch mar marks ks on t on the beari he b...

Page 92: ...cien ient t Lo Loos osen en th the e ad adju just stin ing g nu nut on the rear t on the rear si side de of t of the he ri ring ng ge gear ar an and tigh d tighte ten n th the e ad adju just stin ing...

Page 93: ...tisf sfie ied d in incr crea ease se or de or de cre crease the shi ase the shim m thi thickne ckness ss for adjust for adjustmen ment t Shim thickness Shim thickness 0 1 0 13 3 0 1 0 1 0 1 0 15 5 0...

Page 94: ...0 60020 020 C D C D 09150 10170 71 09150 10170 71 After After assembly assembly apply apply grease grease on on the the oil oil seal seal lip lip portion portion Point 8 Point 8 Disassembly Disassembl...

Page 95: ...t P Point oint 3 3 4 4 Re Remo move ve th the di e diff ffer eren enti tial al ca case ASS se ASSY Y S See p ee pag age 3 e 3 20 fo 20 for th r the dis e disas asse semb mbly ly in insp spec ecti tion...

Page 96: ...tall the adjusting the adjusting nuts nuts 2 Ins 2 Instal tall the beari l the bearing ng cap by a cap by alig lignin ning g the the mat match ch mar marks ks and and tem tempor porari arily ly tig ti...

Page 97: ...teeth th sid side e as much as much to bri to bring the ng the ri ring gear away from ng gear away from the driv the drive e pin pinion ion 7 Tight 7 Tighten en the adjusti the adjusting ng nut nut on...

Page 98: ...Re Remo move the ve the si side de ge gear a ar and nd pi pini nion g on gea ear r P Point oint 3 3 4 4 R Rem emov ove th e the e ri ring ng ge gea ar r P Point oint 4 4 3 3 2 2 T T N m kgf N m kgf cm...

Page 99: ...e set set bolt bolt threaded threaded porti portion on before before reass reassembly embly P Poi oint nt 3 3 Inspection Inspection Measu Measure the re the insid inside diamete e diameter r of of the...

Page 100: ...fac facing ing the gear the gear Reassembly Reassembly Apply Apply chassis chassis grease grease molybdenum molybdenum disulfide disulfide grease grease on on bot both sides h sides of t of the sp he...

Page 101: ...oint 3 3 5 5 Rem Remove ovethe bea the bearin ring sp g space acer 1 r 1 ton s ton seri eries es f fron ront beari t bearing ro ng rolle ller r spa spacer cer and and pil pilot be ot beari aring ex n...

Page 102: ...he the shi shim s m s Reassembly Reassembly Ins Instal tall the shim l the shim s s rea rear bear r bearing ing rol roller ler wash washer er and and loc lock k nut nut 1 1 Whil While e suppo supporti...

Page 103: ...09420 23000 71 Reassembly Reassembly Insta Install the drive ll the drive pinio pinion n front front beari bearing ng 1 1 Che Check ck cor correc rectne tness ss of sp of space acer r dir direct ectio...

Page 104: ...sembly Disassembly SST SST 09950 09950 6001 0 6001 0 C D C D 09950 09950 7001 7001 0 0 094 09420 20 230 23000 00 71 71 Reassembly Reassembly SST 09 SST 09950 950 60 60010 010 C C D D 099 09950 50 700...

Page 105: ...3 26 3 26 Point 8 Point 8 Reassembly Reassembly SST 09370 20270 71 SST 09370 20270 71 https www besttruckmanuals com...

Page 106: ...A APPENDIX PPENDIX Page Page SS SST T LIS LIST T 4 2 4 2 SE SERV RVIC ICE E STAN STANDARD DARD LIST LIST 4 4 4 4 4 1 4 1 https www besttruckmanuals com...

Page 107: ...09950 40011 09950 40011 Pul Pulle ler r B B se set t 0 0 0 0 e e l l cg cg d6 d6 09 0995 950 0 6 600 0010 10 Re Rep plla ac cer er s set et 0 0 0 0 I I J J 0 0 Repl Replacer acer set set 0 0 0 0 0 0...

Page 108: ...ction 3 3 o o 4 3 4 3 09370 20270 71 09370 20270 71 Drive Drive pinion pinion 0 0 0 0 I I I I bearing replacer bearing replacer 09410 23320 71 09410 23320 71 Differential Differential carrier carrier...

Page 109: ...ter mm mm in in Second Second gear forward gear forward gear gear Limit Limit 39 9 39 9 1 57 1 571 1 First First gear reverse gear reverse gear inside di gear inside diameter ameter m mm m iin n L Lii...

Page 110: ...wash washer er thick thickness ness mm mm in in Limit Limit 1 3 1 3 0 051 0 051 Standard Standard 1 6 1 6 0 063 0 063 Pinio Pinion n gear thru gear thrust st washe washer r thick thickness ness mm mm...

Page 111: ...OOM LOOM WORKS WORKS LTD LTD Pub Publis lished hed by by TOY TOYOTA OTA MOT MOTOR OR CORP CORPORATION ORATION 1 1st st Pr Prin inti ting ng Se Sep 2000 p 2000 Pub Pub No CE0 No CE029 29 Print Printed...

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