00_Service Specifications(A).pdf
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SERVICE SPECIFICATIONS
Page
CLUTCH
-
MANUAL TRANSMISSION (G40 and G52)
A-3
MANUAL TRANSMISSION (H41 and H55F)
A-5
MANUAL TRANSMISSION
(R141F, R150F and R151F)
A-7
AUTOMATIC TRANSMISSION
A-9
TRANSFER
A-1
PROPELLER SHAFT
A-14
SUSPENSION AND AXLE
A-15
BRAKE SYSTEM
A-
STEERING
-
BODY
A-2
LUBRICANT
A-29
A-2
SERVICE SPECIFICATIONS - Clutch
CLUTCH
Specifications
Pedal height (from asphalt sheet)
Pedal freeplay
w/o Clutch booster
w/ Clutch booster
181 mm
13 - 23 mm
15 -30 mm
1 - 5 mm
5-9mm
0 mm
0.3 mm
0
.8 mm
1
.0 mm
0 .6 mm
5.0 mm
0 .2 mm
7 .13 in .
0 .51 - 0.91 in .
0.59 - 1 .18 in .
0.04 - 0.20 in .
0.20 - 0.35 in .
0 in .
0.012 in .
0.031 in .
0.039 in .
0.024 in .
0.197 in .
0.008 in .
Push rod play at pedal top
Booster air valve stroke at pedal top
Booster push rod to piston clearance
Disc rivet head depth
Disc runout
Diaphragm spring tip alignment
Diaphragm spring finger wear
Depth
Width
w/ SST
Limit
Limit
Limit
Limit
Limit
Limit
Flywheel runout
Torque Specifications
Part tightened
kg-cm
ft-lb
N
•m
Master cylinder
x
Body
Clutch line union
Clevis lock nut
Master cylinder
x
Clutch booster
Clutch Booster
x
Bracket
Bracket
x
Body
Accumulator bracket
x
Accumulator housing
Accumulator line union
Accumulator bleeder plug
Accumulator bracket
x
Transmission
(2L-T Engine Europe RHD Models Only)
Release cylinder set bolt
Release cylinder bleeder plug
Clutch cover x Flywheel
Master cylinder union bolt
80
155
250
130
130
130
55
155
110
120
700
120
110
195
250
69 in .-lb
7.8
11
15
18
25
9
13
9
13
9
13
48 in .-lb
5.4
11
15
8
11
9
12
51
69
9
12
8
11
14
19
18
25
SERVICE SPECIFICATIONS
-Manual Transmission (R141 F, R150F and R151F)
A-7
MANUAL TRANSMISSION (R141F, R15OF an
Specifications
Output shaft
1 st gear journal diameter
Limit
38 .860 mm
1
.5299 in .
2nd gear journal diameter
Limit
46 .860 mm
1
.8449 in.
3rd gear journal diameter
Limit
37 .860 mm
1 .4905 in
.
Flange thickness
Limit
4.70 mm
0
.1850 in.
Runout
Limit
0.06 mm
0
.0024 in.
Counter gear
Roller bearing journal diameter
Limit
27.860 mm
1 .0968 in.
Gear thrust clearance
1 St
STD
0.10 - 0 .45 mm
0
.0039 - 0 .0177 in.
Limit
0.50 mm
0
.0197 in.
2nd & 3rd
STD
0 .10 - 0.25 mm
0.0039 - 0 .0098 in .
Limit
0 .30 mm
0.0118 in.
Counter 5th
ST ID
0 .10 - 0.35 mm
0.0039 - 0 .0138 in.
Limit
0.40 mm
0.0157 in .
Gear oil clearance
1 St
ST ID
0.020 - 0.073 mm
0.0008- 0.0029 in .
0.015 - 0.068 mm
0 .0006- 0.0027 in
.
2nd, 3rd & Counter 5th
STD
1st, 2nd, 3rd & Counter 5th
Limit
0.16 mm
0 .0063 in .
Reverse
STD
0.040 - 0.082 mm
0 .0016 - 0 .0032 in
.
Limit
0.13 mm
0.0051 in .
Shift fork to hub sleeve clearance
Limit
1 .0 mm
0.039 in .
Synchronizer ring to gear clearance
STD
0 .8 - 1 .6 mm
0.031 - 0.063 in
.
Limit
0 .6 mm
0.024 in .
Oil seal drive in depth
Front bearing retainer
10.5 - 11 .5 mm
0.413 - 0.453 in
.
Speedometer driven gear
25 mm
0.98 in.
Input shaft to synchronizer ring
STD
0.8 - 1 .6 mm
0.031 - 0.063 in
.
Limit
0.6 mm
0.024 in .
Reverse idler gear to shift arm shoe
ST ID
0.05 - 0
.25 mm
0.0020 - 0
.0098 in .
Limit
0.5 mm
0.020 in .
Input shaft snap ring thickness
Mark
A
2.10 -
2.15 mm
0.0827 - 0
.0846 in .
B
2.15 -
2.20 mm
0.0846 -
0.0866 in .
C
2.20 -
2 .25 mm
0.0866 - 0
.0886 in .
D
2 .25 - 2
.30 mm
0.0886 - 0
.0906 in .
E
2 .30 - 2 .35 mm
0.0906 - 0
.0925 in .
F
2 .35 -
2 .40 mm
0.0925 - 0
.0945 in .
G
2 .40 -
2 .45 mm
0.0945 -
0.0965 in .
Counter gear snap ring (Front bearing)
Mark
A
2.00 -
2.05 mm
0.0787 -
0.0807 in .
B
2.05 -
2.10 mm
0.0807 -
0.0827 in .
C
2.10 -
2.15 mm
0.0827 - 0
.0846 in .
D
2.15 - 2
.20 mm
0 .0846 - 0
.0866 in .
E
2.20 -
2.25 mm
0 .0866 -
0.0886 in .
A-8
SERVICE SPECIFICATIONS -
Manual Transm
ission (R141 F, R150F and R151 F)
Specifications (Cont'd)
Output shaft snap ring thickness
Clutch hub No-2
Mark
A
1 .80 - 1 .85 mm
0.0709 - 0.0728 in.
B
1 .85 - 1 .90 mm
0.0728 - 0.0748 in.
C
1 .90 - 1 .95 mm
0.0748 - 0.0768 in.
D
1 .95 - 2.00 mm
0.0768 - 0 .0787 in.
E
2.00 - 2.05 mm
0.0787 - 0 .0807 in .
F
2.05 - 2.10 mm
0.0807 - 0 .0827 in .
G
2.10 - 2 .15 mm
0 .0827 - 0.0846 in .
Clutch hub No .1
Mark
A
2 .30 - 2 .35 mm
0.0906 - 0.0925 in .
B
2 .35 - 2 .40 mm
0.0925 - 0.0945 in .
C
2 .40 - 2.45 mm
0.0945 - 0.0965 in .
D
2 .45 - 2.50 mm
0.0965 - 0 .0984 in.
E
2.50 - 2.55 mm
0.0984 - 0 .1004 in.
F
2.55 - 2.60 mm
0 .1004- 0.1024 in.
G
2.60 - 2 .65 mm
0 .1024 - 0.1043 in.
Rear
Mark
A
2 .65 - 2 .70 mm
0.1043 - 0.1063 in.
B
2 .70 - 2.75 mm
0.1063 - 0.1083 in.
C
2 .75 - 2.80 mm
0.1083 - 0 .1 102 in.
D
2.80 - 2.85 mm
0.1102 - 0 .1 122 in .
E
2.85 - 2.90 mm
0.1122 - 0 .1 142 in .
F
2.90 - 2.95 mm
0 .1142 - 0.1161 in .
G
2.95 - 3 .00 mm
0 .1161 - 0.1181 in .
H
3 .00 - 3 .05 mm
0.1181 - 0.1201 in.
J
3 .05 - 3
.10 mm
0.1201 - 0.1220 in
.
K
3 .10 - 3
.15 mm
0.1220 - 0.1240 in
.
L
3.15 - 3
.20 mm
0.1240 - 0.1260 in
.
M
3.20 - 3
.25 mm
0.1260 - 0.1280 in
.
N
3.25 - 3.30 mm
0 .1280 - 0 .1299 in
.
P
3.30 - 3
.35 mm
0 .1299 - 0.1319 in
.
Q
3 .35 - 3
.40 mm
0.1319 - 0.1339 in
.
R
3 .40 -
3 .45 mm
0.1339 - 0
.1358 in.
S
3 .45 -
3.50 mm
0.1358 - 0
.1378 in.
Torque Specifications
Part tightened
kg-cm
ft-l b
N•m
Reverse shift arm bracket
185
13
18
18
185
13
Rear bearing retainer x Intermediate plate
127
94
Counter gear rear lock nut
1,300
20
200
14
Shift fork x Shift fork shaft
19
190
14
Straight screw plug
17
170
12
Front bearing retainer x Transmission case
37
380
27
Transmission case x Transfer adaptor
38
390
28
Shift lever housing bolt
36
370
27
Clutch housing x Transmission case
44
450
33
Back-up light switch
37
380
27
Restrict pin
18
185
13
Shift lever retainer x Transfer adaptor
A-12
SERVICE SPECIFICATIONS -
Transfer
TRANSFER
Specifications
Rear output shaft
High gear journal diameter
Limit
40.009 mm
40.009 mm
0.03 mm
0.019 - 0.068 mm
0.068 mm
0.10 - 0 .25 mm
0.25 mm
1 .0 mm
1 .5752 in
.
1 .5752 in
.
0.0012 in
.
0.0007 - 0
.0027 in .
0
.0027 in .
0
.0039 - 0 .0098 in .
0.0098 in
.
0.039 in
.
Low gear journal diameter
Limit
Runout
High and low gear oil clearance
STD
Limit
High and low gear thrust clearance
STD
Limit
Shift fork to hub sleeve clearance
Limit
Rear output shaft snap ring thickness
Mark
11
17
STD
Limit
New bearing
Reused bearing
2 .30 - 2 .35 mm 0.0906
- 0.0925 in.
2 .60 - 2 .65 mm 0
.1024 - 0.1043 in.
0.275 - 0.625 mm
0.0108 - 0.0246 in.
0.625 mm
0.0246 in.
15 - 24.7 kg-cm (13.0 -
21 .4 in .-lb, 1 .5 - 2 .4 N -m)
7 - 12 kg-cm (6 .1 - 10
.4 in .-lb, 0.7 - 1 .2 N
•m
)
Idler gear thrust clearance
Rear output shaft preload
Rear output shaft preload adjusting shim
Mark
0
4
5
6
7
8
9
10
11
12
13
14
15
0.15 mm
0
.0059 in .
0.4 mm
0 .016 in .
0 .5 mm
0 .020 in .
0 .6 mm
0
.024 in .
0 .7 mm
0.028 in .
0.8 mm
0
.031 in.
0.9 mm
0.035 in
.
1 .0 mm
0
.039 in .
1 .1 mm
0.043 in .
1 .2 mm
0.047 in .
1 .3 mm
0.051 in .
1 .4 mm
0 .055 in .
1 .5 mm
0 .059 in .
Oil seal drive in depth
Speedometer driven gear
20 mm
0.79 in .
Plik z chomika:
vgreg
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Suspension & Axle.pdf
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Steering(SR).pdf
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Rear Axle and Suspension(RA).pdf
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