CHASSIS GENERAL MAINTENANCE

PROCEDURE

1. INSPECT CLUTCH FLUID

   
   

   1. Inspect the clutch fluid.

      Click here

2. INSPECT POWER STEERING FLUID

   
   

   1. Inspect the power steering fluid.

      Click here

3. INSPECT STEERING LINKAGE AND GEAR HOUSING

   
   

   1. Check the steering wheel free play.

   2. Check the steering linkage for looseness or damage.

      
      

      1. Check that the tie rod ends do not have excessive play.

      2. Check that the dust seals and boots are not damaged.

      3. Check that the boot clamps are not loose.

      4. Check that the steering gear housing is not damaged.

      5. Check that the connectors are properly connected to the steering gear housing.

4. LUBRICATE PROPELLER SHAFT AND TIGHTEN BOLTS (for TMT Made)

   
   

   1. Lubricate the propeller shaft by referring to the lubrication chart. Before pumping in grease, wipe off any mud and dust on the grease fitting.

      Type	See procedure
      Front propeller shaft	Click here
      Propeller shaft	Click here

   2. Tighten the bolts of the propeller shaft.

      Type	See procedure
      Front propeller shaft	Click here
      Propeller shaft	Click here

5. LUBRICATE PROPELLER SHAFT AND TIGHTEN BOLTS (for TSAM Made)

   
   

   1. Lubricate the propeller shaft by referring to the lubrication chart. Before pumping in grease, wipe off any mud and dust on the grease fitting.

      Type	See procedure
      Front propeller shaft	Click here
      Propeller shaft	Click here

   2. Tighten the bolts of the propeller shaft.

      Type	See procedure
      Front propeller shaft	Click here
      Propeller shaft	Click here

6. INSPECT DRIVE SHAFT BOOTS

   
   

   1. Check the drive shaft boots for loose clamps, grease leakage, kinks or damage.

7. INSPECT BALL JOINTS AND DUST COVERS

   
   

   1. Inspect the ball joints for excessive looseness.

      
      

      1. Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7.09 to 7.87 in.) under the front tires.

      2. Lower the vehicle until the front coil spring has about half its ordinary load. Place stands under the vehicle for safety.

      3. Check that the front wheels are pointing straight ahead. Use wheel chocks on all 4 wheels.

      4. Using a lever, pry up the end of the lower arm. Check the amount of play.

         Maximum ball joint vertical play
         0 mm (0 in.)

         If there is any play, replace the ball joint.

   2. Check the dust cover for damage.

8. INSPECT MANUAL TRANSMISSION OIL

   
   

   1. Visually check the transmission for fluid leaks. If fluid is leaking, find the cause and repair it.

      Type	See procedure
      R151	Click here
      R151F	Click here
      RC60 / RC61	Click here
      RC60F / RC61F	Click here

9. REPLACE MANUAL TRANSMISSION OIL

   
   

   1. Replace the manual transmission fluid.

      Type	See procedure
      R151	Click here
      R151F	Click here
      RC60 / RC61	Click here
      RC60F / RC61F	Click here

10. INSPECT AUTOMATIC TRANSMISSION FLUID

    
    

    1. Visually check the transmission for fluid leaks. If fluid is leaking, find the cause and repair it.

11. REPLACE AUTOMATIC TRANSMISSION FLUID

    
    

    1. Replace the automatic transmission fluid.

       Type	See procedure
       AC60E	Click here
       AC60F	Click here

12. INSPECT AUTOMATIC TRANSMISSION FLUID COOLER HOSE AND CONNECTIONS (for AC60E, AC60F)

    
    

    1. Check the automatic transmission fluid cooler hoses (oil cooler hoses) for cracks, leakage, loose connections and deformation.

13. INSPECT TRANSFER OIL

    
    

    1. Visually check the transfer for fluid leaks. If fluid is leaking, find the cause and repair it.

    2. Inspect the transfer oil.

       Click here

14. REPLACE TRANSFER OIL

    
    

    1. Replace the transfer oil.

       Click here

15. INSPECT FRONT DIFFERENTIAL OIL

    
    

    1. Visually check the differentia for fluid leaks. If fluid is leaking, find the cause and repair it.

    2. Inspect the front differential oil.

       Click here

16. REPLACE FRONT DIFFERENTIAL OIL

    
    

    1. Replace the front differential oil.

       Click here

17. INSPECT REAR DIFFERENTIAL OIL

    
    

    1. Visually check the differentia for fluid leaks. If fluid is leaking, find the cause and repair it.

    2. Inspect the rear differential oil.

       Click here

18. REPLACE REAR DIFFERENTIAL OIL

    
    

    1. Replace the rear differential oil.

       Click here

19. INSPECT FRONT AND REAR SUSPENSION

    Type	See procedure
    Front	Click here
    Rear	Click here