Chassis - General Maintenance
INSPECTION
1. INSPECT STEERING LINKAGE
a. Check the steering wheel freeplay
b. Check the steering linkage for loosenness or damage.
Check that:
- Tie rod ends do not have excessive play.
- Dust seals and boots are not damaged.
- Boot clamps are not loose.
2. INSPECT STEERING WHEEL PAD AND SPIRAL CABLE
3. INSPECT FRONT PASSENGER AIRBAG ASSEMBLY
4. INSPECT AIRBAG SENSOR ASSEMBLY
5. INSPECT WIRE HARNESS AND CONNECTOR
6. INSPECT STEERING GEAR HOUSING
Check the steering gear housing for oil leaks.
If leakage is found, check for cause and repair.
7. 4WD:
INSPECT DRIVE SHAFT BOOTS
Inspect the drive shaft boots for clamp looseness, grease leak- age or damage.
8. INSPECT BALL JOINTS AND DUST COVERS
a. Inspect the ball joints for excessive looseness
b. Inspect the dust cover for damage.
9. 2WD:
CHECK OIL LEVEL IN MANUAL TRANSMISSION, AUTOMATIC TRANSMISSION AND DIFFERENTIAL
a. Manual transmission:
Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole.
W59 Transmission oil (M/T):
b. Automatic transmission:
Check that the fluid level is in the "HOT" range at the normal operating temperature (70 - 80°C or 158 - 176°F) and add as necessary.
NOTE: Do not overfill.
Transmission fluid (A/T):
c. Differential:
Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole.
Differential oil:
10. 4WD:
CHECK OIL LEVEL IN MANUAL TRANSMISSION, AUTOMATIC TRANSMISSION, TRANSFER AND DIFFERENTIAL
a. Manual transmission:
Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole.
W59 Transmission oil (M/T):
R15 OF Transmission oil (M/T):
b. Automatic transmission:
Check that the fluid level is in the "HOT" range at the normal operating temperature (70 - 80° C or 158 - 176° F) and add as necessary.
NOTE: Do not overfill.
Transmission fluid (A/T):
c. Transfer:
Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole.
Transfer oil:
d. Differential:
Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole.
Front differential:
Rear differential oil:
11. REPLACE MANUAL TRANSMISSION, TRANSFER (4WD) AND DIFFERENTIAL OIL
a. Transfer:
Remove the transfer cover.
b. Remove the drain plug and drain the oil.
c. Reinstall drain plug securely.
d. Add new oil until it begins to run out of the filler hole.
W59 (2WD) Transmission oil (M/T):
W59 (4WD) Transmission oil (M/T):
R15 OF Transmission oil (M/T):
Transfer oil:
Front differential:
Rear differential oil:
12. REPLACE AUTOMATIC TRANSMISSION FLUID
a. Remove the drain plug(s) and drain the fluid.
b. Reinstall the drain plug(s) securely.
c. With the engine OFF, add new fluid through the oil filler pipe.
Transmission fluid (A/T):
d. Start the engine and shift the selector into all positions from "P" through "L" and then shift into "P".
e. With the engine idling, check the fluid level.
Add fluid up to the "COOL" level on the dipstick.
f. Check that the fluid level is in the "HOT" range at the normal operating temperature (70 - 80° C or 158 - 176° F) and add as necessary.
NOTE: Do not overfill.
13. 4WD:
LUBRICATE PROPELLER SHAFT
Lubricate propeller shaft, referring to the lubrication chart. Before pumping in grease, wipe off any mud and dust on the grease fitting.
Grease grade:
Spiders: Lithium base chassis grease NLGI No.2
Slide yoke and double cardan joint:
Molybdenum-disulphidelithium base chassis grease
NLGI No.2
14. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
- Tighten these parts:
Seat mounting bolts
Torque: 37 N.m (375 kgf.cm, 27 ft.lbf)
- Under Severe Conditions:
In addition to the above maintenance items, check for
loose or missing bolts and nuts on the following.
- Steering system
- Drive train
- Suspension system
- Fuel tank mounts Engine mounts, etc.
15. FINAL INSPECTION
a. Check operation of body parts:
- Hood:
- Auxiliary catch operates properly
- Hood locks securely when closed
- Doors:
- Door locks operate properly
- Doors close properly
- Seats:
- Seat adjusts easily and locks securely in any positions.
- Seat backs lock securely at any angle
- Fold-down seat backs lock securely
b. Road test:
- Engine and chassis parts do not have abnormal noises.
- Vehicle does not wander or pull to one side.
- Brakes work properly and do not drag.
c. Be sure to deliver a clean vehicle and especially check:
- Steering wheel
- Shift lever knob
- All switch knobs
- Door handles Seats