Manual PDF Isuzu FX FY GX Series 2025 2026 Mechanical Repair Procedures FXHTML-WEN-2541

[Truck]

Download this document, you need 4400 Gallons

Isuzu FX FY GX Series 2025 2026 Mechanical Repair Procedures FXHTML-WEN-2541
Size: 451.98 MB
Format: PDF
Language: English
Brand: Isuzu
Type of Machine: Truck
Type of Manual: Workshop Manual - Mechanical Repair Procedures
Model: Isuzu FX Series ; FY Series ; GX Series 25 Cab model Truck
Date: 2025, 2026
Engine: Isuzu 6UZ1 Engine
General Export (Date: 2026/08/28)
Part Number: FXHTML-WEN-2541
Number of Pages: 6797 Pages

Contents:
1. Engine (6UZ1)

1B. Mechanical​

Camshaft - disassembly​

Camshaft - inspection​

Camshaft - installation​

Camshaft - reassembly​

Camshaft - removal​

Crankshaft - disassembly​

Crankshaft - inspection​

Crankshaft - installation​

Crankshaft - reassembly​

Crankshaft - removal​

Crankshaft front oil seal - installation​

Crankshaft front oil seal - removal​

Crankshaft pulley - disassembly​

Crankshaft pulley - inspection​

Crankshaft pulley - installation​

Crankshaft pulley - reassembly​

Crankshaft pulley - removal​

Crankshaft rear oil seal - installation​

Crankshaft rear oil seal - removal​

Cylinder block - disassembly​

Cylinder block - inspection​

Cylinder block - installation​

Cylinder block - reassembly​

Cylinder block - removal​

Cylinder head - disassembly​

Cylinder head - inspection​

Cylinder head - installation​

Cylinder head - reassembly​

Cylinder head - removal​

Cylinder head cover - installation​

Cylinder head cover - removal​

Engine - installation​

Engine - removal​

Engine mounting - installation​

Engine mounting - removal​

Exhaust manifold - inspection​

Exhaust manifold - installation​

Exhaust manifold - removal​

Flywheel - disassembly​

Flywheel - inspection​

Flywheel - installation​

Flywheel - reassembly​

Flywheel - removal​

Flywheel housing - installation​

Flywheel housing - removal​

Front cover - installation​

Front cover - removal​

Idle gear - inspection​

Idle gear - installation​

Idle gear - removal​

Inlet cover - installation​

Inlet cover - removal​

Intake throttle valve - installation​

Intake throttle valve - removal​

Piston - disassembly​

Piston - inspection​

Piston - installation​

Piston - reassembly​

Piston - removal​

Rocker arm shaft - disassembly​

Rocker arm shaft - inspection​

Rocker arm shaft - installation​

Rocker arm shaft - reassembly​

Rocker arm shaft - removal​

Supplementary Information​

1C. Fuel System​

Common rail (fuel rail) - installation​

Common rail (fuel rail) - removal​

Fuel - air bleed​

Fuel - drain water​

Fuel - inspection​

Fuel filter - installation​

Fuel filter - removal​

Fuel filter element - installation​

Fuel filter element - removal​

Fuel supply pump - inspection​

Fuel supply pump - installation​

Fuel supply pump - removal​

Fuel tank - installation​

Fuel tank - removal​

Fuel tank unit - inspection​

Fuel tank unit - installation​

Fuel tank unit - removal​

Injector - inspection​

Injector - installation​

Injector - removal​

Pre-fuel filter - installation​

Pre-fuel filter - removal​

Pre-fuel filter element - inspection​

Pre-fuel filter element - installation​

Pre-fuel filter element - removal​

Pressure limiter - installation​

Pressure limiter - removal​

Supplementary Information​

Water sedimenter switch - inspection​

Water sedimenter switch - installation​

Water sedimenter switch - removal​

1D. Cooling​

Coolant - inspection​

Coolant - replacement​

Cooling fan belt - inspection​

Cooling fan belt - installation​

Cooling fan belt - removal​

Cooling fan clutch - inspection​

Cooling fan clutch - installation​

Cooling fan clutch - removal​

Insect screen - inspection​

Insect screen - installation​

Insect screen - removal​

Radiator - inspection​

Radiator - installation​

Radiator - removal​

Radiator sub-tank - installation​

Radiator sub-tank - removal​

Supplementary Information​

Thermostat - inspection​

Thermostat - installation​

Thermostat - removal​

Water pump - inspection​

Water pump - installation​

Water pump - removal​

1E. Lubrication​

Engine oil - inspection​

Engine oil - replacement​

Oil cooler - disassembly​

Oil cooler - inspection​

Oil cooler - installation​

Oil cooler - reassembly​

Oil cooler - removal​

Oil filter - installation​

Oil filter - removal​

Oil filter element - installation​

Oil filter element - removal​

Oil pan - installation​

Oil pan - removal​

Oil pressure switch - installation​

Oil pressure switch - removal​

Oil pump - inspection​

Oil pump - installation​

Oil pump - removal​

Oil separator - installation​

Oil separator - removal​

Oil separator element - installation​

Oil separator element - removal​

Partial oil filter - installation​

Partial oil filter - removal​

Partial oil filter element - installation​

Partial oil filter element - removal​

Supplementary Information​

1F. Induction​

Air cleaner element - inspection​

Air cleaner element - installation​

Air cleaner element - removal​

Intercooler - inspection​

Intercooler - installation​

Intercooler - removal​

Supplementary Information​

Turbocharger - inspection​

Turbocharger - installation​

Turbocharger - removal​

Vertical air intake duct - installation​

Vertical air intake duct - removal​

1G. Exhaust​

DPD - disassembly​

DPD - inspection​

DPD - installation​

DPD - reassembly​

DPD - removal​

Exhaust pipe - inspection​

Exhaust pipe - installation​

Exhaust pipe - removal​

Exhaust throttle solenoid valve - inspection​

Exhaust throttle solenoid valve - installation​

Exhaust throttle solenoid valve - removal​

Exhaust throttle valve - inspection​

Exhaust throttle valve - installation​

Exhaust throttle valve - removal​

Supplementary Information​

1H. Aux. Emission Control Devices​

Dosing module - disassembly​

Dosing module - installation​

Dosing module - reassembly​

Dosing module - removal​

EGR cooler - inspection​

EGR cooler - installation​

EGR cooler - removal​

EGR valve - inspection​

EGR valve - installation​

EGR valve - removal​

Supplementary Information​

Urea fluid - inspection​

Urea fluid supply module - disassembly​

Urea fluid supply module - inspection​

Urea fluid supply module - installation​

Urea fluid supply module - reassembly​

Urea fluid supply module - removal​

Urea fluid supply module filter - installation​

Urea fluid supply module filter - removal​

Urea fluid tank - installation​

Urea fluid tank - removal​

Urea fluid tank heater coolant control valve - installation​

Urea fluid tank heater coolant control valve - removal​

Urea fluid tank level gauge - installation​

Urea fluid tank level gauge - removal​

Urea SCR - disassembly​

Urea SCR - inspection​

Urea SCR - installation​

Urea SCR - reassembly​

Urea SCR - removal​

1I. Speed Control Systems​

Accelerator control link - inspection​

Accelerator control link - installation​

Accelerator control link - removal​

Accelerator pedal - installation​

Accelerator pedal - removal​

Idle up sensor - installation​

Idle up sensor - removal​

Supplementary Information​

1J. Electrical​

Generator (Nikko) - disassembly​

Generator (Nikko) - inspection​

Generator (Nikko) - installation​

Generator (Nikko) - reassembly​

Generator (Nikko) - removal​

Generator(Mitsubishi) - disassembly​

Generator(Mitsubishi) - inspection​

Generator(Mitsubishi) - installation​

Generator(Mitsubishi) - reassembly​

Generator(Mitsubishi) - removal​

Starter motor - disassembly​

Starter motor - inspection​

Starter motor - installation​

Starter motor - reassembly​

Starter motor - removal​

Supplementary Information​

1M. Flywheel PTO​

Flywheel PTO - disassembly​

Flywheel PTO - inspection​

Flywheel PTO - installation​

Flywheel PTO - reassembly​

Flywheel PTO - removal​

Supplementary Information​

1Z. Engine Electrical Control​

Atmospheric temperature sensor - inspection​

Atmospheric temperature sensor - installation​

Atmospheric temperature sensor - removal​

Boost pressure sensor - inspection​

Boost pressure sensor - installation​

Boost pressure sensor - removal​

Charge air cooler temperature sensor 1 - inspection​

Charge air cooler temperature sensor 1 - installation​

Charge air cooler temperature sensor 1 - removal​

Charge air cooler temperature sensor - inspection​

Charge air cooler temperature sensor - installation​

Charge air cooler temperature sensor - removal​

CKP sensor - inspection​

CKP sensor - installation​

CKP sensor - removal​

DCU - installation​

DCU - removal​

DCU - setting​

ECM - inspection​

ECM - installation​

ECM - removal​

ECM - setting​

EGR gas temperature sensor 1 - inspection​

EGR gas temperature sensor 1 - installation​

EGR gas temperature sensor 1 - removal​

EGR gas temperature sensor 2 - inspection​

EGR gas temperature sensor 2 - installation​

EGR gas temperature sensor 2 - removal​

EGR gas temperature sensor 3 - inspection​

EGR gas temperature sensor 3 - installation​

EGR gas temperature sensor 3 - removal​

EGR gas temperature sensor 4 - inspection​

EGR gas temperature sensor 4 - installation​

EGR gas temperature sensor 4 - removal​

Engine coolant temperature sensor - inspection​

Engine coolant temperature sensor - installation​

Engine coolant temperature sensor - removal​

Exhaust differential pressure sensor - inspection​

Exhaust differential pressure sensor - installation​

Exhaust differential pressure sensor - removal​

Exhaust gas temperature sensor 3 - installation​

Exhaust gas temperature sensor 3 - removal​

Exhaust gas temperature sensor 4 - installation​

Exhaust gas temperature sensor 4 - removal​

Exhaust gas temperature sensor - inspection​

Exhaust gas temperature sensor - installation​

Exhaust gas temperature sensor - removal​

FRP sensor - inspection​

FRP sensor - installation​

FRP sensor - removal​

Fuel temperature sensor - inspection​

Fuel temperature sensor - installation​

Fuel temperature sensor - removal​

IMT sensor - inspection​

IMT sensor - installation​

IMT sensor - removal​

MAF and IAT sensor - inspection​

MAF and IAT sensor - installation​

MAF and IAT sensor - removal​

NOx sensor 1 - inspection​

NOx sensor 1 - installation​

NOx sensor 1 - removal​

NOx sensor 2 - inspection​

NOx sensor 2 - installation​

NOx sensor 2 - removal​

PM sensor - installation​

PM sensor - removal​

Turbocharger outlet temperature sensor - inspection​

Turbocharger outlet temperature sensor - installation​

Turbocharger outlet temperature sensor - removal​

Urea fluid sensor - installation​

Urea fluid sensor - removal​

VGS control unit - installation​

VGS control unit - removal​

2. Suspension

2B. Front Suspension​

Leaf rigid suspension - disassembly​

Leaf rigid suspension - inspection​

Leaf rigid suspension - installation​

Leaf rigid suspension - reassembly​

Leaf rigid suspension - removal​

Supplementary Information​

2C. Rear Suspension​

Air suspension (HENDRICKSON) - inspection​

Air suspension (HENDRICKSON) - installation​

Air suspension (HENDRICKSON) - removal​

Leaf rigid suspension - disassembly​

Leaf rigid suspension - inspection​

Leaf rigid suspension - installation​

Leaf rigid suspension - reassembly​

Leaf rigid suspension - removal​

Supplementary Information​

Trunnion suspension - disassembly​

Trunnion suspension - inspection​

Trunnion suspension - installation​

Trunnion suspension - reassembly​

Trunnion suspension - removal​

2D. Wheel, Tire System​

Disc wheel and tire - inspection​

Disc wheel and tire - installation​

Disc wheel and tire - removal​

3.1. Driveline, Axle (Isuzu production model)

3B. Differentials​

Differential oil - replacement​

Inter axle differential lock shift unit (16.5HT) - disassembly​

Inter axle differential lock shift unit (16.5HT) - inspection​

Inter axle differential lock shift unit (16.5HT) - installation​

Inter axle differential lock shift unit (16.5HT) - reassembly​

Inter axle differential lock shift unit (16.5HT) - removal​

Inter axle differential lock shift unit (17.5HT) - disassembly​

Inter axle differential lock shift unit (17.5HT) - inspection​

Inter axle differential lock shift unit (17.5HT) - installation​

Inter axle differential lock shift unit (17.5HT) - reassembly​

Inter axle differential lock shift unit (17.5HT) - removal​

Rear differential (single) (16.5H) - disassembly​

Rear differential (single) (16.5H) - inspection​

Rear differential (single) (16.5H) - installation​

Rear differential (single) (16.5H) - reassembly​

Rear differential (single) (16.5H) - removal​

Rear differential (single) (17.5H) - disassembly​

Rear differential (single) (17.5H) - inspection​

Rear differential (single) (17.5H) - installation​

Rear differential (single) (17.5H) - reassembly​

Rear differential (single) (17.5H) - removal​

Rear differential (tandem)（16.5HT） - disassembly​

Rear differential (tandem)（16.5HT） - inspection​

Rear differential (tandem)（16.5HT） - installation​

Rear differential (tandem)（16.5HT） - reassembly​

Rear differential (tandem)（16.5HT） - removal​

Rear differential (tandem)（17.5HT） - disassembly​

Rear differential (tandem)（17.5HT） - inspection​

Rear differential (tandem)（17.5HT） - installation​

Rear differential (tandem)（17.5HT） - reassembly​

Rear differential (tandem)（17.5HT） - removal​

Supplementary Information​

3C. Drive Shaft System​

Front axle (full air brake) - disassembly​

Front axle (full air brake) - inspection​

Front axle (full air brake) - installation​

Front axle (full air brake) - reassembly​

Front axle (full air brake) - removal​

Front hub - disassembly​

Front hub - inspection​

Front hub - installation​

Front hub - reassembly​

Front hub - removal​

Knuckle (full air brake) - disassembly​

Knuckle (full air brake) - inspection​

Knuckle (full air brake) - installation​

Knuckle (full air brake) - reassembly​

Knuckle (full air brake) - removal​

Knuckle arm - inspection​

Knuckle arm - installation​

Knuckle arm - removal​

Propeller shaft - disassembly​

Propeller shaft - inspection​

Propeller shaft - installation​

Propeller shaft - reassembly​

Propeller shaft - removal​

Propeller shaft between tandem axles - disassembly​

Propeller shaft between tandem axles - inspection​

Propeller shaft between tandem axles - installation​

Propeller shaft between tandem axles - reassembly​

Propeller shaft between tandem axles - removal​

Rear axle (full air brake) - disassembly​

Rear axle (full air brake) - inspection​

Rear axle (full air brake) - installation​

Rear axle (full air brake) - reassembly​

Rear axle (full air brake) - removal​

Rear axle shaft - installation​

Rear axle shaft - removal​

Rear hub - disassembly​

Rear hub - inspection​

Rear hub - installation​

Rear hub - reassembly​

Rear hub - removal​

Supplementary Information​

Tie rod - disassembly​

Tie rod - inspection​

Tie rod - installation​

Tie rod - reassembly​

Tie rod - removal​

Tie rod arm - inspection​

Tie rod arm - installation​

Tie rod arm - removal​

Wheel alignment check​

3.2. Driveline, Axle (Meritor production model)

3B. Differentials​

Driver controlled main differential lock (forward rear differential) - installation​

Driver controlled main differential lock (forward rear differential) - removal​

Driver controlled main differential lock (single and rearward rear differential) - installation​

Driver controlled main differential lock (single and rearward rear differential) - removal​

Rear differential (single) - disassembly​

Rear differential (single) - inspection​

Rear differential (single) - installation​

Rear differential (single) - reassembly​

Rear differential (single) - removal​

Rear differential (tandem) - disassembly​

Rear differential (tandem) - inspection​

Rear differential (tandem) - installation​

Rear differential (tandem) - reassembly​

Rear differential (tandem) - removal​

Supplementary Information​

3C. Drive Shaft System​

Front axle (disc brake) - installation​

Front axle (disc brake) - removal​

Front hub (disc brake) - disassembly​

Front hub (disc brake) - inspection​

Front hub (disc brake) - installation​

Front hub (disc brake) - reassembly​

Front hub (disc brake) - removal​

Knuckle (disc brake) - disassembly​

Knuckle (disc brake) - inspection​

Knuckle (disc brake) - installation​

Knuckle (disc brake) - reassembly​

Knuckle (disc brake) - removal​

Knuckle arm - inspection​

Knuckle arm - installation​

Knuckle arm - removal​

Propeller shaft - disassembly​

Propeller shaft - inspection​

Propeller shaft - installation​

Propeller shaft - reassembly​

Propeller shaft - removal​

Propeller shaft between tandem axles - disassembly​

Propeller shaft between tandem axles - inspection​

Propeller shaft between tandem axles - installation​

Propeller shaft between tandem axles - reassembly​

Propeller shaft between tandem axles - removal​

Rear axle (air suspension) - disassembly​

Rear axle (air suspension) - inspection​

Rear axle (air suspension) - installation​

Rear axle (air suspension) - reassembly​

Rear axle (air suspension) - removal​

Rear axle (leaf spring suspension) - disassembly​

Rear axle (leaf spring suspension) - inspection​

Rear axle (leaf spring suspension) - installation​

Rear axle (leaf spring suspension) - reassembly​

Rear axle (leaf spring suspension) - removal​

Rear axle (trunnion suspension) - disassembly​

Rear axle (trunnion suspension) - inspection​

Rear axle (trunnion suspension) - installation​

Rear axle (trunnion suspension) - reassembly​

Rear axle (trunnion suspension) - removal​

Rear hub (disc brake) - disassembly​

Rear hub (disc brake) - inspection​

Rear hub (disc brake) - installation​

Rear hub (disc brake) - reassembly​

Rear hub (disc brake) - removal​

Supplementary Information​

Tie rod - disassembly​

Tie rod - inspection​

Tie rod - installation​

Tie rod - reassembly​

Tie rod - removal​

Tie rod arm - installation​

Tie rod arm - removal​

Wheel alignment check​

4.1. Brakes (Isuzu production model)

4B. Brake System​

Air dryer - disassembly​

Air dryer - inspection​

Air dryer - installation​

Air dryer - reassembly​

Air dryer - removal​

Brake pedal box - disassembly​

Brake pedal box - installation​

Brake pedal box - reassembly​

Brake pedal box - removal​

Brake valve - inspection​

Brake valve - installation​

Brake valve - removal​

Dual relay valve - disassembly​

Dual relay valve - inspection​

Dual relay valve - installation​

Dual relay valve - reassembly​

Dual relay valve - removal​

Front brake chamber (power) - disassembly​

Front brake chamber (power) - inspection​

Front brake chamber (power) - installation​

Front brake chamber (power) - reassembly​

Front brake chamber (power) - removal​

Front drum brake - disassembly​

Front drum brake - inspection​

Front drum brake - installation​

Front drum brake - reassembly​

Front drum brake - removal​

Front expander - disassembly​

Front expander - inspection​

Front expander - installation​

Front expander - reassembly​

Front expander - removal​

Low pressure switch - inspection​

Low pressure switch - installation​

Low pressure switch - removal​

Multi-protection valve - inspection​

Multi-protection valve - installation​

Multi-protection valve - removal​

Rear brake chamber (spring) - disassembly​

Rear brake chamber (spring) - inspection​

Rear brake chamber (spring) - installation​

Rear brake chamber (spring) - reassembly​

Rear brake chamber (spring) - removal​

Rear drum brake - disassembly​

Rear drum brake - inspection​

Rear drum brake - installation​

Rear drum brake - reassembly​

Rear drum brake - removal​

Rear expander - disassembly​

Rear expander - inspection​

Rear expander - installation​

Rear expander - reassembly​

Rear expander - removal​

Silencer - inspection​

Silencer - installation​

Silencer - removal​

Single air compressor - disassembly​

Single air compressor - inspection​

Single air compressor - installation​

Single air compressor - reassembly​

Single air compressor - removal​

Stoplight switch - inspection​

Stoplight switch - installation​

Stoplight switch - removal​

Supplementary Information​

4C. Parking Brake System​

Hand control brake valve - disassembly​

Hand control brake valve - inspection​

Hand control brake valve - installation​

Hand control brake valve - reassembly​

Hand control brake valve - removal​

Parking brake switch - inspection​

Parking brake switch - installation​

Parking brake switch - removal​

Supplementary Information​

4D. ABS​

Front ABS modulator - disassembly​

Front ABS modulator - inspection​

Front ABS modulator - installation​

Front ABS modulator - reassembly​

Front ABS modulator - removal​

Front exciter ring - inspection​

Front exciter ring - installation​

Front exciter ring - removal​

Front relay valve - disassembly​

Front relay valve - inspection​

Front relay valve - installation​

Front relay valve - reassembly​

Front relay valve - removal​

Rear exciter ring - inspection​

Rear exciter ring - installation​

Rear exciter ring - removal​

Rear relay valve - disassembly​

Rear relay valve - inspection​

Rear relay valve - installation​

Rear relay valve - reassembly​

Rear relay valve - removal​

Supplementary Information​

4E. Speed Retarder System​

Exhaust brake solenoid valve - inspection​

Exhaust brake solenoid valve - installation​

Exhaust brake solenoid valve - removal​

Exhaust brake valve - inspection​

Exhaust brake valve - installation​

Exhaust brake valve - removal​

4Z. Brake Electrical Control​

EBS control unit - installation​

EBS control unit - removal​

EBS control unit - setting​

Front wheel speed sensor - inspection​

Front wheel speed sensor - installation​

Front wheel speed sensor - removal​

Rear wheel speed sensor - inspection​

Rear wheel speed sensor - installation​

Rear wheel speed sensor - removal​

Supplementary Information​

Yaw rate sensor - installation​

Yaw rate sensor - removal​

Yaw rate sensor - setting​

4.2. Brakes (Meritor production model)

4B. Brake System​

Air dryer - disassembly​

Air dryer - inspection​

Air dryer - installation​

Air dryer - reassembly​

Air dryer - removal​

Brake pedal box - disassembly​

Brake pedal box - installation​

Brake pedal box - reassembly​

Brake pedal box - removal​

Brake valve - inspection​

Brake valve - installation​

Brake valve - removal​

Dual relay valve - disassembly​

Dual relay valve - inspection​

Dual relay valve - installation​

Dual relay valve - reassembly​

Dual relay valve - removal​

Front brake chamber (power) - installation​

Front brake chamber (power) - removal​

Front disc brake - disassembly​

Front disc brake - inspection​

Front disc brake - installation​

Front disc brake - reassembly​

Front disc brake - removal​

Front disc brake pad - inspection​

Front disc brake pad - installation​

Front disc brake pad - removal​

Low pressure switch - inspection​

Low pressure switch - installation​

Low pressure switch - removal​

Multi-protection valve - inspection​

Multi-protection valve - installation​

Multi-protection valve - removal​

Rear brake chamber (spring) - installation​

Rear brake chamber (spring) - removal​

Rear disc brake - disassembly​

Rear disc brake - inspection​

Rear disc brake - installation​

Rear disc brake - reassembly​

Rear disc brake - removal​

Rear disc brake pad - inspection​

Rear disc brake pad - installation​

Rear disc brake pad - removal​

Silencer - inspection​

Silencer - installation​

Silencer - removal​

Single air compressor - disassembly​

Single air compressor - inspection​

Single air compressor - installation​

Single air compressor - reassembly​

Single air compressor - removal​

Stoplight switch - inspection​

Stoplight switch - installation​

Stoplight switch - removal​

Supplementary Information​

4C. Parking Brake System​

Hand control brake valve - disassembly​

Hand control brake valve - inspection​

Hand control brake valve - installation​

Hand control brake valve - reassembly​

Hand control brake valve - removal​

Parking brake switch - inspection​

Parking brake switch - installation​

Parking brake switch - removal​

Supplementary Information​

4D. ABS​

Front ABS modulator - disassembly​

Front ABS modulator - inspection​

Front ABS modulator - installation​

Front ABS modulator - reassembly​

Front ABS modulator - removal​

Front exciter ring - inspection​

Front exciter ring - installation​

Front exciter ring - removal​

Front relay valve - disassembly​

Front relay valve - inspection​

Front relay valve - installation​

Front relay valve - reassembly​

Front relay valve - removal​

Rear exciter ring - inspection​

Rear exciter ring - installation​

Rear exciter ring - removal​

Rear relay valve - disassembly​

Rear relay valve - inspection​

Rear relay valve - installation​

Rear relay valve - reassembly​

Rear relay valve - removal​

Supplementary Information​

4E. Speed Retarder System​

Exhaust brake solenoid valve - inspection​

Exhaust brake solenoid valve - installation​

Exhaust brake solenoid valve - removal​

Exhaust brake valve - inspection​

Exhaust brake valve - installation​

Exhaust brake valve - removal​

4Z. Brake Electrical Control​

EBS control unit - installation​

EBS control unit - removal​

EBS control unit - setting​

Front pad wear sensor - installation​

Front pad wear sensor - removal​

Front wheel speed sensor - inspection​

Front wheel speed sensor - installation​

Front wheel speed sensor - removal​

Rear pad wear sensor - installation​

Rear pad wear sensor - removal​

Rear wheel speed sensor - inspection​

Rear wheel speed sensor - installation​

Rear wheel speed sensor - removal​

Supplementary Information​

Wheel park air tank pressure sensor - installation​

Wheel park air tank pressure sensor - removal​

Yaw rate sensor - installation​

Yaw rate sensor - removal​

Yaw rate sensor - setting​

4.3. Transmission, Transaxle (Allison 4430)

5B. Automatic​

ATF - inspection​

ATF - replacement​

ATF cooler - disassembly​

ATF cooler - inspection​

ATF cooler - reassembly​

ATF filter - inspection​

ATF filter - installation​

ATF filter - removal​

Selector button - installation​

Selector button - removal​

Supplementary Information​

Transmission - inspection​

Transmission - installation​

Transmission - removal​

5Z. Transmission Electrical Control​

TCM - installation​

TCM - removal​

Vehicle speed sensor - installation​

Vehicle speed sensor - removal​

4.4. Transmission, Transaxle (MJT)

5C. Manual​

Counter shaft - disassembly​

Counter shaft - inspection​

Counter shaft - reassembly​

Gear control cable - installation​

Gear control cable - removal​

Input shaft - disassembly​

Input shaft - inspection​

Input shaft - reassembly​

Main shaft - disassembly​

Main shaft - inspection​

Main shaft - reassembly​

Oil cooler - inspection​

Oil cooler - installation​

Oil cooler - removal​

Power assist - disassembly​

Power assist - inspection​

Power assist - reassembly​

Relay lever cover - disassembly​

Relay lever cover - reassembly​

Shift lever - installation​

Shift lever - removal​

Shift rod - disassembly​

Shift rod - inspection​

Shift rod - reassembly​

Supplementary Information​

Transmission - disassembly​

Transmission - inspection​

Transmission - installation​

Transmission - reassembly​

Transmission - removal​

Transmission oil - inspection​

Transmission oil - replacement​

Upper quadrant box - disassembly​

Upper quadrant box - inspection​

Upper quadrant box - reassembly​

5E. Clutch System​

Clutch (single plate push type) - disassembly​

Clutch (single plate push type) - inspection​

Clutch (single plate push type) - installation​

Clutch (single plate push type) - reassembly​

Clutch (single plate push type) - removal​

Clutch booster - disassembly​

Clutch booster - inspection​

Clutch booster - installation​

Clutch booster - reassembly​

Clutch booster - removal​

Clutch master cylinder - disassembly​

Clutch master cylinder - inspection​

Clutch master cylinder - installation​

Clutch master cylinder - reassembly​

Clutch master cylinder - removal​

Clutch oil pressure switch - installation​

Clutch oil pressure switch - removal​

Clutch switch - installation​

Clutch switch - removal​

Shift fork(single plate push-type) - installation​

Shift fork(single plate push-type) - removal​

Supplementary Information​

5F. PTO​

Side PTO - disassembly​

Side PTO - inspection​

Side PTO - installation​

Side PTO - reassembly​

Side PTO - removal​

Side PTO(large capacity type) - disassembly​

Side PTO(large capacity type) - inspection​

Side PTO(large capacity type) - installation​

Side PTO(large capacity type) - reassembly​

Side PTO(large capacity type) - removal​

Supplementary Information​

5Z. Transmission Electrical Control​

Clutch pedal stroke sensor - installation​

Clutch pedal stroke sensor - removal​

Vehicle speed sensor - inspection​

Vehicle speed sensor - installation​

Vehicle speed sensor - removal​

4.5. Transmission, Transaxle (ZF9S1310)

5C. Manual​

Clutch housing - installation​

Clutch housing - removal​

Counter shaft - disassembly​

Counter shaft - reassembly​

Flange - installation​

Flange - removal​

Gear control cable - installation​

Gear control cable - removal​

Input shaft - disassembly​

Input shaft - reassembly​

Main shaft - disassembly​

Main shaft - reassembly​

Planetary drive (with synchronizer unit) - disassembly​

Planetary drive (with synchronizer unit) - reassembly​

Rear cover - disassembly​

Rear cover - reassembly​

Shift lever - disassembly​

Shift lever - inspection​

Shift lever - installation​

Shift lever - reassembly​

Shift lever - removal​

Shift turret (double H) - disassembly​

Shift turret (double H) - reassembly​

Supplementary Information​

Transmission (double H) - disassembly​

Transmission (double H) - installation​

Transmission (double H) - reassembly​

Transmission (double H) - removal​

Transmission case - disassembly​

Transmission case - reassembly​

Transmission oil - inspection​

Transmission oil - replacement​

5E. Clutch System​

Clutch (single plate push type) - disassembly​

Clutch (single plate push type) - inspection​

Clutch (single plate push type) - installation​

Clutch (single plate push type) - reassembly​

Clutch (single plate push type) - removal​

Clutch booster - installation​

Clutch booster - removal​

Clutch master cylinder - disassembly​

Clutch master cylinder - inspection​

Clutch master cylinder - installation​

Clutch master cylinder - reassembly​

Clutch master cylinder - removal​

Clutch oil pressure switch - installation​

Clutch oil pressure switch - removal​

Clutch switch - installation​

Clutch switch - removal​

Shift fork(single plate push-type) - inspection​

Shift fork(single plate push-type) - installation​

Shift fork(single plate push-type) - removal​

Supplementary Information​

5Z. Transmission Electrical Control​

Clutch pedal stroke sensor - installation​

Clutch pedal stroke sensor - removal​

Vehicle speed sensor - installation​

Vehicle speed sensor - removal​

6. Steering

6B. Power Assisted System​

Drag link - disassembly​

Drag link - inspection​

Drag link - installation​

Drag link - reassembly​

Drag link - removal​

Link rod - disassembly​

Link rod - inspection​

Link rod - installation​

Link rod - reassembly​

Link rod - removal​

Power steering booster - disassembly​

Power steering booster - inspection​

Power steering booster - installation​

Power steering booster - reassembly​

Power steering booster - removal​

Power steering fluid - replacement​

Power steering oil pump (6U series engine) - disassembly​

Power steering oil pump (6U series engine) - inspection​

Power steering oil pump (6U series engine) - installation​

Power steering oil pump (6U series engine) - reassembly​

Power steering oil pump (6U series engine) - removal​

Power steering unit - disassembly​

Power steering unit - inspection​

Power steering unit - installation​

Power steering unit - reassembly​

Power steering unit - removal​

Steering shaft (with steering motor control unit) - inspection​

Steering shaft (with steering motor control unit) - installation​

Steering shaft (with steering motor control unit) - removal​

Steering shaft (with steering motor control unit) - setting​

Steering shaft - inspection​

Steering shaft - installation​

Steering shaft - removal​

Supplementary Information​

6Z. Steering Electrical Control​

DC-DC converter (EHPS) - installation​

DC-DC converter (EHPS) - removal​

Steering angle sensor - installation​

Steering angle sensor - removal​

Steering angle sensor - setting​

Steering angle sensor - writing​

7. HVAC

7B. Heater Ventilator Airconditioner​

A_C compressor (6UZ1) - installation​

A_C compressor (6UZ1) - removal​

A_C compressor drive belt(6UZ1) - inspection​

A_C compressor drive belt(6UZ1) - installation​

A_C compressor drive belt(6UZ1) - removal​

Air mix door - installation​

Air mix door - removal​

Blower - installation​

Blower - removal​

Blower module - inspection​

Blower module - installation​

Blower module - removal​

Blower motor - inspection​

Blower motor - installation​

Blower motor - removal​

Condenser - installation​

Condenser - removal​

Condenser fan - inspection​

Condenser fan - installation​

Condenser fan - removal​

Control panel - inspection​

Control panel - installation​

Control panel - removal​

Control panel - setting​

Evaporator core - installation​

Evaporator core - removal​

Expansion valve - installation​

Expansion valve - removal​

Heater core - installation​

Heater core - removal​

Heater evaporator unit - installation​

Heater evaporator unit - removal​

Inside air filter - installation​

Inside air filter - removal​

Intake actuator - installation​

Intake actuator - removal​

Intake door - installation​

Intake door - removal​

Mix actuator - installation​

Mix actuator - removal​

Mode actuator - installation​

Mode actuator - removal​

Mode door - installation​

Mode door - removal​

Outside air filter - installation​

Outside air filter - removal​

Receiver dryer - installation​

Receiver dryer - removal​

Supplementary Information​

Vent grille (center and driver side) - installation​

Vent grille (center and driver side) - removal​

Vent grille (passenger side) - installation​

Vent grille (passenger side) - removal​

Ventilation duct - installation​

Ventilation duct - removal​

7Z. HVAC Control​

A_C control unit - installation​

A_C control unit - removal​

A_C control unit - setting​

Inside air temperature sensor - inspection​

Inside air temperature sensor - installation​

Inside air temperature sensor - removal​

Outside air temperature sensor - inspection​

Outside air temperature sensor - installation​

Outside air temperature sensor - removal​

Sun sensor - inspection​

Sun sensor - installation​

Sun sensor - removal​

Supplementary Information​

8. Restraints

8B. Airbag Systems​

Driver airbag - installation​

Driver airbag - removal​

Driver airbag - scrapping​

Passenger airbag - installation​

Passenger airbag - removal​

Passenger airbag - scrapping​

SRS coil - installation​

SRS coil - removal​

8C. Seat Belt Systems​

Buckle side driver seat belt - installation​

Buckle side driver seat belt - removal​

Buckle side passenger seat belt - installation​

Buckle side passenger seat belt - removal​

Front buckle side center seat belt - installation​

Front buckle side center seat belt - removal​

Front tongue side center seat belt - installation​

Front tongue side center seat belt - removal​

Seat belt with pretensioner - installation​

Seat belt with pretensioner - removal​

Seat belt with pretensioner - scrapping​

Seat belt without pretensioner - installation​

Seat belt without pretensioner - removal​

Supplementary Information​

8Z. Seat Belt and SRS Airbag Electrical Control​

Satellite sensor - installation​

Satellite sensor - removal​

SRS control unit - installation​

SRS control unit - removal​

SRS control unit - setting​

9. Body, Cab, Accessories

9A. Lighting Systems​

Backup light bulb - installation​

Backup light bulb - removal​

Clearance light - installation​

Clearance light - removal​

Combination switch - inspection​

Combination switch - installation​

Combination switch - removal​

Daytime running light - installation​

Daytime running light - removal​

Door interlocking switch - inspection​

Door interlocking switch - installation​

Door interlocking switch - removal​

Door switch - inspection​

Door switch - installation​

Door switch - removal​

Fog light - installation​

Fog light - removal​

Front turn signal light - installation​

Front turn signal light - removal​

Hazard warning flasher switch - inspection​

Hazard warning flasher switch - installation​

Hazard warning flasher switch - removal​

Headlight - inspection​

Headlight - installation​

Headlight - removal​

Headlight leveling switch - inspection​

Headlight leveling switch - installation​

Headlight leveling switch - removal​

Key reminder switch - inspection​

Key reminder switch - installation​

Key reminder switch - removal​

LED dome light - installation​

LED dome light - removal​

LED dome light and map light - installation​

LED dome light and map light - removal​

LED dome light bulb - installation​

LED dome light bulb - removal​

LED interior light - installation​

LED interior light - removal​

LED interior light switch - inspection​

LED interior light switch - installation​

LED interior light switch - removal​

License plate light bulb - installation​

License plate light bulb - removal​

Push switch - inspection​

Push switch - installation​

Push switch - removal​

Rear combination light - inspection​

Rear combination light - installation​

Rear combination light - removal​

Rear turn signal light bulb - installation​

Rear turn signal light bulb - removal​

Roof-mounted clearance light bulb - installation​

Roof-mounted clearance light bulb - removal​

Side turn signal light - installation​

Side turn signal light - removal​

Tail stoplight bulb - installation​

Tail stoplight bulb - removal​

9B. Wiper, Washer Systems​

Headlight washer nozzle - installation​

Headlight washer nozzle - removal​

Supplementary Information​

Washer motor - inspection​

Washer motor - installation​

Washer motor - removal​

Washer nozzle - installation​

Washer nozzle - removal​

Wiper arm - installation​

Wiper arm - removal​

Wiper blade rubber - installation​

Wiper blade rubber - removal​

Wiper linkage - installation​

Wiper linkage - removal​

Wiper motor - installation​

Wiper motor - removal​

9C. Electrical Control, Entertainment​

Accessory socket - installation​

Accessory socket - removal​

Antenna - inspection​

Antenna - installation​

Antenna - removal​

Differential lock switch - inspection​

Differential lock switch - installation​

Differential lock switch - removal​

Door speaker - inspection​

Door speaker - installation​

Door speaker - removal​

DPD switch - inspection​

DPD switch - installation​

DPD switch - removal​

Horn - inspection​

Horn - installation​

Horn - removal​

Horn switch - installation​

Horn switch - removal​

Ignition switch - inspection​

Ignition switch - installation​

Ignition switch - removal​

Integrated DC-DC converter (single cab) - installation​

Integrated DC-DC converter (single cab) - removal​

LDWS switch and ESC OFF switch - inspection​

LDWS switch and ESC OFF switch - installation​

LDWS switch and ESC OFF switch - removal​

Radio - installation​

Radio - removal​

Steering wheel switch - inspection​

Steering wheel switch - installation​

Steering wheel switch - removal​

USB charger - installation​

USB charger - removal​

9E. Instrumentation, Driver Info​

Back buzzer - inspection​

Back buzzer - installation​

Back buzzer - removal​

Camera (vehicle front sensing) - installation​

Camera (vehicle front sensing) - removal​

Camera (vehicle front sensing) - setting​

Camera (vehicle front sensing) - writing​

Instrument panel cluster - installation​

Instrument panel cluster - removal​

Instrument panel cluster - setting​

9G. Hood, Fenders, Doors​

Cab back panel - installation​

Cab back panel - removal​

Engine hood insulator - installation​

Engine hood insulator - removal​

Front door - disassembly​

Front door - installation​

Front door - reassembly​

Front door - removal​

Front fender - installation​

Front fender - removal​

Front step - installation​

Front step - removal​

Rear fender - installation​

Rear fender - removal​

Rear mudguard - installation​

Rear mudguard - removal​

Supplementary Information​

9H. Cab Structure​

Air outlet valve - installation​

Air outlet valve - removal​

Front bumper - disassembly​

Front bumper - installation​

Front bumper - reassembly​

Front bumper - removal​

Front lid - disassembly​

Front lid - installation​

Front lid - reassembly​

Front lid - removal​

Front panel - installation​

Front panel - removal​

Front side panel - installation​

Front side panel - removal​

Front underrun protection - installation​

Front underrun protection - removal​

Lower radiator grille - installation​

Lower radiator grille - removal​

Supplementary Information​

Upper radiator grille - disassembly​

Upper radiator grille - installation​

Upper radiator grille - reassembly​

Upper radiator grille - removal​

Wiper panel - installation​

Wiper panel - removal​

9I. Seats​

Center seat - disassembly​

Center seat - installation​

Center seat - reassembly​

Center seat - removal​

Driver seat - disassembly​

Driver seat - installation​

Driver seat - reassembly​

Driver seat - removal​

High performance seat (ISRI) - disassembly​

High performance seat (ISRI) - inspection​

High performance seat (ISRI) - installation​

High performance seat (ISRI) - reassembly​

High performance seat (ISRI) - removal​

Passenger seat - disassembly​

Passenger seat - installation​

Passenger seat - reassembly​

Passenger seat - removal​

Supplementary Information​

9J. Security and Locks​

Cab external antenna - installation​

Cab external antenna - removal​

Cab internal antenna - installation​

Cab internal antenna - removal​

Electronic key - disassembly​

Electronic key - reassembly​

Electronic key - setting​

External buzzer - installation​

External buzzer - removal​

Front door lock - installation​

Front door lock - removal​

Key cylinder - installation​

Key cylinder - removal​

Receiver - installation​

Receiver - removal​

Remote controller key - disassembly​

Remote controller key - reassembly​

Remote controller key - setting​

Steering lock - installation​

Steering lock - removal​

Steering lock - setting​

Steering lock barrel - installation​

Steering lock barrel - removal​

Supplementary Information​

Transponder key - setting​

9L. Exterior, Interior Trim​

Back upper trim - installation​

Back upper trim - removal​

Center console box - installation​

Center console box - removal​

Floor carpet (short cab, full cab) - installation​

Floor carpet (short cab, full cab) - removal​

Head lining (short cab, full cab) - installation​

Head lining (short cab, full cab) - removal​

Header console - installation​

Header console - removal​

Header tray - installation​

Header tray - removal​

Instrument panel - disassembly​

Instrument panel - installation​

Instrument panel - reassembly​

Instrument panel - removal​

Reinforcement - installation​

Reinforcement - removal​

Supplementary Information​

9M. Cab Mounting​

Cab - installation​

Cab - removal​

Cab lock - installation​

Cab lock - removal​

Cab lock switch - inspection​

Cab lock switch - installation​

Cab lock switch - removal​

Cab tilt cylinder - disassembly​

Cab tilt cylinder - inspection​

Cab tilt cylinder - installation​

Cab tilt cylinder - reassembly​

Cab tilt cylinder - removal​

Electric - hydraulic power tilt pump - disassembly​

Electric - hydraulic power tilt pump - inspection​

Electric - hydraulic power tilt pump - installation​

Electric - hydraulic power tilt pump - reassembly​

Electric - hydraulic power tilt pump - removal​

Front cab mounting (full-floating cab suspension) - inspection​

Front cab mounting (full-floating cab suspension) - installation​

Front cab mounting (full-floating cab suspension) - removal​

Rear cab mounting (full-floating cab suspension) - inspection​

Rear cab mounting (full-floating cab suspension) - installation​

Rear cab mounting (full-floating cab suspension) - removal​

Supplementary Information​

9T. Glass, Windows, Mirrors​

Backlight glass - installation​

Backlight glass - removal​

Door mounted outside rearview mirror - installation​

Door mounted outside rearview mirror - removal​

Front door power window switch - inspection​

Front door power window switch - installation​

Front door power window switch - removal​

Front windshield glass - installation​

Front windshield glass - removal​

Mirror heater switch - inspection​

Mirror heater switch - installation​

Mirror heater switch - removal​

Mirror remote switch - inspection​

Mirror remote switch - installation​

Mirror remote switch - removal​

Pillar mounted outside rearview mirror (driver side) - disassembly​

Pillar mounted outside rearview mirror (driver side) - inspection​

Pillar mounted outside rearview mirror (driver side) - installation​

Pillar mounted outside rearview mirror (driver side) - reassembly​

Pillar mounted outside rearview mirror (driver side) - removal​

Pillar mounted outside rearview mirror (passenger side) - disassembly​

Pillar mounted outside rearview mirror (passenger side) - inspection​

Pillar mounted outside rearview mirror (passenger side) - installation​

Pillar mounted outside rearview mirror (passenger side) - reassembly​

Pillar mounted outside rearview mirror (passenger side) - removal​

Supplementary Information​

9Z. Body, Cab, Accessories Electrical Control​

Adaptive driving beam headlight control unit - installation​

Adaptive driving beam headlight control unit - removal​

Adaptive driving beam headlight control unit - setting​

Air pressure sensor - inspection​

Air pressure sensor - installation​

Air pressure sensor - removal​

BCM - installation​

BCM - removal​

BCM - setting​

CAN converter control unit (FCG) - installation​

CAN converter control unit (FCG) - removal​

CAN converter control unit (FCG) - setting​

Central ECU - installation​

Central ECU - removal​

Central ECU - setting​

Central gateway control unit - installation​

Central gateway control unit - removal​

Central gateway control unit - setting​

Front height sensor - inspection​

Front height sensor - installation​

Front height sensor - removal​

I_O control unit - installation​

I_O control unit - removal​

I_O control unit - setting​

Illuminance sensor - inspection​

Illuminance sensor - installation​

Illuminance sensor - removal​

Image processing unit (vehicle front sensing) - installation​

Image processing unit (vehicle front sensing) - removal​

Image processing unit (vehicle front sensing) - setting​

Information module - installation​

Information module - removal​

Information module - setting​

Milliwave radar unit - installation​

Milliwave radar unit - removal​

Milliwave radar unit - setting​

Milliwave radar unit - writing​

Rain sensor - installation​

Rain sensor - removal​

Rear height sensor - inspection​

Rear height sensor - installation​

Rear height sensor - removal​

Wireless access module - installation​

Wireless access module - removal​

Wireless access module - setting (with passive entry and start system)​

Wireless access module - setting (without passive entry and start system)​