POWER TRAIN

Removal and Installation

Removal of Engine and Transmission Assembly (for Gasoline-engine Trucks)

The engine and transmission are installed as an
assembled unit. The engine may be removed
independently of the transmission, but the transmission
can only be removed together with the engine.

Overhead Guard, Covers, Air Cleaner and Other Components

5
6
1

3
8
4

7
9

10 209792

Sequence
1 Overhead guard, Headlamps 6 Radiator cover
2 Batteries, Cables 7 Floor plate, Floor mat
3 Steering wheel 8 Air hose, Air cleaner
4 Gas springs 9 Exhaust pipe
5 Engine cover, Seat 10 Fuel hoses (without LPG engine models)

Suggestions for Removal

(1) When removing the batteries 2, be sure to
disconnect the ground (negative) cable first.
(2) Remove the floor plate and mat 7 together with the
accelerator pedal after disconnecting the pedal from
the linkage rod.
(3) Disconnect the exhaust pipe 9 from the engine.
(4) Before removing the fuel hose 10, make sure to
close the cock on the fuel tank.
(5) The harness connectors disconnected from the
sockets and terminals on the engine and
transmission should be attached to the main
harness, in order to avoid damaging them.

5-1
POWER TRAIN

Controls

2
4

4 5
6 1

210118

Sequence
1 Brake pipe 4 Connector (Throttle, Stop lamp switches)
2 Inching cable, Clevis pin, Washer, Snap pin 5 Pedal assembly
3 Oil tank 6 Accelerator bracket

Suggestion for Removal

To remove the inching cable 2, disconnect from both the
inching pedal and the transmission and then loosen the lock
nuts.

Installation
Follow the removal sequence in reverse.

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 POWER TRAIN

LPG system (Dual Fuel Gasoline and LPG Model)

Disassembly

1
5

3
2
To engine

A
To engine

4
7

To engine
8
A

210120

Sequence
1 LPG tank 5 Water hose
2 Tank bracket 6 LPG hose
3 LPG hose 7 Water hose
4 LPG pipe 8 Vaporizer assembly

Start by:
(a) Draining the coolant hose from the engine by removing
the drain plug.
(b) Draining the coolant from the radiator by loosening the
cock at the bottom of the radiator.

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POWER TRAIN

Radiator and Pipes

4 5
7

6 3
2
1

11
8
10
9
209796

Sequence
1 Reserve tank 7 Cooler hose (between radiator and powershift
2 Hose (upper) transmission)
3 Hose (lower) 8 Cooling fan
4 Hose (between hydraulic tank and control 9 Fan belt
valve) 10 Fan guard
5 Hose (between hydraulic tank and oil pump) 11 Universal joint (between transmission and
6 Hose (between oil pump and steering control reduction/differential gears)
valve)

Start by: Installation

(a) Draining the coolant from the engine by removing Follow the removal sequence in reverse.
the drain plug (note that the position of the drain
plug differs by engine type).
(b) Draining the coolant from the radiator by loosening
the cock at the bottom of the radiator.

Suggestion for Removal

Disconnect the cooler hose 7 from the transmission side
and temporarily attach it to the right side of the frame.

5-4
 POWER TRAIN

Engine and Transmission Assembly

209797

Sequence
1 Transmission mounting bolt 3 Engine and transmission assembly
2 Engine mounting bolt

Start by:
(a) Lifting the engine and transmission assembly with a
hoist and slings.

Suggestions for Removal

(1) Lift the engine and transmission assembly just the
amount necessary to remove the load on the mounting
cushion before removing the mounting bolts 1 and 2.
Remove the engine support mounting bolts.
(2) Slowly lift the engine and transmission assembly 3 out
by moving it backwards referring to the balance.
Note: (1) Drain the transmission oil and clutch oil with the
engine and transmission assembly suspended.
(2) There is only one drain plug in the powershift
transmission.

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POWER TRAIN

Installation
Follow the removal sequence in reverse.

Suggestions for Installation

(1) Engine and transmission assembly Engine side
(a) Slowly lift the assembly.
(b) On the transmission side, tighten the bolts of the Cushion
left and right mounts after aligning them with the
Bolt
holes in the differential case.
(c) On the engine side, tighten the bolts of the left and
right engine supports after aligning them with the Engine support
holes in the engine mounts.

Frame-side
engine mount 209798

(2) For powershift transmission trucks, check that the

clutch valve plunger is pushed out completely when the
cable is connected between the inching pedal and the
transmission.
(3) Bleed the air out of the brake fluid circuit after
connecting the brake pipe.
(4) When installing the exhaust pipe, use a new gasket.
(5) Connect the ground (negative) cable to the battery only
after making sure that all wiring is connected properly.
(6) Refill the engine, radiator, and transmission with
oils/coolant, and check for leakage. Unless otherwise
specified, use soft water (tap water) mixed with
antifreeze at a concentration of 35%.
(7) Bleed the air out of the fuel circuit of the engine.
(8) After checking the parts, start the engine and check
that the clutch booster functions properly (wet-type
clutch transmission trucks only). Operate the mast
lifting/tilting and steering, and check the hydraulic oil
level. Also recheck the engine oil, coolant and
transmission oil levels.

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 POWER TRAIN

Removal of Engine and Transmission Assembly (for Diesel-engine Trucks)

The engine and transmission are installed as an
assembled unit. The engine may be removed
independently of the transmission, but the transmission
can only be removed together with the engine.
Note: There are two types of transmission, namely the
torque converter drive type (powershift
transmission) and the direct drive type (manual
transmission). Removal procedures vary for
direct drive type transmissions according to
whether they have a dry-type clutch or a wet-
type clutch.

Overhead Guard, Covers, Air Cleaner and Other Components

5
1
6

4 8
9

10
209800

Sequence
1 Overhead guard, Headlamps 6 Radiator cover
2 Batteries, Cables 7 Floor plate, Floor mat
3 Steering wheel 8 Air hose, Air cleaner
4 Gas springs 9 Exhaust pipe
5 Engine cover, Seat 10 Fuel hose

Suggestions for Removal

(1) When removing the batteries 2, be sure to
disconnect the ground (negative) cable first.
(2) Remove the floor plate and mat 7 together with the
accelerator pedal after disconnecting the pedal from
the linkage rod.
(3) Disconnect the exhaust pipe 9 from the engine.
(4) Before removing the fuel hose 10, make sure to
close the cock on the fuel tank.
(5) The harness connectors disconnected from the
sockets and terminals on the engine and
transmission should be attached to the main
harness, in order to avoid damaging them.

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POWER TRAIN

Controls
This section describes only removal and installation
procedures specific to diesel-engine trucks. Follow the
instructions for the gasoline-engine trucks in the preceding
sections for the common procedures.

Sequence
1 Throttle cable

209802

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 POWER TRAIN

Radiator and Pipes

5
7

3
2
1
8

11

6
10

209804

Sequence
1 Reserve tank 7 Cooler hose (between radiator and powershift
2 Hose (upper) transmission)
3 Hose (lower) 8 Cooling fan
4 Hose (between hydraulic tank and control 9 Fan belt
valve) 10 Fan guard
5 Hose (between hydraulic tank and oil pump) 11 Universal joint (between transmission and
6 Hose (between oil pump and steering control reduction/differential gears)
valve)

Start by: Installation

(a) Draining the coolant from the engine by removing Follow the removal sequence in reverse.
the drain plug (note that the position of the drain
plug differs by engine type).
(b) Draining the coolant from the radiator by loosening
the cock at the bottom of the radiator.

Suggestion for Removal

Disconnect the cooler hose 7 from the transmission side
and temporarily attach it to the right side of the frame.

5-9
POWER TRAIN

Engine and Transmission Assembly

209805

Sequence
1 Transmission mounting bolt 3 Engine and transmission assembly
2 Engine mounting bolt

Start by: Installation

(a) Lifting the engine and transmission assembly with
a hoist and slings.
Suggestions for Removal
(1) Lift the engine and transmission assembly just the
amount necessary to remove the load on the
mounting cushion before removing the mounting
bolts 1 and 2. Remove the engine support
mounting bolts.
(2) Slowly lift the engine and transmission assembly 3
out by moving it backwards referring to the
balance.
Note: Drain the powershift transmission oil with the
engine and transmission assembly suspended.
This section describes only removal and installation
procedures specific to diesel-engine trucks. Follow the
instructions for the gasoline-engine trucks in the
preceding sections for the common procedures.
Suggestion for Installation (those not shared with
gasoline-engine trucks)
Connect the accelerator pedal linkage on the floor plate
to the throttle cable. Check that the injection pump
lever at the full-open position when the accelerator
pedal is fully depressed.

5-10