PDF Workshop Manual 2004 Hino FD FE SG Truck - 7 MB
This is the official workshop manual for the 2004 Hino truck models FD, FE, and SG.
It provides detailed, factory-authorized procedures for all repair and maintenance tasks.
The manual covers the engine, chassis, electrical systems, and all other major components.
This is the same resource used by professional Hino technicians, making it essential for any serious repair work.
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--- Page 1 ---
FOREWORD
This workshop manual has been prepared to provide information covering repairs on 2004 FD, FE, and SG
series Hino trucks.
To use Hino trucks for years, smoothly, safely, and economically without trouble, it is important to perform
inspections.
Maintenance required to be performed is the responsibility of the owner. Some recommended repairs of
your truck are mentioned.
When making any repair of your truck, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner's and Driver's Manual.
All information and specifications in this manual are based upon the latest product information available at
the time of printing.
HINO DIESEL TRUCKS (U.S.A.),INC. reserves the right to make changes at any time without prior notice.
--- Page 3 ---
5-2 CLUTCH Models FD and FE
TROUBLESHOOTING
Symptom Possible cause Remedy
Clutch dragging Clutch disc distorted or warped ................ Replace clutch disc
Transmission input shaft worn ................. Replace input shaft and check clutch
hub for excessive wear
If worn, replace disc
Check flywheel housing alignment
Excessive clutch control ........................... Replace control parts
parts wear
Clutch control parts not ............................ Replace control parts
functioning properly
Improper clutch control ............................ Adjust clutch control
adjustment
Clutch disc assembly too thick ................. Replace clutch disc
Clutch slipping - - - - ~ - Release lever and release bearing .......... Adjust clearance
clearance incorrectly adjusted
Clutch disc facing gummed with .............. Replace disc assembly
oil or grease
Release bearing worn .............................. Replace bearing
Clutch pedal free-play incorrectly ............. Adjust free-play
adjusted
Compression spring weak ........................ Replace cover assembly
Clutch facing worn ................................... Replace facing or disc assembly
Failing to remove plate from .................... Remove plate
the clutch pressure plate assembly.
Driver riding clutch pedal ......................... Do not ride on the clutch pedal
Vehicle vibrates when--~- Improper engine idling ............................. Adjust idling
starting Clutch control incorrectly adjusted ........... Adjust clutch control
Clutch disc facing gummed with .............. Replace disc assembly
oil or grease
Glazed flywheel friction surface ............... Deg laze flywheel surface with coarse
emery cloth, stroking parallel to
machining lines
Clutch disc distorted or warped ................ Replace disc
Improper clutch cover tightening .............. Tighten bolts
Flywheel housing misalignment ............... Replace flywheel housing
--- Page 4 ---
Models FD and FE CLUTCH 5-13
3. INSPECT THE RELEASE FORK.
1. Check the release fork for wear and damage.
If necessary, replace the parts.
SM6-129C
ASSEMBLY OF CLUTCH HOUSING
1. INSTALL THE RELEASE SHAFT AND RELEASE FORK.
1. Insert the release shaft into the flywheel housing.
When inserting, insert the release fork onto the re-
lease shaft.
Fig. 30
2. Install the key on the shaft.
3. Slide the release fork on the key and then align the
release fork hole with the release shaft hole.
Fig. 31
4. Tighten the lock bolt.
Tightening Torque: 140 - 180 kg-cm (11 - 13 lb-ft)
Fig. 32
2. INSTALL THE CLUTCH HOUSING IN THE TRANSMIS-
SION CASE.
Install the fitting bolts and tighten them.
Tightening Torque: 2,500 - 3,300 kg-cm (181 - 238 lb-ft)
Fig. 33
--- Page 5 ---
5-8 CLUTCH Model SG
DISASSEMBLY OF CLUTCH UNIT
1. USING A PRESS, COMPRESS THE CLUTCH COVER
TO RELIEVE THE COMPRESSION SPRING TENSION.
SM5-096A
Fig. 8
2. REMOVE THE LOCK PLATE OF RELEASE LEVER
SUPPORT NUT.
1. Remove the lock bolts.
2. Remove the lock plates.
SM5-073A
Fig. 9
3. REMOVE THE RELEASE LEVER SUPPORT NUTS.
Fig.10
4. REMOVE THE STRAP PLATE CLAMPING BOLTS.
Fig.11
5. REMOVE THE SPECIAL TOOLS.
Special Tool: Pressure plate fixing bolt
(9010 - 10700)
Plain washer (9260 - 10240)
Fig.12
--- Page 6 ---
Model SG CLUTCH 5-19
3. INSPECT THE RELEASE FORK.
Check the release fork for wear and damage.
If necessary, replace the release fork.
SM5-129A
ASSEMBLY OF CLUTCH HOUSING
1. INSTALL THE RELEASE SHAFT AND RELEASE FORK.
1. Insert the release shaft into the flywheel housing.
When inserting, insert the release fork onto the re-
lease shaft.
2. Install the key on the shaft.
3. Slide the release fork on the key and then align the
release fork hole with the release shaft hole.
SMS-091B
Fig. 57
4. Tighten the lock bolt.
Tightening Torque: 140 - 180 kg-cm (11 - 13 lb-ft)
Fig. 58
2. INSTALL THE CLUTCH HOUSING IN THE TRANSMIS-
SION CASE.
Install the fitting bolts and tighten them.
Tightening Torque:
(SG1J):
16 mm dia. bolt:
1,700 - 2,300 kg-cm (123 - 166 lb-ft)
20 mm dia. bolt:
3,500 - 4,700 kg-cm (254 - 339 lb-ft)
(SG2J):
Fig. 59 2,500 - 3,300 kg-cm (181 - 238 lb-ft)
--- Page 7 ---
6-6 CLUTCH CONTROL Models FD, FE and SG
3
2
-+-------
' ,
_____ o __ -----====v
r-----------------7 (
. ,-/ ',
___ )
PIPING
1. Hydraulic hose 4. Elbow
2. Oil pipe 5. Hydraulic hose bracket
3. Accumulator
SM6-222A
Fig. 2
REMOVAL OF CLUTCH PEDAL
1. REMOVE THE CLUTCH PEDAL.
1. Remove the return spring.
2. Remove the push rod fitting pin.
3. Remove the pedal shaft.
Remove the pedal shaft fitting nuts.
4. Remove the clutch pedal.
Fig. 3
INSPECTION OF COMPONENT PARTS OF
PEDAL
Inspect all parts for wear or damage. If necessary,
replace the parts.
SM6-224
Fig. 6
--- Page 8 ---
Models FD, FE and SG CLUTCH CONTROL 6-17
2. Remove the piston assembly from the cylinder.
3. Using a special tool, remove the piston cups from
the piston.
Special Tool: Hook (09653-1780)
Fig. 6-38
Fig. 6-39 06-151
7. DISASSEMBLE THE END PLATE.
1. Remove the control tube fitting bolt.
2. Remove the end plate fitting nuts.
3. Remove the end plate from the cylinder shell.
Fig. 6-40 SM6-069
4. Remove the retainer ring.
5. Remove the push rod washer, cup and washer
retainer, piston cup, and oil seal.
6. Using a special tool, remove the O-ring.
Special Tool: Hook (09653-1780)
Fig. 6-41 SM6-070
©C@®®@@
0
Fig. 6-42 06-150
--- Page 9 ---
6-28 CLUTCH CONTROL Models FD, FE and SG
2. CHECK THE EXPOSED THREADED SECTION OF THE
PUSH ROD.
Measure the exposed threaded section of the slave
cylinder push rod. If its length is less than the serv-
ice limit, replace the clutch facing or clutch disc as-
sembly.
Service Limit:
FD : 33 mm (1.29 in.)
FE : 15.5 mm (0.61 in.)
SG1 J (MF06S T/M) : 25.5 mm (1.00 in.)
SG1 J (RT8709 T/M) : 8 mm (0.31 in.)
Fig.11
ASM6-013
Fig.12
--~./ 3. INSPECT THE CLUTCH PEDAL HEIGHT AND THE
STROKE.
Pedal Height
FD and FE: 185 - 199 mm (7.29 - 7.83 in.)
SG: 170 - 190 mm (6.70 - 7.47 in.)
PEDAL Pedal Stroke
HEIGHT
FD and FE : 21 0 - 230 mm (8.27 - 9.05 in.)
SG: 170 - 190 mm (6.70 - 7.47 in.)
ASM6-011
Fig.13
--- Page 10 ---
Model FD (LF06S) TRANSMISSION 7-11
DISASSEMBLY OF GEAR SHIFT HOUSING
NOTE: 0 Examine to see if any parts are worn or if
any abnormal interference or play exists
when moving each shift fork. Disassemble
the transmission and replace faulty parts,
if any.
0 Be sure that no pins and springs are left
inside the gear shift housing.
1. REMOVE THE SHIFT LEVER SHAFT HOUSING.
Remove the housing fitting bolts and remove the
housing from the transmission case cover.
2. REMOVE THE TRANSMISSION CASE COVER.
Remove the case cover fitting bolts and remove the
case cover from the transmission case.
3. DISASSEMBLE THE TRANSMISSION CASE COVER.
WARNING
The steel ball may pop out from the hole. Wear safety
glasses to protect your eyes.
Fig. 2 ASM7-017
1. Remove the back-up lamp switch.
2. Clamp the case cover in a soft jaw vise.
Fig. 3 ASM7-018
4. REMOVE THE PIN.
1. Set the transmission case cover on a vise.
2. Drive out the shift head and shift fork fitting pins with
a 5 mm (0.197 in.) diameter tapping rod.
Fig. 4
--- Page 11 ---
7-22 TRANSMISSION Model FD (LF06S)
3. Remove the reverse gear needle roller bearing.
Fig. 22
lfr«r f t r
SM7-173F
4. Remove the constant sleeve.
SMTM-477A
5. Remove the retainer ring at the front face of the out-
put shaft.
WARNING
The retainer ring is spring steel and may pop out of
the groove. Wear safety glasses to protect your eyes.
SMTM-478C
6. Remove the 5th-6th synchronizer unit.
Fig. 25 SMTM-479A
7. Remove the 5th synchronizer ring.
Fig. 26 SMTM-558A
--- Page 12 ---
Model FD (LF06S) TRANSMISSION 7-33
10. Install the needle roller bearing for the reverse gear.
Fig. 75 SM7-173G
11. Install the constant sleeve.
Fig. 76 SMTM-499A
12. Install the reverse gear.
Fig. 77 SM?-173D
13. Hold the thrust washer with a jig.
WARNING
If the output shaft assembly is installed to the trans-
mission without a jig, the reverse gear will drop from
the shaft and possibly result in personal injury.
Fig. 78 SM?-256B
14. Install the needle roller bearing for the 3rd gear.
15. Install the 3rd gear.
Fig. 79 SMTM-1691
--- Page 13 ---
7-44 TRANSMISSION Model FD (LF06S)
COUNTER SHAFT, REVERSE IDLER SHAFT AND GEARS
1. Seal cover 8. Thrust washer
2. Cylindrical bearing 9. Reverse idler gear
3. Retainer ring 10. Needle roller bearing
4. Counter shaft drive gear 11 . Reverse idler shaft
5. Counter 5th gear 12. O-ring
6. Counter shaft 13. Lock plate
7. Woodruff key 14. Bolt
Fig.1
--- Page 14 ---
Model FD (LF06S) TRANSMISSION 7-55
9. INSTALL THE PROPELLER SHAFT CENTER BEARING
AND CONNECT THE PROPELLER SHAFT.
1. Install the center bearing holder and tighten the fit-
ting bolts and nuts.
Tightening Torque: 380 - 500 kg-cm (28-36 lb-ft)
Fig. 9 SMTM-428
10. FILL TRANSMISSION WITH GEAR OIL UP TO THE
BOTTOM OF FILLER PLUG.
Clean the drain plug with a magnet and tighten the
plug with a new gasket.
Oil Capacity: Approx. 7.0 liters
(7.40 US Qt., 6.16 Imp.Qt.)
Tightening Torque: 800-1,200 kg-cm (58-86 lb-ft)
Fig.10 SM7-186A
11. CHECK THE CLUTCH PEDAL PLAY.
1. Depress the clutch pedal and measure the distance
that the pedal travels before resistance is felt.
Standard 50-65 mm (1.97-2.55 in.)
Service Limit: 35 mm (1.38 in.)
2. If the pedal stroke is less than 35 mm (1.38 in.), ad-
just the clutch control system in accordance with
CHAPTER 6, CLUTCH CONTROL.
Fig.11
12. CHECK THE GEAR SHIFT IN EACH POSITION.
Fig.12
--- Page 15 ---
7-10 TRANSMISSION Model FE (LJ06S)
GEAR SHIFT HOUSING
8~
33
8
8~
ASM?-027
1. Shift lever shaft 21. Interlock plunger
2. O-ring 22. 3rd-4th shift shaft
3. Shift lever shaft housing 23. Interlock pin
4. Outer select lever 24. 3rd-4th shift fork
5. Shift lever pin 25. 5th-6th shift head
6. Plain washer 26. Slotted nut
7. Oil seal 27. Cotter pin
8. Expansion plug 28. Air breather
9. Set screw 29. Straight pin
10. Lock out plunger 30. Back-up lamp switch
11. Compression spring 31. Reverse shift head
12. Retainer ring 32. Reverse shift fork
13. Select lever shaft 33. Reverse shift shaft
14. Inner shift lever 34. Transmission case cover
15. Plug 35. 1st-2nd shift head
16. Soft washer 36. 1st-2nd shift fork
17. Steel ball 37. 1st-2nd shift shaft
18. 5th-6th shift shaft 38. Plain washer
19. 5th-6th shift fork 39. Inversion lever
20. Pin 40. Inversion pin
Fig.1
--- Page 16 ---
Model FE (LJ06S) TRANSMISSION 7-21
3. Remove the rear bearing.
Fig.17 SMTM-395A
JIG (NUT AND ROD)
10. ATTACH A JIG TO THE END OF THE OUTPUT SHAFT.
WARNING
If the output shaft assembly is removed from the
transmission without a jig, the reverse gear will drop
from the shaft and possibly result in personal injury.
Fig.18 SM7-233
11. REMOVE THE OUTPUT SHAFT ASSEMBLY FROM THE
TRANSMISSION CASE.
When removing the output shaft assembly, remove
the synchronizer ring and the cone of the input shaft
gear.
Fig.19 SMTM-456
12. DISASSEMBLE THE OUTPUT SHAFT.
1. Remove the jig from the end of the output shaft.
JIG
Fig. 20 SMTM-256
2. Remove the reverse gear.
Fig. 21 SM7-173E
--- Page 17 ---
7-32 TRANSMISSION Model FE (LJ06S)
5. Heat the 2nd synchronizer unit for about 5 minutes
in water or oil heated to 120°c to 130°C (248°F to
266°F).
Then install the synchronizer unit on the shaft.
NOTE: Do not heat the synchronizer unit in excess
of 150°C (302°F).
If the unit has been warmed with hot water,
remove moisture before installation.
Fig. 68 WARNING
Never touch hot water and heated synchronizer unit
with your bare hands. This can result in personal
injury.
6. Install the 1st gear bushing
Heat the bushing to approximately 125°C (257°F) in
a heater and place on output shaft against the end
stop.
WARNING
Do not handle the bushing with bare hands when it
is heated.
Fig. 69
7. Install the needle roller bearing for the 1st gear.
Fig. 70
8. Install the 1st gear.
--- Page 18 ---
Model FE (LJ06S) TRANSMISSION 7-43
14. INSTALL THE PARKING BRAKE DRUM. [MODEL FE]
1. Install the drum.
2. Tighten the fitting nuts.
Tightening Torque: 650-870 kg-cm (47-62 lb-ft)
WARNING
Be sure to secure the parking brake drum to the
transmission flange. Otherwise, the parking brake
drum may drop suddenly, resulting in personal injury.
Fig. 121 SMTM-519B SMTM-519C
--- Page 19 ---
7-54 TRANSMISSION Model FE (LJ06S)
4. INSTALL THE FOLLOWING COMPONENT PARTS.
1. Electric harness
2. Parking brake cable
3. Speedometer cable
Fig. 5 SMTM-429
5. CONNECT THE TRANSMISSION SHIFT ROD.
1. Tighten the link rod end nut.
Tightening Torque: 250-380 kg-cm (19-27 lb-ft)
2. Tighten the control rod end nut.
Tightening Torque: 380-500 kg-cm (28-36 lb-ft)
6. INSTALL THE CROSS SHAFT TO THE SIDE OF THE
ENGINE AND CHASSIS FRAME.
Tightening Torque:
Engine side bracket. - 380-500 kg-cm
(28-36 lb-ft)
Chassis side bracket. - 650-870 kg-cm
(47-62 lb-ft)
NOTE: Do not forget to install the heat insulators.
Fig. 6 ASM7-015
7. INSTALL THE CLUTCH SLAVE CYLINDER OR CLUTCH
BOOSTER.
1. Tighten the fitting bolts.
Tightening Torque: 380 - 500 kg-cm (28-36 lb-ft)
2. Install the tension spring.
Fig. 7 SM6-068 SM6-078
Fig. 8 ASM7-026
--- Page 20 ---
Model SG1J (MF06S) TRANSMISSION 7-9
2. Place a transmission jack under the transmission.
3. Remove the remaining bolts around the clutch hous-
ing.
4. Pull the transmission backwards. Lower the Trans-
mission jack and pull the transmission out from un-
der the truck.
Fig. 7-1-9 SM?-184
8. REMOVE THE CLUTCH HOUSING.
Fig. 7-1-10 SM5-084A
9. MOUNT THE TRANSMISSION ASSEMBLY ON A
WORKSTAND.
Fig. 7-1-11 SMTM-434
--- Page 21 ---
7-20 TRANSMISSION Model SG1J (MF06S)
15. INSTALL THE TRANSMISSION CASE COVER.
1. Apply the sealing compound to the face of the
transmission case.
NOTE: 0 The trace of the sealing compound should
be continuous.
0 The sealing compound should be "THREE
BOND #1215" or equivalent.
TRANSMISSION
CASE
Unit: mm (in.)
Fig. 7-2-41
2. Install the transmission case cover with the fitting bolts.
3. Using a torque wrench, tighten the bolts.
Tightening Torque:
1O mm dia. bolt: 450 - 550 kg-cm (33 - 39 lb-ft)
14 mm dia. bolt : 950 - 1,200 kg-cm (69 - 86 lb-ft)
Fig. 7-2-42 SMTM-474
16. INSTALL THE SHIFT LEVER SHAFT, COMPRESSION
SPRING AND INNER SHIFT LEVER.
1. Apply gear oil lightly to the gear shift lever shaft and
insert the shaft into the shift lever shaft housing.
Fig. 7-2-43 ASM7-041
17. INSTALL THE SHIFT LEVER SHAFT HOUSING.
1. Apply the sealing compound to the face of the trans-
mission case cover.
NOTE: 0 The trace of the sealing compound should
be continuous.
0 The sealing compound should be "THREE
BOND #1215" or equivalent.
TRANSMISSION
CASE COVER
Unit : mm (in.)
Fig. 7-2-44
2. Install the shift lever shaft housing with fitting bolts.
NOTE: Reamer bolts are used on two diagonally op-
posite corners of the shift lever shaft hous-
ing.
Fig. 7-2-45 ASM7-042
--- Page 22 ---
Model SG1J (MF06S) TRANSMISSION 7-31
22. Remove the 2nd gear with synchronizer ring.
RR
Fig. 7-3-42
23. Remove the needle roller bearing.
Fig. 7-3-43 SM7-169A
13. DISASSEMBLE THE SYNCHRONIZER UNIT.
1. Remove the sleeve.
Fig. 7-3-44 SMTM-485
2. Remove the synchronizer key and head.
WARNING
The compression spring is spring steel and may pop
out of the hole. Wear safety glasses to protect your
eyes.
Fig. 7-3-45
3. Remove the compression spring.
Fig. 7-3-46 SMTM-485B
--- Page 23 ---
7-42 TRANSMISSION Model SG1J (MF06S)
2. Install the retainer rings.
a. Select a retainer ring that will provide a tight fit.
b. Install the retainer ring. Make sure that the retainer
ring seats in pace.
Retainer rings are available in the following sizes.
Thickness Color code
2.8 mm (0.110 in.) None
Fig. 7-3-90 SMTM-453 2.9 mm (0.114 in.) Blue
3.0 mm (0.118 in.) Green
3.1 mm (0.122 in.) Yellow
3.2 mm (0.126 in.) Red
NOTE: Always use a new retainer ring.
c. Check the clearance.
Assembly Standard: Zero
Fig. 7-3-91 SM7-310
3. Install the roller bearings in the counterbore of the
input shaft.
a. Apply gear oil to the bearings.
b. Place spacers at both ends of the bearings.
NOTE: Always use roller bearings of uniform diam-
eter (15 pieces per set). There are 3 types of
roller bearings in different diameters. These
are distinguished by the colors red, blue and
white.
Fig. 7-3-92 SM7-304
4. Install the retainer ring.
WARNING
The retainer ring is spring steel and may pop out of
the groove. Wear safety glasses to protect your eyes.
Fig. 7-3-93 SMTM-454
6. INSTALL THE INPUT SHAFT ASSEMBLY.
1. Align the output shaft front end center with the input
shaft center to prevent the roller bearings and gears
from being damaged.
2. Drive the cylindrical bearing inner race with a suit-
able driving tool and a hammer.
Fig. 7-3-94 SMTM-374
--- Page 24 ---
Model SG1J (MF06S) TRANSMISSION 7-53
INSPECTION OF THE COUNTER SHAFT, RE-
VERSE IDLER SHAFT AND GEARS
~;);1;;~ 1. CHECK ALL GEARS AND COUNTER SHAFT FOR
CRACKS OR DEFECTS.
8~'®® a. If a gear has chipped, worn or missing teeth, replace
the gear. Check the gears for binding on the shaft.
b. Check the counter shaft for wear or damage. If any
wear and damage is detected, replace the shaft.
Fig. 7-4-20 SMTM-509
2. CHECK THE COUNTER SHAFT KEY GROOVE AND
KEY FOR DAMAGE OR LOOSENESS.
If any damage or looseness is detected, replace the
key and/or counter shaft.
Fig. 7-4-21 SMTM-509A
3. CHECK THE CYLINDRICAL BEARINGS FOR WEAR OR
DAMAGE.
Check the bearing races for roughness. Inspect the