Rocky Service
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Tools:
- floor jack, jack stands, wheel chocks
- jack, jack bar, hub cap remover, lug nut wrench: 21 mm, tire lock key
- screwdrivers: slotted, Phillips, stubby
- pliers: slip-joint, needle nose, locking, snap ring
- adjustable wrenches: small, medium, large
- hex keys: 5 8 mm
- wrenches: 1/2" 8 10 12 14 17 19 22 24 mm
- sockets: 1/2" 8 10 12 14 17 19 22 24 mm
- spark plug socket: 16 mm (5/8")
- ratchet, extension, breaker bar, socket adapter
- torque wrench
AXLE, FRONT
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Suspension, Front: FS-43-48, FS-28-42
* tools: hex keys: 5 8 mm, axle nut sockets: 49 54 mm, shims, snap ring pliers
oil seal puller, oil seal/bearing driver, brass bar, press
long breaker bar, socket adapter, torque wrench, spring scale
hub anti-rotation tool, large slotted screwdriver / pry bar, hammer
* parts: hub cover gasket, snap ring, lock washer, oil seals, bearings
lithium based MP high temperature wheel bearing grease, Daihatsu Bond 4
- remove front wheel
- remove brake mounting support together with calipers
- remove hub cover, gasket, snap ring, hub body
- remove lock nut outer, lock washer, lock nut inner
- remove front axle hub & outer roller bearing
- remove outer oil seal & inner roller bearing
- remove bearing races from hub
- remove brake disc from hub
Shock Absorber, Front: FS-68-71
- jack up vehicle
- remove dust cover
- remove upper nuts, washers, cushions
- remove lower bolt
- remove shock absorber
Steering Knuckle: FS-79-87
* tools: oil seal puller, oil seal press, ball joint puller, grease gun
* parts: oil seal, lithium based MP high temperature wheel bearing grease
- remove stabilizer bar
- remove torsion spring (?)
- remove front axle hub
- remove tie rod end (?)
- remove lower arm ball joint nuts
- remove upper arm ball joint nuts
- remove steering knuckle
- remove oil seal. check bush
- remove ball joints: cotter pins, castle nuts
AXLE, REAR
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Shock Absorber, Rear: RS-18-22
- jack up vehicle
- remove lower nuts, plate washers, cushions
- remove upper nuts, plate washers, cushions
- remove shock absorber
Axle Shaft, Rear: RS-23-31
* tools: axle shaft puller / slide hammer & axle shaft hub bolts attachment bar
oil seal puller / removal tool, oil seal driver
* parts: oil seals, bearing, retainer
lithium based MP high temperature wheel bearing grease, Three Bond 1104
- remove rear wheel
- disassemble rear brake
- remove backing plate nuts
- remove rear axle shaft
- remove oil seals: inner & outer (?)
BRAKES
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Bleeding: BR-17-19
* tools: wrench: 10 mm, plastic bottle, vinyl hose
* parts: bleeder plug caps
* fluids: Brake Fluid: DOT 3 / SAEJ 1703
Brakes, Front: BR-26-38
* tools: hub cap remover, lug nut wrench: 21 mm, breaker bar
ratchet, sockets: 14 17 mm, hex key: 5 mm, hex socket: 8 mm
C-clamp, aluminum plate
* parts: brake hose clip, brake shims, guide plates, brake pads, cylinder boot
antisqueal brake grease, rubber grease, brake hose copper gaskets
Three Bond 1105B (Ultra Black)
- remove front wheel
- detach brake hose clip, remove caliper attaching bolt, lift caliper body
- remove brake pads, antisqueal shims, guide plates
- inspect & measure brake pads & disc
- inspect caliper piston
- remove brake caliper, brake mounting support
- disassemble caliper: rubber boot, slide bush, dust boot, set ring, piston seal
Brakes, Rear: BR-39-52
* tools: hub cap remover, lug nut wrench: 21 mm, breaker bar, M10x1.25 bolts (2)
ratchet, sockets: 10 14 mm, wrench: 10 mm, flare nut wrench: 10 mm
rubber mallet, brake spring tool/pliers, vice grips, needle nose pliers
* parts: brake shoes, rear wheel cylinder / repair kit, "C" washer, hole plug
brake grease, Three Bond 1105B (Ultra Black)
- remove rear wheel
- remove brake drum
- detach springs, hold down spring pins, shoes, adjusting lever, shoe strut
- loosen parking brake lever adjusting nut
- disconnect parking brake cable from shoe lever
- drain brake fluid from rear wheel cylinder air bleeder plug
- disconnect brake pipes from rear wheel cylinder (use flare nut wrench)
- remove rear wheel cylinder
- remove parking brake cable
- disassemble leading side shoe: "C" washer, shoe lever, lever pin
- disassemble & inspect rear wheel cylinder: boots, pistons, cups, spring
- inspect & measure brake drum & shoes
COOLING
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Water Pump: CO-5-7
* tools: bucket, gasket scraper
* parts: dust seals (2), water pump gasket, gasket sealant (?)
- remove engine undercover
- drain coolant
- remove timing belt
- remove water pump
Thermostat: CO-8-9
* tools: bucket
* parts: thermostat, thermostat rubber grommet, hose, clamp
- remove engine undercover
- drain coolant
- loosen power steering adjusting bolt nut & mounting bolts
- remove power steering pump
- cover alternator
- remove hose from water inlet (?)
- remove water inlet & thermostat
Radiator: CO-10-13
* tools: bucket, pressure tester
* parts: radiator drain plug rubber gasket, radiator cap, hoses, clamps
- remove engine undercover
- drain coolant
- remove reserve tank, engine wire screw, clutch cable clamps, air cleaner
- remove power steering pump (?)
- remove upper & lower hoses from radiator
- remove fan shroud bolts & unlock from radiator
- remove radiator grill
- remove radiator bolts
- remove radiator
- remove fan shroud
ENGINE
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Timing Belt: EM-21-35
* tools: bucket, socket: 19 mm, long breaker bar, socket adapter: 1/2" to 3/8"
* parts: timing belt, tensioner bearing, spring
- remove engine undercover
- drain coolant
- remove air cleaner, reserve tank, engine wire screw, clutch cable clamps
- loosen power steering adjusting bolt nut & mounting bolts
- remove power steering / air conditioner drive belt
- loosen alternator mounting bolts
- remove alternator / water pump drive belt
- remove upper hoses from radiator
- remove water pump pulley nuts
- remove fan shroud bolts & unlock from radiator
- remove fan shroud & fluid coupling with fan
- remove water pump pulley
- remove crankshaft pulley
- remove timing belt covers
- put arrow mark on timing belt for direction
- rotate crankshaft until "F" mark aligned with indicator on cylinder head cover
- loosen timing belt tensioner bolt, move tensioner far left, tighten bolt
- remove timing belt
MAINTENANCE
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Timing Belt: MA-7
* parts: GTK0182
Drive Belts: MA-7
* parts: 4K305, 5K490
Spark Plugs: MA-7-8
* tools: boot removal tool, spark plug socket: 16 mm (5/8"), plug gap gauge
* parts: spark plugs: NGK BKR6E-11
Spark Plug Wires & Distributor: MA-9
Air Filter: MA-9
* parts: air filter (K&N)
Engine Oil & Filter: MA-10
* tools: ratchet, extension (?), sockets: 12 14 mm, oil filter wrench: ?? mm
drain pan, funnel
* parts: drain plug gasket, engine oil: 10W-30 (5 qt), oil filter: M1-103A
- remove skid plate (4 bolts)
Engine Coolant: MA-10
* parts: rubber drain plug gasket
Catalytic Converter: MA-11
PCV system: MA-11
* parts: hoses
Charcoal Canister: MA-11
* parts: hoses
Fuel Filter: MA-12
* tools: wrench: 17 mm
* parts: fuel filter, copper gaskets
Fuel Tank Cap: MA-12
* parts: gasket
Fuel Lines: MA-12
Exhaust Pipe: MA-12
Oxygen Sensor: MA-13
* tools: oxygen sensor socket: 22 mm
EGR system: MA-13
Valve Clearance: MA-13
* tools: feeler gauge
Idle Speed: MA-14-15
* tools: tachometer
Clutch Pedal: MA-15-16
* parts: clutch cable, clip: ?? mm
Brake Linings & Drums (rear): MA-16
* tools: calipers
Brake Pads & Discs (front): MA-16-17
* tools: calipers
Brake Lines & Hoses: MA-17
Steering Linkage: MA-17-18
Steering Gear Box: MA-18-19
Transmission & Transfer Oil: MA-19
* parts: oil: 75W90 GL-3, aluminum crush washer
Differential Oil: MA-19
* parts: oil: 80W90 GL-5, aluminum crush washer
Wheel Bearing: MA-19-20
* parts: lithium based MP high temperature wheel bearing grease
Steering Knuckle & Linkage Chassis Grease: MA-20
* tools: grease gun
* parts: lithium base multipurpose grease, grease fitting caps
- upper & lower arm ball joints
- steering ball joints
- tie rods (2), relay rod (2), pitman arm, idler arm (?)
Propeller Shafts Grease: MA-21
* tools: grease gun
* parts: lithium base multipurpose grease, grease fitting caps
- front propeller shaft (2)
- rear propeller shaft (2)
Bolts & Nuts on Chassis & Body: MA-21
- front suspension
- power train
- rear suspension
- steering system
- wheel hub nuts