Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Toyota Hilux Pickup 1988-1995. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your truck like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Toyota Hilux 1988-1995 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

EXCERPT:

TRANSFER – Component Parts (Rear Output Shaft Assembly)

DISASSEMBLY OF REAR OUTPUT SHAFT ASSEMBLY
1. MEASURE DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10 – 0.25 mm
(0.0039 – 0.0098 in.)
Maximum clearance: 0.25 mm (0.0098 in.)
If the clearance exceeds the limit, replace the drive sprocket.
2.–1 (MT)
REMOVE HIGH AND LOW HUB SLEEVE ASSEMBLY
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the hub sleeve and shifting keys.
(c) Using a press, remove the clutch hub, key springs and key retainer.
2.–2 (AT)
REMOVE HIGH AND LOW HUB SLEEVE ASSEMBLY
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the hub sleeve.
(c) Using a press, remove the clutch hub.
3.–1 (w/ A.D.D.)
REMOVE REAR BEARING, SPACER AND DRIVE SPROCKET WITH FRONT DRIVE HUB SLEEVE ASSEMBLY
(a) Using SST and a press, remove the bearing.
SST 09950–00020
(b) Remove the spacer and ball.
(c) Remove the drive sprocket with front drive hub and hub sleeve.
(d) Remove the needle roller bearing.
(e) Remove the synchronizer ring.
3.–2 (w/o A.D.D.)
REMOVE REAR BEARING, SPACER AND DRIVE SPROCKET WITH FRONT DRIVE HUB SLEEVE ASSEMBLY
(a) Using SST and a press, remove the bearing.
SST 09950–00020
(b) Remove the spacer and ball.
(c) Remove the drive sprocket with front drive hub and hub sleeve.
(d) Remove the needle roller bearing.
4. (w/ A.D.D.)
REMOVE SHIFTING KEYS AND KEY SPRINGS FROM FRONT DRIVE HUB ASSEMBLY
Using screwdriver, remove the two shifting key springs and three shifting keys.

INSPECTION OF REAR OUTPUT SHAFT
ASSEMBLY
1. INSPECT REAR OUTPUT SHAFT
Using a micrometer, measure the outer diameter of the rear output shaft journal surface.
Minimum diameter:
Part A 27.98 mm (1.1016 in.)
B 36.98 mm (1.4559 in.)
2. CHECK OIL CLEARANCE OF DRIVE SPROCKET
Using a dial indicator, measure the oil clearance between the sprocket and shaft with the needle roller bearing installed.
Standard clearance: 0.010 – 0.055 mm
(0.0004 – 0.0022 in.)
Maximum clearance: 0.055 mm (0.022 in.)
If the clearance exceeds the limit, replace the drive sprocket, rear output shaft or needle roller bearing.
3. MEASURE CLEARANCE OF FRONT DRIVE SHIFT FORK AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the front drive shift fork and hub sleeve.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.
4. MEASURE CLEARANCE OF HIGH AND LOW SHIFT FORK AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the high and low shift fork and hub sleeve.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.
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