---===SME_1007_00128_0001.djvu===---
FOREWORD 
This Shop Manual is published for the information and guid- 
ance of personnel responsible for maintenance of Mitsubishi 
ROSA series bus chassis, and includes procedures for ad- 
justment and maintenance services. We earnestly look for- 
ward to seeing that full use is made of this manual in order to 
services vehicles correctly and not waste time. 
In addition to this manual, you can also refer to the following 
manuals when performing services: 
• Diesel Engine ROSA BE6 4D3 
........ ....... ............ ....... .... Pub. No. TWDE0217 
• Petrol Engine ROSA BC6 4G64 
........ ....... ............ ....... .... Pub. No. TWDE9507-1 
• Chassis ROSA BE6. BC6 
........ ....... ............ ........... Pub. No. TWSE0329 
• Electrical ROSA BE6. BC6 
........ ....... ............ ....... .... Pub. No. THSE0314 
For more details, please consult your nearest authorized 
Mitsubishi dealer or distributor. 
Kindly note that the specifications and maintenance service 
figures are subject to change without prior notice in line with 
improvement which will be effected from time to time in the 
future. 
Applicable models 
BE 
BC 
Dec. 2003 
©2003 Mitsubisi Fuso Truck & Bus Corporation Printed in Japan 
GROUP INDEX 
HOW TO READ THIS MANUAL 
GENERAL ....... ........................ ......... 
CLUTCH .......... ........................ ......... 
MANUAL TRANSMISSION..... ......... 
PROPELLER SHAFT.. ..................... 
FRONT AXLE <RIGID>........... ......... 
FRONT AXLE ................. ......... 
<INDEPENDENT> 
REAR AXLE ................ ..................... 
WHEEL AND TIRE.................. ......... 
FRONT SUSPENSION <RIGID>...... 
FRONT SUSPENSION............ ......... 
<INDEPENDENT> 
REAR SUSPENSION .. ..................... 
BRAKE ............ ........................ ......... 
ANTI-LOCK BRAKE SYSTEM ........ 
PARKING BRAKE................... ......... 
STEERING <BALL NUT> ....... ......... 
STEERING <RACK AND PINION>.. 
FRAME ............ ........................ ......... 
HEATER AND AIR-CONDITIONER 
BODY .. ........................ ..................... 
---===SME_1007_00128_0001.djvu===---
FOREWORD 
This Shop Manual is published for the information and guid- 
ance of personnel responsible for maintenance of Mitsubishi 
ROSA series bus chassis, and includes procedures for ad- 
justment and maintenance services. We earnestly look for- 
ward to seeing that full use is made of this manual in order to 
services vehicles correctly and not waste time. 
In addition to this manual, you can also refer to the following 
manuals when performing services: 
• Diesel Engine ROSA BE6 4D3 
........ ....... ............ ....... .... Pub. No. TWDE0217 
• Petrol Engine ROSA BC6 4G64 
........ ....... ............ ....... .... Pub. No. TWDE9507-1 
• Chassis ROSA BE6. BC6 
........ ....... ............ ........... Pub. No. TWSE0329 
• Electrical ROSA BE6. BC6 
........ ....... ............ ....... .... Pub. No. THSE0314 
For more details, please consult your nearest authorized 
Mitsubishi dealer or distributor. 
Kindly note that the specifications and maintenance service 
figures are subject to change without prior notice in line with 
improvement which will be effected from time to time in the 
future. 
Applicable models 
BE 
BC 
Dec. 2003 
©2003 Mitsubisi Fuso Truck & Bus Corporation Printed in Japan 
GROUP INDEX 
HOW TO READ THIS MANUAL 
GENERAL ....... ........................ ......... 
CLUTCH .......... ........................ ......... 
MANUAL TRANSMISSION..... ......... 
PROPELLER SHAFT.. ..................... 
FRONT AXLE <RIGID>........... ......... 
FRONT AXLE ................. ......... 
<INDEPENDENT> 
REAR AXLE ................ ..................... 
WHEEL AND TIRE.................. ......... 
FRONT SUSPENSION <RIGID>...... 
FRONT SUSPENSION............ ......... 
<INDEPENDENT> 
REAR SUSPENSION .. ..................... 
BRAKE ............ ........................ ......... 
ANTI-LOCK BRAKE SYSTEM ........ 
PARKING BRAKE................... ......... 
STEERING <BALL NUT> ....... ......... 
STEERING <RACK AND PINION>.. 
FRAME ............ ........................ ......... 
HEATER AND AIR-CONDITIONER 
BODY .. ........................ ..................... 
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1 
HOW TO READ THIS MANUAL 
HOW THIS MANUAL IS STRUCTURED ............................................. 2 
TERMS AND UNITS ............................................................................. 12 
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HOW TO READ THIS MANUAL 
2 
How This Manual is Structured 
23915 
23929 
21 
27 
• 
• 
• 
23916 
23917 
I'm here to explain how to use 
this manual. To get the most out 
of your manual, follow along 
carefully and read all the notes 
given by my assistant. 
Each group is divided into 
five parts, as shown 
below. 
Specifications 
Specifications, oil quantities, and 
other information pertaining to 
system components. 
Structure and Operation 
Information on the structure and 
operation of the overall system 
and its components. 
Troubleshooting 
An item-by-item guide to fault 
symptoms and their probable 
causes. 
On-Vehicle Inspection and 
Adjustment 
Instructions for on-vehicle inspec- 
tion and adjustment operations. 
Service Instructions 
(See the next and subsequent 
pages.) 
The service instructions are the most important 
parts of this manual. Starting on the next page, 
you'll learn more about them. 
This manual is divided into groups, 
with one group for each main area of 
the vehicle. (An index of groups is 
given on page 2.) 
By way of example, let's look at 
Group 21, which covers the clutch. 
We're here 
to help you. 
Group 21 
Group 27 
Group 31 
GROUP 21: CLUTCH 
SPECIFICATIONS . ... . . ... . . ............................................... 
STRUCTURE AND OPERATION ................................... 
TROUBLESHOOTING ................................................... 
ON-VEHICLE INSPECTION AND ADJUSTMENT 
Clutch Fluid Replacement and Air Bleeding ................... 
Inspection of Clutch Booster Functionality .................... 
Clutch Pedal Play ............................................................... 
CLUTCH PEDAL ............................................................ 
CLUTCH MASTER CYLINDER ...................................... 
CLUTCH BOOSTER AND CLUTCH MASTER 
CYLINDER...................................................................... 
CLUTCH POWER CYLINDER ........................................ 
CLUTCH-PROPER ........................................................ 
CLUTCH HOUSING ....................................................... 
CLUTCH DISC WEAR INDICATOR SWITCH ................. 
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3 
23918 
26310 
20244 
1 
2 
Now, let's take a 
detailed look at the 
service instructions. 
Please follow along 
carefully. 
CLUTCH PEDAL ................................................... 
CLUTCH MASTER CYLINDER ............................. 
CLUTCH BOOSTER AND CLUTCH MASTER 
CYLINDER ............................................................. 
CLUTCH POWER CYLINDER .............................. 
CLUTCH-PROPER ................................................ 
CLUTCH HOUSING .............................................. 
ON-VEHICLE INSPECTION AND ADJUSTMENT 
• Clutch Fluid Replacement and Air Bleeding ........ 
• Inspection of Clutch Booster Functionality ......... 
• Clutch Pedal Play ................................................... 
The service instructions consist of the parts shown 
below. Starting on page 6, these parts are described in 
detail in order of the circled numbers. 
GROUP 21: CLUTCH 
SPECIFICATIONS ................................................. 
Service procedures 
Name of system or 
assembly 
Key numbers 
List of part 
names 
Group number 
This appears on each 
right-hand page. 
4 Lubricants, fluids 
and/or sealants 
This table shows the required 
brands and quantities of oils, 
greases and/or sealants. 
5 Special tools 
6 Service 
procedure 
1 Exploded view 
This shows the system 
or assembly in its dis- 
assembled form. 
2 Service 
standards 
3 Tightening 
torques 
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HOW TO READ THIS MANUAL 
4 
23922 
26312 
20245 
23921 
26311 
3 
4 
5 
Look at the exploded view 
first; it gives an overview of 
the system or assembly. 
All other information is 
given in parts 2 to 6. 
Basically, you should find the information 
you need from parts 2 to 6 as you 
perform the service procedure. 
Sotheparts2to6can 
be a kind of data book. 
But how should I find 
the information I need? 
I'll show you on the 
next page. 
I see... First I look at the exploded 
view, then I look at parts 2 to 6. 
---===SME_1007_00128_0007.djvu===---
5 
26314 
20252 
26313 
6 
Find the information you need using 
the key numbers. 
For example, let's assume you're 
assembling the clutch and need the 
tightening torque for the bolt 1. 
To find the tightening torque, 
just look up key number 1 in the 
"Tightening torques" table. 
I see... The key numbers for the 
exploded view match the key 
numbers on other parts of the page. 
To help you find information quickly: 
Tightening torques are 
marked with T . 
Lubricants, fluids and seal- 
ants are marked with . 
And every key number that ap- 
pears in the service procedure is 
enclosed with a square. 
---===SME_1007_00128_0008.djvu===---
HOW TO READ THIS MANUAL 
6 
2 
3 
8 
6 
5 
1 
1 
T 
2 
3 
12 
7 
8 
6 
11 
5 
X 
23925 
23927 
23928 
1 
8 
23926 
P 
P 
1 
T 
12 
7 
11 
X 
13 
14 
9 
4 
10 
13 
14 
9 
4 
10 
Exploded view 
Explanatory notes for the 
exploded view are given 
below. Explanatory notes 
for the parts list are given 
on the facing page. 
CLUTCH-PROPER <C5> 
Pressure Plate-and-Lever Assembly 
P Pre-disassembly operations 
P21-44 
P Disassembly sequence 
Bolt 
Lock plate 
Support nut 
Pressure spring 
Pressure spring cap 
Return spring 
Release lever plate 
Clutch cover 
Release lever pin 
Support lever pin 
Support lever 
Release lever 
Bushing 
Pressure plate 
1 
2 
3 
4 
5 
6 
7 
8 
9 
10 
11 
12 
13 
14 
X: Non-reusable part 
NOTE 
Do not remove the bushing 13 
unless it is defective. 
P Assembly sequence 
Reverse the order of disassembly. 
Repair kit : Clutch release 
Lever kit 
P Post-assembly Inspection 
and adjustment 
P21-44 
This mark indicates a part 
that cannot be reused. 
: Indicates dowel pin. 
So parts without T marks don't 
have specified tightening torques ? 
No, they don't. But every bolt and nut must be 
tightened to a standard torque. A T mark shows 
either that the part must be tightened to a torque 
other than the standard torque or that the standard 
torque cannot be determined from the part's shape 
or markings. 
Standard tightening torques are explained 
at the bottom of the next page. 
Pressure Plate-and-Lever Assembly 
This mark indicates that 
lubricant or sealant must 
be applied to the part. 
This mark indicates 
that a tightening torque 
is specified for the part. 
The key number enclosed 
with a square indicates 
that the part is men- 
tioned in the service 
procedure. 
---===SME_1007_00128_0009.djvu===---