2007 Hino 145 165 185 238 258LP 268 338 Chassis Workshop Manual

Description

2007 Hino Chassis Workshop Manual – 145, 165, 185, 238, 258LP, 268, 338 Series Trucks

This 2007 Hino chassis workshop manual delivers complete repair and service information for Hino 145, 165, 185, 238, 258LP, 268, and 338 series trucks equipped with J05D-TA, J08E-TA, and J08E-TB engines. Covering every major chassis system from clutch and transmission through differential, brakes, steering, axles, suspension, cab, and electrical wiring, this 2007 Hino 145 165 185 238 258LP 268 338 chassis workshop manual gives technicians and fleet operators the diagnostic charts, overhaul procedures, torque specifications, and component locator diagrams needed for accurate repair. Whether you are performing routine maintenance or a complete chassis system rebuild, this manual provides the factory-derived procedures and service limits that commercial truck work demands.

File Details

• Manual Type: Chassis Workshop Manual
• Brand: Hino
• Models Covered: HINO 145, 165, 185, 238, 258, 258LP, 268, 338
• Engines Covered: J05D-TA, J08E-TA, J08E-TB
• Publication Numbers: S1-UNAE03A 1/2, S1-UNAE03A 2/2 (U.S.A.); S1-CNAE03A 1/2, S1-CNAE03A 2/2 (Canada)
• Publication Date: ‘06.02 (June 2002)
• Language: English
• Page Count: 1163 pages
• File Format: PDF
• Publisher: Hino Motors Sales U.S.A., Inc.

Chapters Covered

• General Introduction – General Precautions, Towing, Clean Air Act, Vehicle Identification Number, Vehicle Certification Label, Vehicle Noise Emission Control Information, Engine Serial Numbers, Chassis Serial Number, How to Use This Workshop Manual, Definition of Terms
• Clutch Equipment – Clutch Main Unit, Clutch Control
• Transmission Equipment – Transmission Main Unit, Transfer Main Unit, Automatic Transmission, P.T.O. (Power Take-Off), Transmission / Transfer Control
• Propeller Shaft Equipment – Propeller Shaft
• Differential Equipment – Differential Carrier
• Brake Equipment – Service Brake, ABS & ASR, ES Start (Easy & Smooth Start) System, Exhaust Brake, Retarder Brake, Parking Brake
• Steering Equipment – Steering Unit, Power Steering
• Axle Equipment – Front Axle, Rear Axle, Wheel & Tire
• Suspension Equipment – Suspension
• Chassis Equipment – Chassis Frame, Coupler (5th Wheel), Pintle Hook
• Cab Equipment – Cab
• Electrical Equipment – Electric Wire, Hybrid System
• Engine Control, Fuel Control, Brake Control, Suspension Control, Cab Equipment Control, Others

This Hino chassis workshop manual organizes its content the way a working technician actually approaches a repair job. Each chapter begins with an index and a troubleshooting guide before moving into component-specific overhaul procedures. The general introduction establishes the safety protocols, towing procedures, VIN decoding, and documentation standards that frame every job covered in the manual. From there, individual systems chapters walk through disassembly, inspection, repair, and reassembly in sequence, with the relevant specifications and service limits placed directly alongside the procedures that require them. Component locator pages, exploded views, and hydraulic or wiring diagrams support the text throughout, so you are never working from description alone.

Comprehensive Chassis System Coverage

The breadth of this 2007 Hino 145 165 185 238 258LP 268 338 chassis workshop manual is one of its strongest assets. Clutch coverage spans the clutch main unit and clutch control, including master cylinder and release bearing service. Transmission chapters address the Eaton FS 4205, FS 5406, and FS 6406 manual transmissions alongside the Aisin 450-43LE and Allison 2200RDS, 2500RDS, and 3000RDS automatic transmissions, with disassembly, inspection, and reassembly procedures for each. Differential carrier coverage includes the Meritor MS-113 and the RS-13, RS-17, RS-19, RS-21, and RS-23 series carriers, with backlash adjustment, tooth contact pattern checking, and bearing preload procedures. Brake chapters cover both hydraulic and full air brake systems, including the Hydro-Max booster, ABS modulators, wheel brake overhaul, air dryer service, brake valves, relay valves, spring brake chambers, and automatic slack adjusters.

Steering coverage includes the TRW TAS40 and TAS65 integral power steering gears, with poppet valve adjustment, input shaft seal replacement, sector shaft adjustment, and complete reseal procedures. Front axle chapters detail the Meritor MFS-6, MFS-8, MFS-10, and MFS-12 non-drive steer axles, covering king pin bushings, knuckle end play, wheel bearing adjustment, tie rod ends, and cross tube service. Rear axle coverage includes wheel end disassembly and assembly for the MS-12-113 and RS series axles, with oil-lubricated wheel bearing adjustment procedures. Suspension chapters cover leaf spring and air suspension systems, and the chassis frame, cab, and electrical sections round out the manual with body and wiring service information.

Diagnostics and Troubleshooting

Every major system in this Hino 145 165 185 238 258LP 268 338 chassis workshop manual includes a troubleshooting section that maps symptoms to possible causes and recommended remedies. Clutch dragging, slipping, and noise are covered with specific diagnostic steps. Transmission gear slip-off, difficult engagement, and abnormal noise are charted by cause and correction. Brake system symptoms from insufficient braking to pedal pulsation are addressed in both hydraulic and full air configurations. ABS and ASR systems include diagnosis trouble code tables, blink code procedures, and component testing instructions. Differential carrier noise and oil leak diagnosis is laid out in flowchart form. This diagnostic structure means the manual is useful not just for planned overhaul work but for tracing an active fault to its source.

Specifications and Service Data

Throughout this 2007 Hino chassis workshop manual, specifications are presented in the units technicians need: tightening torques in N·m, kgf·cm, and lbf·ft; clearances and wear limits in mm and inches; fluid capacities in liters and U.S. pints; and pressures in kPa, kgf/cm², and lbf/in². Clutch facing thickness limits, flywheel runout, pressure plate misalignment, and pilot bearing service data are given for each clutch variant. Transmission end play, bearing preload, and shift rail torque values are specified. Differential backlash settings, pinion bearing preload, ring gear runout, and gear tooth contact pattern examples are included. Wheel bearing end play, king pin bushing dimensions, and steering gear rotating torque values are all documented so you can measure, compare, and decide.

Procedures Built for Real Truck Work

This Hino chassis workshop manual assumes the reader is working on a truck, not a bench. Procedures account for vehicle conditions: parking brake application, wheel blocking, safety stand placement, and the order of component removal to avoid damage. Overhaul sections include special tool callouts with part numbers where Hino specifies them, and cautions appear where a wrong step could damage a component or create a safety risk. The manual also includes general precautions that apply across all systems, covering safe handling of fluids, protection of electronic components during welding, and proper battery service. For any technician new to these Hino models, the general introduction and the per-chapter troubleshooting guides provide the orientation needed to work efficiently.

Why This Manual Matters

Commercial truck repair leaves little room for guesswork. A clutch installed without the correct release bearing clearance will drag or slip. A differential assembled without proper backlash will whine and fail early. A steering gear adjusted without the specified preload will feel vague or bind. This 2007 Hino 145 165 185 238 258LP 268 338 chassis workshop manual provides the measured values, sequences, and diagnostic logic that turn a repair into a reliable result. It covers multiple model years and configurations in one document, so a shop servicing a mixed fleet of Hino 145, 165, 185, 238, 258LP, 268, and 338 trucks has a single reference that addresses the clutch, transmission, driveline, brake, steering, axle, suspension, cab, and electrical systems across the range.

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Instant PDF Delivery

This Hino chassis workshop manual is delivered as an instant PDF download after purchase. No shipping, no waiting for a physical book. The file can be viewed on any device that reads PDFs, from a shop desktop to a tablet or laptop, and pages can be printed for use at the vehicle when a paper copy is more practical. Having the manual in digital form also means you can search within the document, jump between the troubleshooting guide and the relevant overhaul procedure, and keep the full 1163 pages accessible without carrying a binder. Whether you are maintaining one truck or running a fleet, this 2007 Hino 145 165 185 238 258LP 268 338 chassis workshop manual gives you the information needed to diagnose, repair, and maintain these vehicles correctly.