2002 Mitsubishi Fuso FE639 FE640 FE649 FG639 FG649 Truck Service Manual (P/N TWSE0101-H)

Looking for baseline factory documentation for a 2002 Mitsubishi Fuso FE or FG? This is the April 2001 OEM service publication, Pub No. TWSE0101-H, supplied as a 1,599-page PDF. It covers diagnosis, adjustment, removal, inspection, overhaul, and repair work rather than stopping at routine service information.

• Covers FE639, FE640, FE649, FG639, and FG649, with model coding, VIN decoding, chassis and engine number locations, and powertrain-label data.
• Separates repair procedures for the 4M50T2 DOHC and 4D34T3 OHV diesels, including compression and valve checks, engine removal, cylinder-head work, timing systems, pistons and liners or sleeves, crankshaft, and crankcase service.
• Maps the C4W30 clutch, M035S5 manual transmission, M035A4 automatic transmission, and TF3 transfer configurations, with clutch hydraulics, transmission testing, driveline removal, propeller-shaft overhaul, and balancing.
• Distinguishes FE and FG axle layouts and covers hubs, rotors and drums, kingpins, FG drive shafts and front differential, rear final drive, optional limited-slip differential, brakes, ABS, and steering.
• Includes ECU pinouts, wiring diagrams, connector-face and terminal charts, component tests and locations, plus frame and cab repair, air-conditioning and heater service, factory specifications, and special-tool listings.

Configuration and Factory Repair Depth

The powertrain table separates the factory combinations before parts or procedures are selected. FE640 is paired with the 4M50T2 and M035A4. FE639 and FE649 use the 4D34T3 with the M035S5 or M035A4 according to chassis configuration; FG639 is shown with the M035A4 plus TF3 transfer, while FG649 uses the M035S5 plus TF3. P2 and P3 propeller shafts, the R033T rear axle, D033H final drive, and D1H-modified FG front drive are identified as well.

The 4M50T2 chapter covers its twin-cam rocker and camshaft-frame layout, timing gears, balance shafts, cylinder liners, and split crankcase. The 4D34T3 material follows the pushrod valve train, timing gear and camshaft, cylinder sleeves, and flywheel assemblies with and without flywheel PTO. Both engines include removal, disassembly, inspection, measurement, reassembly, and adjustment procedures.

Manual-transmission repair goes through the M035S5 shifter, reverse idler, transmission body, drive pinion, mainshaft, countershaft, and control assemblies. M035A4 coverage is diagnostic and service focused: stall, time-lag, line-pressure and road tests, fluid service, unit removal, cooler and control work, replacement of designated service parts, and wiring. It is not presented as a full internal planetary-unit rebuild manual. FG chapters add transfer front and rear drive service plus propeller-shaft balancing.

Axle coverage includes FE hub/rotor and knuckle/kingpin work, FG hub/drum and drive-shaft service, differential work, rear final-drive setup, and limited-slip clutch-plate adjustment. Brake and steering chapters cover disc and drum systems, the master cylinder and Master Vac booster, vacuum pump, exhaust brake, ABS testing and bleeding, power-steering performance checks, booster variants, pump, drag link, and tie rod.

Two repair traps show the value of the factory procedures. On the 4M50T2, the camshaft frame and cylinder head were machined together at the factory and must stay as a matched pair; the camshaft gear is pressed off rather than hammered. In the ABS procedure, powering the system before primary-side bleeding is complete can move air into the secondary circuit, while excessive MUT-II actuator cycling can damage the hydraulic unit.

Diagrams, Diagnostics, Cab, and HVAC

Representative drawings include the 4M50T2 timing-gear and balance-shaft exploded view, Engine Electronic Control Unit pin configuration, automatic-transmission electrical wiring diagram, ABS electric circuit and part installation locations, 425 Water Temperature Gauge Circuit, and 810 Four-Wheel Drive Circuit. Circuit pages identify terminals, wire colors and sizes, grounds, harness areas, and linked component tests. The connector-configuration chart adds connector-face views and pin numbering for harness repair.

The electronic fuel-system groups cover MUT-II connection, trouble-code reading and erasing, service data, 4M50T2 actuator tests, ECU connector checks, intermittent-fault diagnosis, part locations, and wiring. Group 54 adds power and ground, starting and preheating, lighting, meter and warning circuits, four-wheel drive and PTO, starter/alternator repair, and component tests.

Cab coverage includes tilt and door-fit adjustment, fixed- and tilt-cab removal, mounts, front and crew-cab rear doors, mirrors, wipers, instrument panel, trim, and glass. The air-conditioner section documents refrigeration-system layout, troubleshooting, removal and installation, post-installation treatment, maintenance, cooling unit, and compressor/clutch work; the heater group covers hoses, controls, ducts, and the heater/blower assembly.

Maintenance schedules and lubrication charts are included. Factory reference data is then organized by assembly, including torque tables, capacities, lubricants and sealants, service limits, clearances, adjustment data, and electrical test values. Listed tools include belt-tension gauge MH062345, compression adapters MH063434 and MH061460, engine front hanger MH062781, and MUT-II accessories MB991499 and MB991500.

The PDF also contains additional Group 27 Rear Axle and Group 37 Steering publications, TWSE0304-27 and TWSE0304-37, plus the Group 55A Air-conditioner publication TWME0103-55A.

Major engine, driveline, cab, brake, ABS, and refrigerant work requires suitable support equipment and technical training. Follow the factory safety precautions or have the repair performed by a qualified technician.