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7
Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
1. Specifications.......................................................................................... 7-12. Structure .................................................................................................. 7-2
2.1 Standard Model (with Drum Brake) .........................................................................7-22.2 Option Model (with Wet Disc Brake)........................................................................7-3
3. Removal and Installation........................................................................ 7-43.1 Front Wheels (Common to Standard and Option Truck) .........................................7-43.2 Shoe and Lining (Standard Truck)...........................................................................7-73.3 Wet Disc Brake Assembly (Option Truck) ...............................................................7-83.4 Front Axle Assembly (Standard Truck)....................................................................7-93.5 Front Axle Assembly (Option Truck)...................................................................... 7-133.6 Removal and Installation of Each Assembly (Standard Truck) ............................. 7-173.7 Removal and Installation of Each Assembly (Option Truck) ................................. 7-20
4. Disassembly and Reassembly............................................................. 7-214.1 Tube Assembly and Final Reduction (Standard Truck)......................................... 7-214.2 Tube Assembly and Final Reduction (Option Truck)............................................. 7-314.3 Wear Gauge for Wet Disc Brakes ......................................................................... 7-454.4 Reduction Differential (Common to Standard and Option Truck) .......................... 7-46
5. Troubleshooting (Common to Standard and Option Truck) ............. 7-616. Service Data........................................................................................... 7-62
7-1
FRONT AXLE AND REDUCTION DIFFERENTIAL
Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
1. Specifications
ItemTruck model
P8000 P9000 P10000 P11000 P12000PD8000 PD9000 PD10000 PD11000 PD12000
Power transmission device
Reduction gearsGear type Hypoid gear
Reduction gear ratio 5.667
Final reduction gears
Gear type Planet gear
Reduction gear ratio 4.125
Differential gears
Case type Banjo type
Gear type and number
Large Straight bevel gear x 2
Small Straight bevel pinion x 2
Traveling deviceFront axle type Full-floating axle tube
Suspension sys-tem Front wheel Built-in frame
7-2
FRONT AXLE AND REDUCTION DIFFERENTIAL
2. Structure2.1 Standard Model (with Drum Brake)
The front axle assembly is bolted to the frame at theframe supports.The reduction differential is double-reduction gearwhich is composed of an input flange and reductionpinion, reduction pinion and reduction gear.Transmission power generated from the center shaft,reduces power at the final reduction, and the powergoes out to the axle shaft.
The axle shaft relays this power to the wheel hubs,which causes the wheels to rotate, and the lift truck tomove.The wheel brake, which is connected to the axle tubevia the frame support, produces braking force by gen-erating friction between the shoe and drum.
1 Frame support2 Universal joint3 Input flange4 Drive gear5 Driven gear6 Reduction pinion
7 Reduction gear8 Differential pinion9 Differential gear
10 Center shaft11 Planet carrier12 Planet gear
13 Ring gear14 Axle shaft15 Wheel hub16 Wheel brake drum17 Wheel Brakes
Wheel hub and brake
Final reduction
Reduction differential
116 1715
2
3
4
56
7810
12
1311
149
215693
7-3
FRONT AXLE AND REDUCTION DIFFERENTIAL
2.2 Option Model (with Wet Disc Brake)
1 Frame support2 Universal joint3 Input flange4 Drive gear5 Driven gear6 Reduction pinion
7 Reduction gear8 Differential pinion9 Differential gear
10 Center shaft11 Planet carrier12 Planet gear
13 Ring gear14 Axle shaft15 Wheel hub16 Wet disc brake assembly
Wheel hub and brake
Final reduction
Reduction differential
11615
2
3
4
56
7810
12
1311
149
215693
7-4
FRONT AXLE AND REDUCTION DIFFERENTIAL
3. Removal and Installation3.1 Front Wheels (Common to Standard and Option Truck)3.1.1 Preparation(1) Block the rear wheels.
(2) Loosen the wheel nuts by two full turns.
(3) Raise the front wheels off the ground by eithermethod below.
(4) Stop the engine.
Raising the front wheels(a) Method using a crane
Hitch slings to the eye-bolts at both ends of thetop cross member on the outer mast, and thenlift the front end of the lift truck with a hoist.
(b) Using hydraulic systemFirstly, tilt the mast all the way back and placewood blocks under the mast. Then, tilt the mastforward to raise the front wheels.
213685
215907
After the front wheels are raised by either method, be sure to place jack stands under the frame to support it.
215908
7-5
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.1.2 RemovalRemoval sequence (single tires)
Removal sequence (double tires)
Suggestions for removal
In the case of double wheels, remove the outer wheelnuts and outer wheel. Then, remove the inner wheelnuts and the inner wheel.
1 Wheel nuts2 Front wheels
1
2
215694
1 Extension valves2 Wheel nuts (outer)3 Front wheels (outer)4 Wheel nuts (inner)5 Front wheels (inner)
1
2
3
5
4
216935
216936
Inner wheel nuts
Outer wheel nuts
7-6
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.1.3 InstallationFor installation, follow the removal sequence inreverse by referring to the following instructions below.(1) Wheel nuts
(a) Thoroughly clean the fitting surfaces of thewheel bolts and nuts using a metal cleaningsolvent. Make sure all of the oil is cleaned offthe fitting.
(b) Evenly tighten the wheel nuts with a torquewrench to the specified torque so that thewheels do not wobble during operation. Use atorque wrench.
(2) Retighten wheel nuts
(a) After installation, perform a test drive for 10minutes to check for proper performance of for-ward/reverse drive and the braking system.
(b) Retighten all the wheel nuts with a torquewrench to the specified torque.
(3) Do not forget to tighten the inner wheel nuts whenretightening the outer wheel nuts of the doubletires.
Unit: N·m (kgf·m) [lbf·ft]
Tightening torquesingle tires double tires
600 (61.2) [442.8]
Follow the proper tightening order by referring to the illustration on the right. Tighten the wheel nuts with a torque wrench.
16
4
2 5
3
215695
216989
Loosen the outer nut
Tighten the inner nut
Tighten the outer nut
Tightening sequence of double tires
7-7
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.2 Shoe and Lining (Standard Truck)Note: Removal and installation of brake shoes and
linings can be done by removing the wheelbrake drum (the work can be done without re-moving the axle shaft and wheel hub.) This sec-tion describes the removal and installationprocedure of the shoes and linings. Refer to "9BRAKE SYSTEM" for more details.
3.2.1 PreparationRemove the front wheels. For removing front wheels,refer to the previous section.
3.2.2 Removal(1) Brake drums
Evenly tighten the two jack bolts into place asshown in the illustration, and remove the brakedrum.
(2) Brake shoeUse the notch in the wheel hub to remove shoeand lining. Refer to "9 BRAKE SYSTEM" for moredetails.
3.2.3 Inspection and AdjustmentBrake drums
(a) Thoroughly clean and remove any dirt on thefriction surface with a clean rag.
(b) If oil or grease adheres to the lining or drum,use a brake cleaner.
3.2.4 InstallationBrake drumsEvenly tap the wheel fitting surface to secure the brakedrum in place.
Unit: mm (in.)
Jack bolt M14 x 1.5 Nominal length:50 (1.97)
215696
Return springinstallingpoint
Hold down spring215909
Concaved pointof wheel hub
7-8
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.3 Wet Disc Brake Assembly (Option Truck)3.3.1 PreparationRemove the front wheels. For removing front wheels,refer to "3.1 Front Wheels (Common to Standard andOption truck)".
3.3.2 RemovalFor removing the wet disc brake assembly, refer to "9.BRAKE SYSTEM".
3.3.3 Inspection and AdjustmentFor inspection and adjustment of wet disc brakeassembly, refer to "9. BRAKE SYSTEM".
3.3.4 InstallationFor installing the wet disc brake assembly, refer to "9.BRAKE SYSTEM".
7-9
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.4 Front Axle Assembly (Standard Truck)3.4.1 Preparation(1) Block the rear wheels.
(2) Remove the mast assembly. For removing mastassembly, refer to "12 MAST AND FORKS."
(3) Place a proper-sized container under the fronthousing to collect oil. Drain the oil from the frontaxle by removing the oil filler plug and the drainplug from the front housing.
(4) Remove the front wheels. For removing frontwheels, refer to "3.1 Front Wheels."
(5) Place jack stands under the frame to support it.For raising the front wheels, refer to "3.1 FrontWheels."
(6) Support the front axle housing with a mission jack.
Unit: liter (cu.in.)
Oil capacity 7.9 (482.1)
215698
Unit: kg (lb)
Item
Truck modelP8000, P9000 P10000, P11000, P12000
PD8000, PD9000
PD10000, PD11000, PD12000
Front axle weight
Approximately 440 (970)
Approximately 460 (1014)
Be sure to support the front axle housing securely to prevent it from falling because the differential is not located in the center of the front axle.
215989
Mission jack
7-10
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.4.2 Removal
215699
1
2
3
Removal sequence1 Brake pipe 2 Universal joint 3 Front axle assembly
7-11
FRONT AXLE AND REDUCTION DIFFERENTIAL
Suggestions for Removal
(1) Brake pipeAfter removing the brake pipe, close the brakepipe connector with tape to prevent dust or foreignsubstances from entering.
(2) Universal joint
(a) Using a rope, hold the universal joint to thetransmission.
(b) Separate the universal joint from the inputflange side of the reduction differential.
(3) Front axle assembly
(a) Place jack stands under the transmission toprevent it from falling.
(b) Remove the connecting bolts between thetransmission and the front axle.
(c) Remove mounting nuts from each side of theaxle support, then remove the front axleassembly.
Note: The two bolts (shown in the right illustration) onthe left support contact to the brake hose andconnector. Displace or remove the brake hoseand connector to remove the bolts.
Transmission oil will drain if the universal joint sepa-rates from the transmission.
Input flange side ofreduction differential
Remove the bolt on theinput flange side
Universal joint
215700
Front axle
Transmission
Connecting bolts
Place jack stand 215701
215910
Mounting nut
217317
The bolt contacts
Connector
Bolt
Brake hoseConnector
Bolt
Brake hose
Top view
7-12
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.4.3 InstallationFor installation, follow the removal sequence inreverse.
Suggestions for Installation
Bleeding the air out of the brake oil circuit Bleed the air out of the brake oil circuit before install-ing the mast assembly. For bleeding air, refer to "9 BRAKE SYSTEM."
Tightening torque for main partsUnit: N·m (kgf·m) [lbf·ft]
Item All truck model
Mounting bolts on input flange side
54.0 to 63.8(5.5 to 6.5)
[39.9 to 47.1]Apply LOCTITE 242.
Connecting bolts between the transmission and the front axle
59.8 ± 5.98(6.1 ± 0.6)[44.1 ± 4.4]
Axle support mounting nuts94 ± 69
(70.8 ± 7.0)[512.2 ± 50.9]
7-13
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.5 Front Axle Assembly (Option Truck)3.5.1 Preparation(1) Block the rear wheels.
(2) Remove the mast assembly. For removing mastassembly, refer to "12 MAST AND FORKS."
(3) Place a proper-sized container under the fronthousing to collect oil. Drain the oil from the frontaxle by removing the oil filler plug and the drainplug from the front housing.
(4) Remove the front wheels. For removing frontwheels, refer to "3.1 Front Wheels."
(5) Place jack stands under the frame to support it.For raising the front wheels, refer to "3.1 FrontWheels."
(6) Remove the drain plug that installed on the backof right and left wet disc brake assemblies. Then,drain brake oil.
(7) Support the front axle housing with a mission jack.
Unit: liter (cu.in.)
Oil capacity 7.9 (482.1)
215698
217163
Unit: kg (lb)
Item All truck model
Front axle weight Approximately438 (965.8)
Be sure to support the front axle housing securely to prevent it from falling because the differential is not located in the center of the front axle.
215989
Mission jack
7-14
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.5.2 Removal
215699
12
4
3
Removal sequence1 Brake pipe2 Universal joint
3 Cooling return horse4 Front axle assembly
7-15
FRONT AXLE AND REDUCTION DIFFERENTIAL
Suggestions for Removal
(1) Brake pipeAfter removing the brake pipe, close the brakepipe connector with tape to prevent dust or foreignsubstances from entering.
(2) Cooling return horseAfter removing the cooling return horse, close thecooling return horse connector with tape to pre-vent dust or foreign substances from entering.
(3) Universal joint
(a) Using a rope, hold the universal joint to thetransmission.
(b) Separate the universal joint from the inputflange side of the reduction differential.
(4) Front axle assembly
(a) Place jack stands under the transmission toprevent it from falling.
(b) Remove the connecting bolts between thetransmission and the front axle.
(c) Remove mounting nuts from each side of theaxle support, then remove the front axleassembly.
Note: The two bolts (shown in the right illustration) onthe left support contact to the brake hose andconnector. Displace or remove the brake hoseand connector to remove the bolts.
Transmission oil will drain if the universal joint sepa-rates from the transmission.
Input flange side ofreduction differential
Remove the bolt on theinput flange side
Universal joint
215700
Front axle
Transmission
Connecting bolts
Place jack stand 215701
215910
Mounting nut
217317
The bolt contacts
Connector
Bolt
Brake hoseConnector
Bolt
Brake hose
Top view
7-16
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.5.3 InstallationFor installation, follow the removal sequence inreverse.
Suggestions for Installation
Bleeding the air out of the brake oil circuit Bleed the air out of the brake oil circuit before install-ing the mast assembly. For bleeding air, refer to "9 BRAKE SYSTEM."
Tightening torque for main partsUnit: N·m (kgf·m) [lbf·ft]
Item All truck model
Mounting bolts on input flange side
54.0 to 63.8(5.5 to 6.5)
[39.9 to 47.1]Apply LOCTITE 242.
Connecting bolts between the transmission and the front axle
59.8 ± 5.98(6.1 ± 0.6)[44.1 ± 4.4]
Axle support mounting nuts94 ± 69
(70.8 ± 7.0)[512.2 ± 50.9]
7-17
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.6 Removal and Installation of Each Assembly (Standard Truck)3.6.1 Preparation(1) Remove the front axle assembly. For removing
the front axle assembly, refer to "Preparation" of"Front Axle Assembly (Standard Truck)".
3.6.2 Removal
215702
The numbers indicate the removal sequence.
5
4
1
2
3
1 Axle shaft2 Tube assembly and final reduction3 Center shaft
4 Reduction differential assembly5 Axle housing
7-18
FRONT AXLE AND REDUCTION DIFFERENTIAL
Suggestions for Removal
(1) Tube assembly and final reduction
(a) Set a wire rope between the support and thebrake part, and lift the wire rope taut with ahoist.
(b) Remove mounting bolts, and remove the chainassembly while lifting. Then, the center shaftwill be simultaneously disengaged.
Note: Pay attention to the axle housing as the final re-duction ring gear may remain attached to theaxle housing.
(2) Reduction differential assembly
(a) Place the front axle housing with the differentialside facing upward.
(b) Install two eye bolts at the positions indicatedby the "a" in the illustration, attach wire ropesto the eye bolts, and lift the wire ropes taut witha hoist.
(c) Remove the mounting bolts, and install the twojack bolts at the positions indicated by the "b"in the illustration, and evenly tighten the twobolts until the reduction differential assembly isremoved.
Unit: kg (lb)
Item
Truck modelP8000,P9000 P10000,P11000,P12000
PD8000, PD9000
PD10000,PD11000, PD12000
Tube Assembly weight
Approximately147 (324)
Approximately161 (355)
215703
Ring gear
215911
Threaded hole for the eye bolt M12 x 1.25
Unit: mm (in.)
Jack bolt M12 x 1.25Approximate nominal length: 30 (1.18)
a b
a
b215704
Mounting bolt
7-19
FRONT AXLE AND REDUCTION DIFFERENTIAL
(d) Lift the reduction differential assembly using ahoist, and remove the assembly from the frontaxle housing.
3.6.3 InstallationTo install, follow the removal sequence in reverse. Suggestions for Installation
(1) Reduction differential assembly(a) Thoroughly clean the mounting surface, and
apply a liquid gasket onto the surface.
(b) Tighten the mounting bolts to the specifiedtorque.
(2) Tube assembly
(a) Tighten the mounting bolts to the specifiedtorque.
Unit: kg (lb)
Reduction DifferentialAssembly weight 88 (194)
215705
Liquid gasket ThreeBond #1104or equivalent
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque108 ± 9.8
(11.0 ± 0.1)[79.7 ± 7.2]
215706
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 300 (30.6) [221.4]
215912
Tube assembly
7-20
FRONT AXLE AND REDUCTION DIFFERENTIAL
3.7 Removal and Installation of Each Assembly (Option Truck)3.7.1 Preparation(1) Remove the front axle assembly. For removing
the front axle assembly, refer to "Preparation" of"Front Axle Assembly (Option Truck)".
3.7.2 Removal
Suggestions for Removal
The removing procedure is same as for a standardtruck.
3.7.3 InstallationThe installing procedure is same as for a standardtruck.
215702
The numbers indicate the removal sequence.
4
2
1
3
5
1 Axle shaft2 Tube assembly and final reduction3 Center shaft
4 Reduction differential assembly5 Axle housing
Unit: kg (lb)
Item All truck modelTube Assembly weight 150 (330.8)
7-21
FRONT AXLE AND REDUCTION DIFFERENTIAL
4. Disassembly and Reassembly4.1 Tube Assembly and Final Reduction (Standard Truck)4.1.1 Disassembly
215707
910
3
5
67
23
4
2 1
2
14
13
1516 17
18
20 21
2219
25
24
81012
11
Disassembly sequence1 Ring gear2 O-ring3 Plug4 Set screw5 Planet carrier 6 Snap ring7 Ball bearing8 Spring pin9 Planet pin
10 Thrust washer11 Planet gear12 Needle bearing13 Brake drums14 Lock ring15 Lock nut16 Wheel hub17 Tapered roller bearing18 Oil seal
19 Oil seal20 Seal retainer 21 O-ring22 Tapered roller bearing23 Wheel Brakes24 Axle support 25 Axle tube
7-22
FRONT AXLE AND REDUCTION DIFFERENTIAL
Disassembly Suggestions on Final Reduction (1) Ring gear
(a) Tap the ring gear along the periphery with acopper hammer so that the ring gear is stag-gered from the mating face with axle tube.
(b) Remove the ring gear by hammering it from thebottom.
(2) Planet carrier
(a) Remove the plug.
(b) Remove the set screw located deep inside.
(c) Remove the planet carrier assembly.
(3) Ball bearingRemove the snap ring, and then remove the ballbearing.
(4) Planet gear
(a) Install the spring pin into the planet pin hole.
Tap to stagger
Hit and Remove
215708
Unit: mm (in.)
Width across flats ofhexagon socket 5 (0.2)
Unit: mm (in.)
Width across flats ofhexagon socket 3 (0.12) 215709
Plug
Set screwPlanet carrier assembly
215710
Install
Planet pinSpring pin
215913
Into the planet pin hole
7-23
FRONT AXLE AND REDUCTION DIFFERENTIAL
(b) After removing the planet pin, remove theplanet gear, thrust washer, and needle bearingat the same time.
Disassembly Suggestions on Tube Assembly
(1) Lock nut
(a) Remove the lock ring, and remove the lock nutusing a lock nut wrench.
(2) Front wheel hub
(a) Remove the front wheel hub using a wheel hubpuller.
(b) Remove the oil seal from the front wheel hub.
Planet pin
Planet carrierPlanet gear
Needle bearings
Thrust washer
Thrust washer
215711
Special toolLock nut wrench 03703-49000
215712
Special tool
Special tool
Wheel hub puller Commercially available hub puller
Unit: kg (lb)
Weight of front wheel hub Approximately23.5 (805.7)
215914
Special tool
Oil seal
215915
Front wheel hub
7-24
FRONT AXLE AND REDUCTION DIFFERENTIAL
(3) Tapered roller bearing
(a) Remove the tapered roller bearing and the oilseal retainer together using a bearing retainer.
(b) Remove the O-ring from the oil seal retainer.
(4) Wheel Brake assembly
(a) Remove the mounting bolts and remove thewheel brake assembly.
(b) Remove the mounting bolts and remove theaxle support.
215916
Oil seal retainer
O-ring
215917
Wheel brake
215918
Axle support
215919
7-25
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.1.2 Inspection and Repair(1) Axle shaft
(a) Spline backlash Install the planet carrier of the final reduction tothe splined end of the axle shaft, and measurethe shaft rotation backlash with a dial gauge.
(b) Axle shaft deflectionMeasure deflection with a dial gauge posi-tioned on the center of the axle shaft whilerotating the shaft.
(c) Face runout of axle shaft flangeMeasure face runout with a dial gauge posi-tioned against the axle shaft flange while rotat-ing the shaft.
(2) Axle tube
(a) Check the axle tube for distortion, dents, orcracks.
(b) Check the mast bearing sliding area for dam-age.
(3) Oil seal and Oil seal retainer
(a) Check both the outer and inner oil seals forwear or damage.
(b) Check the periphery of the oil seal retainer forwear or damage.
Unit: mm (in.)
Axle shaftSpline backlash
A 0.07 to 0.17(0.0028 to 0.0067)
B 0.5 (0.02)
A: Standard value B: Repair or service limit215941
V block
Dial gauge
Unit: mm (in.)
Axle shaft deflection (1/2 of gauge reading)
A 1.0 (0.04) maximum
B 2.0 (0.08)
A: Standard value B: Repair or service limit
Unit: mm (in.)
Face runout of axle shaft flange
A 0.04 (0.0016)
B 0.5 (0.0197)
A: Standard value B: Repair or service limit
215714
Face runout of axle shaft flange
Axle shaft deflection
215715
Mast bearing sliding area on the axle
Deformation, dents or cracks
7-26
FRONT AXLE AND REDUCTION DIFFERENTIAL
(4) Brake drums
(a) If minor scratches or wear are found on thebrake drum surfaces, grind them smooth.
(b) Measure inside diameter of the brake drum. Ifthe measured value reaches or exceeds theservice limit, replace the brake drum with anew one.
Unit: mm (in.)
Brake drums inside diameter B 318.5 (12.54)
B :Service limit
Measure inside diameterUneven wear and damage
Brake drum 215920
7-27
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.1.3 ReassemblyTo reassemble, follow the disassembly sequence inreverse.
(1) Axle support
(a) Apply liquid gasket to the mating surfacesbetween the axle tube and the brake drum.
(b) Tighten the mounting bolts to the specifiedtorque.
(2) Wheel Brake assemblyThoroughly wash the mounting bolt threads, andapply sealing compound to the threads beforetightening the bolts to the specified torque.
Liquid gasket ThreeBond #1194or equivalent
215717Brake drum side Axle tube side
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 214 (21.8) [157.9]
Axle support
215919
Sealing compound LOCTITE #271or equivalent
Unit: N·m (kgf·m) [lbf·ft]
Item
Truck modelP8000,P9000 P10000,P11000,
P12000
PD8000,PD9000 PD10000,PD11000,PD12000
Tightening torque 214(21.8)[157.9] 295(30.1)[217.7]
Wheel brake
215918
7-28
FRONT AXLE AND REDUCTION DIFFERENTIAL
(3) Tapered roller bearing
(a) Fit a steel pipe of approximately 105 mm (4.13in.) in inside diameter and 150 mm (5.91 in.) inlength over the tapered roller bearing, and thenhammer the steel pipe to install the taperedroller bearing together with the oil seal retainerinto the axle tube.
(b) Fill the roller cage of tapered roller bearing withthe specified grease. Palm press the grease sothat it is thoroughly applied inside the rollercage.
(4) Wheel hub
(a) Fill the inside of the wheel hub with grease asshown in the illustration. For the correct greasebrand.
(b) Apply grease to the oil seal lip.
(5) Tapered roller bearing preload adjustment
(a) Lightly tighten the lock nut using a socketwrench (special tool).
(b) Tap the periphery of the wheel hub with a cop-per hammer while rotating the hub so that thebearing fits snuggly.
(c) Hook a spring balance to the wheel bolt, andmeasure the tangential force.
(d) Adjust the tightening force of lock nut so thatthe tangential force falls within the above spec-ified range.
(e) After the specified tangential force is obtained,place the lock ring on the wheel hub andsecure the lock ring with the lock bolt.
(f) Measure tangential force again to make surethat it is within the specified range.
Grease Auto Rex A
Use extreme care to prevent surplus grease from spilling on the brake portion.
215921
Steel pipe
After the wheel hub is installed, be sure to wipe off excessive grease from the hub.
215719
Special toolSocket wrench 03703-49000
Unit: N (kgf) [lbf]
Tangential force onwheel bolt
22.5 to 40.2(2.3 to 4.1)[5.1 to 9.0]
215720
7-29
FRONT AXLE AND REDUCTION DIFFERENTIAL
(6) Brake drums
(a) Thoroughly clean the brake friction surfaceswith a clean cloth.
(b) If a friction surface is spotted with oil or grease,wash them away with a brake cleaner.
(7) Planet carrier
(a) Apply gear oil to the rolling contact surfaces ofthe needle bearings before installation.
(b) Install the planet pin with its alignment markfacing outward.
(c) Install the spring pin with its cut line oriented ina rotational direction.
(d) Install the planet carrier assembly to the tubeassembly, and then look through the set screwhole to make sure that the groove of the bear-ing is at the center.
Remove contaminants such as oil, grease
Brake drum 215922
Rolling contact surface
Needle bearing215923
215722
Planet pin Spring pin
216028
Planet carrier assembly Groove of bearing
7-30
FRONT AXLE AND REDUCTION DIFFERENTIAL
(e) Apply sealing compound to the thread of theset screw before tightening it.
(f) Tighten the plug.
(8) Axle shaft
(a) Apply liquid gasket to the mating surfacesbetween the wheel hub and the axle shaft.
(b) Tighten the mounting bolt to the specifiedtorque.
Sealing compound LOCTITE #271
216029
Plug
Set screw
Liquid gasket ThreeBond #1194or equivalent
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 219 (22.3) [161.6]215721
7-31
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.2 Tube Assembly and Final Reduction (Option Truck)4.2.1 Disassembly
215707
1817
1920
2122
24
2325
15
1614
13
2
2
1
5
810
12
11
12
109
7630
4 3
29
28 27
24
26
Disassembly sequence1 Ring gear2 O-ring3 Plug4 Set screw5 Planet carrier 6 Snap ring7 Ball bearing8 Spring pin9 Planet pin
10 Thrust washer
11 Planet gear12 Needle bearing13 Lock ring14 Lock nut15 Wheel hub16 Tapered roller bearing17 Oil seal retainer18 O-ring19 Oil seal20 Spacer plate
21 Tapered roller bearing22 Oil seal23 Floating seal retainer24 Floating seal 25 O-ring26 Seal washer27 Wet disc brake assembly28 O-ring29 Axle support30 Axle tube
7-32
FRONT AXLE AND REDUCTION DIFFERENTIAL
Disassembly Suggestions on Final Reduction
The disassembling procedure is same as a standardtruck. Disassembly Suggestions on Tube Assembly
(1) Remove the lock ring.
(2) Using the lock nut wrench (special tool), removethe lock nut.
(3) Using a special tool, remove the front wheel hub.
(4) Remove the floating seal retainer, oil seal, spacerplate, and tapered roller bearing from the frontwheel hub.
Special toolLock nut wrench 03703-59001
215712
Special tool
Special toolWheel hub guide 91K67-03300
Adjusting plate 91K67-03400
Adjusting bolt 91K67-03600
Unit: kg (lb)
Weight of front wheel hub 35 (77.2)
217214
Special tool
217215
Front wheel hub
Front wheel hub
Floating seal retainer
Floating seal
Oil seal
O-ringOil seal
Spacer plate
Tapered roller bearing (Inner race)
Tapered roller bearing (Outer race)
Tapered roller bearing (Outer race)
7-33
FRONT AXLE AND REDUCTION DIFFERENTIAL
(5) Remove the oil seal retainer from the tube assem-bly.
(6) Remove the O-ring from the oil seal retainer.
(7) Remove the installing bolt, and then remove thewet disc brake assembly.
(8) Remove the floating seal from the wet disc brakeassembly.
(9) Remove the brake cover and O-ring from the wetdisc brake assembly.
(10)Remove the mating plate, friction plate and endplate.
Note: Check the sequence of the removed matingplates, friction plates and end plate.
(11)Remove the brake housing.
(12)Remove the O-ring.
217164
O-ring O-ring
Oil seal retainer
Wet disc brake assembly
Axle support
Front axle tube
217165
Floating seal
O-ring
Brake cover
Wet disc brake assembly
Mating plate 5
Friction plate 5
End plate 1
217166
Mating plateFriction plate
End plate
F
217167
Brake housing
Piston housing
O-ring
O-ring
7-34
FRONT AXLE AND REDUCTION DIFFERENTIAL
(13)Remove the snap ring and plain washer that fixedthe return plate, and then remove the return plate.
(14)Remove the gauge plug, gauge rod and O-ringfrom the piston housing.
(15)Remove the plug, O-ring, spring guide and returnspring from the piston housing.
(16)Remove the drain plug, O-ring and breeder screwfrom the piston housing.
(17)Remove the brake piston, piston seal, piston ring,ring seal and O-ring from the piston housing.
(18)Remove the axle support from the front axle tube.
217168
Snap ringPlain washer
Return plate
217169
Drain plug
Plug
Breeder screw
Piston housing
Gauge plugO-ring
O-ring
O-ringSpring guide
Return springGauge rod
217170
Brake piston
Piston seal
Piston ring
Piston housing
O-ring
O-ring
Ring seal
217171
Axle supportFront axle tube
7-35
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.2.2 Inspection and RepairRefer to "Inspection and Repair" of standard truck forthe following (1) to (3).
(1) Axle
(2) Axle shaft deflection
(3) Oil seal and oil seal retainer
(4) Wet disc brake assembly
Piston
Check the sliding areas for any wear or damage. If there is any surface flaw, grind the surface, then wash the surface.
Brake housing and hub
Check the tooth faces for any wear or damage.
Piston housing
Check the sliding areas of the piston for any wear or damage.
Friction plate and mating plate
(c) Check for any burn, trace of uneven contact,deformation or damage.
(d) Check the mating plate for any heat spots.
(e) Check the inner teeth and outer teeth surfacesfor any wear or damage.
(f) Measure the thickness of each plate.
Note: A complete replacement is required with newones if any of the above checks reveal a prob-lem. Upon replacement, perform flushing.
215622
A: Standard value B: Service limit
Unit: mm (in.)
Mating Plate A 2.00 ± 0.08(0.078 ± 0.003)
Friction plateA 3.7 ± 0.1
(0.145 ± 0.004)
B 3.3 (0.13)
End Plate A 3.2 ± 0.1(0.126 ± 0.004)
7-36
FRONT AXLE AND REDUCTION DIFFERENTIAL
(g) Return springMeasure the free length of return spring.
(h) Floating sealCheck the floating seal lip surface for any dam-age, and replace the lip if damaged.
A: Standard value
Unit: mm (in.)
Free length of return spring A 24 (0.94)
214807
7-37
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.2.3 Reassembly(1) Clean the installing bolt for the axle support fully,
apply the sealing compound/
(2) Install the axle support to the axle tube to thespecified torque.
(3) Reassemble the wet disc brake assembly.
(a) Assemble the piston seal, piston ring, O-ring,ring seal to the brake piston as shown in theright illustration.
Note: Apply oil (SAE 10W-30 Engine oil CD) to thebrake piston, piston seal, piston ring, O-ring,ring seal and sliding surface.
(b) Install the brake piston and O-ring to the pistonhousing.
(c) Insert the return spring and spring guide fromthe piston housing, and install the return plate,plain washer and snap spring.
(d) Install the O-ring to the piston housing.
Note: Be sure to install the multiple O-rings.
Sealing compound LOCTITE #271 or equivalent
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 214 (21.8) [157.9]
217171
Axle supportFront axle tube
217172
Brake piston
Piston seal
Piston ring
O-ring
Ring seal
217173
Brake piston assembly
Piston housing
O-ring
217174
Snap ring Plain washer
Piston housing
Return plate
Return spring
O-ring
O-ring
Spring guide
7-38
FRONT AXLE AND REDUCTION DIFFERENTIAL
(e) Install the stud bolt to the brake housing asshown in the right illustration.
(f) Install the brake housing to the piston housing,and tighten the flange nut and bolt to the speci-fied torque.
(g) Using a special tool, install the end plate, fric-tion plate, and mating plate in the same orderas they were removed.
Note: Align the 5 friction plates spline recesses.
(h) Install the O-ring to the wet disc brake assem-bly.
217175
L.H R.H
Stud bolt
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque of bolt137.3 ± 27.5(14.0 ± 2.8)
[101.3 ± 20.3]
Tightening torque of flange nut
73.5 ± 7.4(7.5 ± 0.8)[54.2 ± 5.5]
217176
End plate 1
Friction plate 5
Mating plate 5
Special tool
Friction plate holder 91K67-03200
217177
O-ring
Mating plateFriction plate
End plate Special tool
216027
7-39
FRONT AXLE AND REDUCTION DIFFERENTIAL
(i) Install the brake cover and O-ring to the wetdisc brake assembly to the specified torque.
(j) Install the spacer, plug, and O-ring as shown inthe illustration to fix the friction plate. Then,temporary tighten them to the wet disc brakeassembly.
(k) Install the spacer to the gauge rod, and tempo-rary tighten it to the wet disc brake.
(l) Tighten the air breeder screw and drain plugplug to the wet disc brake assembly to thespecified torque.
(m)Install the taper plug to the wet disc brakeassembly.
(n) Remove the friction plate holder from the wetdisc brake assembly.
(o) Use the special tool to install the floating sealto the wet disc brake assembly.
(p) Install the O-ring to the wet disc brake assem-bly.
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque of hexa-gon socket bolt
60.7 ± 12.1(6.2 ± 1.2)[44.8 ± 8.9]
217178
Hexagon socket bolt
Brake cover
Wet disc brake assembly
Special tool
Spacer 91K33-17900
Spacer 91K33-17900
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque of air breeder screw
6.86 to 11.78(0.7 to 1.2)
[5.06 to 8.69]
Tightening torque of drain plug
19.6 ± 2.0(2.0 ± 0.2)[14.5 ± 1.5]
217179L.H R.H
Inserting positions for spacerAir breeder screw Air breeder screw
Drain plug
217180
SpacerSpacer
Taper plug Special tool
Special tool
Floating seal inserter 91K67-03700
Guide inserter 91K67-03800
217181
Special tool Floating seal
O-ringWet disc brake assembly
7-40
FRONT AXLE AND REDUCTION DIFFERENTIAL
(4) Assemble the front wheel hub.
(a) Use the special tool to install the floating sealto the floating seal retainer.
(b) Install the O-ring to the front wheel hub.
(c) Tighten the floating seal retainer to the frontwheel hub to the specified torque.
(d) Use the special tool installer to tap the oil sealand tapered roller bearing (outer race) into thefront wheel hub.
(e) Insert the tapered roller bearing (inner race) tothe front wheel hub. Then, using the specialtool, install the spacer plate and oil seal.
(f) Apply grease on the inside of front wheel hub.(shaded area in the right illustration)
(5) Install the wet disc brake assembly to the axletube to the specified torque.
Note: 1. Only one bolt is shorter than other bolts. Becareful not to make a mistake when installing.
2. Clean the mounting bolts completely. Then,install the seal washer, and apply sealingcompound.
Special tool
Floating seal inserter 91K67-03700
Guide inserter 91K67-03800
Guide plate 91K67-03900
217182
Floating sealSpecial tool
Floating seal retainer
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque of hexagon socket bolt
38.1 ± 7.6(3.9 ± 0.8)[28.1 ± 5.6]
217183
Hexagon socket bolt
O-ring
Oil seal
Tapered roller bearing (outer race)
Tapered roller bearing (outer race)
Grease Auto Rex A
217184
Tapered roller bearing (inner race) Oil seal
Apply grease
Spacer plate
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 295 (30.1) [217.7]
Unit: mm (in.)
Short bolt 40 (1.6)
Long bolt 92 (3.6)
Sealing compound LOCTITE #271 or equivalent 217185
L.H R.H
Positions for short bolts
7-41
FRONT AXLE AND REDUCTION DIFFERENTIAL
(6) Install the O-ring to the oil seal retainer, andassemble it to the axle tube.
(7) Using a special tool, insert the front wheel hubwith careful not to displace the friction plate.
Note: a) The clearance between the floating seal re-tainer and brake cover must be approx. 3 mm (0.12 in.) when the front wheel hub contacts end fully.If the clearance deviates from the specified value, check for the damage or scratch, and reinsert the front wheel hub again.
b) If the special tool is removed, the clearancebetween the floating seal retainer and brakecover will be changed with a reactive force.Check if the nominal size is approx. 3 mm(0.12 in.), and write down the checked clear-ance size.
(8) Insert the tapered roller bearing (inner race) to thefront wheel hub.
(9) Using the lock nut wrench (special tool), lightlytighten the lock nut of front wheel hub.
217186
Oil seal retainer
O-ring
Special tool
Wheel hub guide 91K67-03300
Adjusting plate 91K67-03400
Adjusting bolt 91K67-03500
Wheel nut MC810632
217191
Approx. 3 mm (0.12 in.)
Special tool
Wheel nut
Special tool
Special tool
Lock nut wrench 03703-59001
217190
Lock nut
Special tool
Tapered roller bearing ( inner race)
7-42
FRONT AXLE AND REDUCTION DIFFERENTIAL
(10)Remove the spacer that fixed the friction plate.Install the plug and gauge rod to the specifiedtorque.
(11)Rotate the front wheel hub and tap its peripherywith a softhead mallet.
(12)Adjust the tightening force of lock nut so that thepreload of tapered roller bearing falls within theservice limit.
Note: a) To check the preload, hook a spring balancer on the wheel nut, then pull it to measure the tangential force.
b) Adjust the preload, and then adjust the clear-ance between the floating seal retainer andbrake cover to be 3 mm (0.12 in.). Too largeclearance causes for looseness of bearing.
(13)After the specified tangential force is obtained,install the lock ring to the lock nut.
(14)Fix the lock ring with the lock bolt that is appliedsealant.
(15)Measure tangential force again to make sure thatit is within the specified range.
Spacer 91K33-17900
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque of plug34.3±3.4
(3.5±0.35)[25.3±2.5]
Tightening torque of gauge rod
39.2±3.9(4.0±0.4)[29.0±2.9] 217187L.H R.H
Gauge rod
Plug
Unit: N (kgf) [lbf]
Tangential force of wheel bolt
22.5 to 40.2(2.3 to 4.1)[5.1 to 9.0]
Add the tangential force before tightening.Example: the tangential force before tightening is 20 (2.0) [4.5]20 + 22.5 to 40.2 = 42.5 to 60.2 (4.3 to 6.1) [9.6 to 13.5]
217188
217314
Approx. 3 mm (0.12 in.)
Floating seal retainer
Brake cover
Specified sealant LOCTITE #271
217189
Lock ring
Bolt
7-43
FRONT AXLE AND REDUCTION DIFFERENTIAL
(16)Planet carrier
(g) Apply gear oil to the rolling contact surfaces ofthe needle bearings before installation.
(h) Install the planet pin with its alignment markfacing outward.
(i) Install the spring pin with its cut line oriented ina rotational direction.
(j) Install the planet carrier assembly to the tubeassembly, and then look through the set screwhole to make sure that the groove of the bear-ing is at the center.
(k) Apply sealing compound to the thread of theset screw before tightening it.
(l) Tighten the plug.
Rolling contact surface
Needle bearing215923
215722
Planet pin Spring pin
216028
Planet carrier assembly Groove of bearing
Sealing compound LOCTITE #271
216029
Plug
Set screw
7-44
FRONT AXLE AND REDUCTION DIFFERENTIAL
(17)Axle shaft
(a) Apply liquid gasket to the mating surfacesbetween the wheel hub and the axle shaft.
(b) Tighten the mounting bolt to the specifiedtorque.
Liquid gasket ThreeBond #1194 or equiv-alent
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque 219 (22.3) [161.6]215721
7-45
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.3 Wear Gauge for Wet Disc BrakesStandard for replacing the plate of a wet disc brake
217198
Replace the plate when the gauge rod has been driven in up to the groove after pushing the gauge rod.
7-46
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.4 Reduction Differential (Common to Standard and Option Truck)4.4.1 Disassembly
Remove 4 through 9 as an assembly.
213699
2
42
4 8
21
16
19
20
15
1
17
7
9
6
5
6
3
3
12
17
1410
11
10
18
13
Disassembly sequence1 Lock plate2 Adjusting screw3 Bearing cap4 Tapered roller bearing5 Spring pin, Pinion shaft 6 Differential pinion, Thrust washer 7 Differential gear, Thrust washer 8 Differential case 9 Reduction gear
10 Cover, O-ring11 Lock nut, Shims
12 Reduction pinion, Tapered roller bearing (inner),Shims
13 Carrier cover14 Tapered roller bearing15 Driven gear16 Plate17 Drive gear, Ball bearing18 Input flange19 Ball bearing20 Oil seal21 Differential carrier
7-47
FRONT AXLE AND REDUCTION DIFFERENTIAL
Suggestions for Disassembly
Note: 1. Before disassembling the reduction differen-tial, be sure to measure and record gearbacklash so that it will be used as a referenceduring reassembly, except when replacingthe reduction gear set.
2. Put alignment marks across the bearing cap,adjusting screw, and the carrier for correct re-fitting.
(1) Removing tapered roller bearing from differentialcase, use a bearing puller to remove the bearinginner race.
(2) Removing shimsAfter removing lock nut 11 and shims, measureand record the total thickness of the shims. Tie allof the shims to the locknut with a string to preventlosing them.
Unit: mm (in.)
Reduction gear-to-reduction pinion backlash
0.20 to 0.26(0.008 to 0.010)
213700
215924
213702
Lock nut
Shims
215925
7-48
FRONT AXLE AND REDUCTION DIFFERENTIAL
(3) Removing tapered roller bearingDo not need to remove the tapered roller bearing(inner) from the reduction pinion 12 unless adefect is found.
(4) Removing carrier coverScrew the two jack bolts into the jack bolt holes (atthe positions marked with *) and remove the car-rier cover while tapping near the dowel pins (2places) with a plastic hammer.
(5) Checking oil sealDo not remove the oil seal 20 from the carriercover 13 unless it is found to be defective.
Tapered roller bearing (inner)
Reduction pinion
Ware, damage,and burns
215926
Unit: mm (in.)
Jack bolt M10×1.25 Nominal length of 50 (1.97) or above
215942
#
#
7-49
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.4.2 Inspection and Repair(1) Reduction bevel gear and reduction pinion
(a) Check both the gear and pinion for uneventooth contact, wear, pitting, flaking, and chip-ping.
(b) Minor flaws on the tooth surfaces can beremoved by grinding with an oil stone or sand-paper.
(c) If the gear and/or pinion is badly damaged,replace them as a set.
(2) Differential
(a) Check the seat surfaces between the differen-tial case and the tapered roller bearing innerrace for flaking.
(b) Check the differential case for cracks. Also,check the sliding contact surfaces of the thrustwasher and the differential gears for wear anddamage.
(c) Check the teeth of the differential pinions andgears for wear, damage, and flaking. Also,check the thrust washer contact area for wearor damage.
(d) Check the inner surface of the differential pin-ions and the outer surface of the pinion shaftsfor wear.
(e) Check the differential gears and axle shaftsplines for wear and free play (looseness).
(3) Drive gear and driven gear
(a) Check both gears for uneven tooth contact,wear, pitting, flaking, and chipping.
(b) Replace both drive and driven gears as a seteven if one of them is defective.
Reduction gear
Reduction pinion
215927
Unit: mm (in.)
Clearance betweenpinions and shafts
A 0.02 to 0.085(0.0008 to 0.0033)
B 0.35 (0.014)
A: Standard value B: Repair or service limit
Unit: mm (in.)
Free play (looseness) of differential gear and axle shaft splines
A 0.09 to 0.28(0.0035 to 0.0110)
A: Standard value
Differential case
Differential gearThrust washer
Differential pinionThrust washer
215928
A
A
Flaking
Pinion shaft
7-50
FRONT AXLE AND REDUCTION DIFFERENTIAL
Note: 1. The combination of drive and driven gearsvaries depending on the model of lift truck.
2. Each gear can be identified by the letter (A, B,C, D, E, or F) stamped on its side face.
3. Before replacing gears, be sure to check thestamped letter marks to make sure of the cor-rect combination.
Driven gear
Drive gear
215929
7-51
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.4.3 Reassembly
215723
56
4 7
8
18
19
13 2
4
11222120121413
15
16
17
10
23
9
Reassembly sequence1 Differential case 2 Reduction gear3 Bolt4 Differential gear, Thrust washer 5 Differential pinion, Thrust washer 6 Pinion shaft, Spring pin 7 Tapered roller bearing8 Differential carrier9 Bearing cap
10 Adjusting screw11 Carrier cover12 Oil seal
13 Ball bearing14 Input flange15 Drive gear16 Ball bearing17 Plate18 Reduction pinion, Shims, Tapered roller bearing (inner)19 Driven gear20 Tapered roller bearing21 Shim22 Lock nut, O-ring, Cover23 Lock plate
7-52
FRONT AXLE AND REDUCTION DIFFERENTIAL
Suggestions for Reassembling Differential
(1) Reassembling differential case assembly
(a) Assemble the thrust washer to the differentialgear, and then install the differential gearassembly to the differential case.
(b) Assemble the thrust washer to the differentialpinion, and then install the differential pinionassembly to the differential case.
(c) Secure the spring pin to the differential caseassembly.
Note: Install the spring pin to the differential assemblyso that its cutting line positions at a right angleto the pinion shaft. (See the illustration.)
(2) Differential case assembly operational check
(a) Install the center shaft to the differential gear,and check for smooth rotation. If rotation is notsmooth, replace the thrust washer of differen-tial gear with a new one. (Check both sides ofthe differential gear assembly.)
(b) Install the center shafts into the differential gearassembly from both sides. Rotate one of thetwo center shaft while clamping the other shaft,and check for smooth differential rotation.
Differential case
Differential gearThrust washer
Differential pinion
Thrust washer
215930
A
A
Pinion shaft
Spring pin
Cutting line
215943
Center shaft
V blockRotate
Differential case assembly
215944
Center shaft
Center shaft
V blockRotate
Differential case assembly
215945
Clamped
7-53
FRONT AXLE AND REDUCTION DIFFERENTIAL
(3) Installing reduction gear
(a) Apply sealing compound to the mounting boltsand tighten them to the specified torque.
(4) Installing differential case assembly
(a) Install the tapered roller bearing to the differen-tial case.
(b) Install the differential case assembly and thebearing cap onto the differential carrier, andloosely tighten the cap bolts in place.
Note: The bearing caps and the differential carrier aremachined together. Pay attention to the align-ment marks so that they are positioned thesame side as they were before disassembly.
(5) Installing adjusting screw When turning the adjusting screws, turn theadjusting screws, right and left, by the sameamount in the same direction in order not to affectthe bearing preload.
Sealing compound LOCTITE No. 271
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque226 ± 9.8(23 ± 1)[167 ± 7]
Reduction gear Differential case
Apply sealing compound
215931
Bearing cap
Differential caseassembly
Tapered roller bearing
Differential carrier
215932
215924
Adjusting screw
215933
7-54
FRONT AXLE AND REDUCTION DIFFERENTIAL
(6) Adjusting bearing preload
(a) Tap the reduction gear on the back with a cop-per hammer while rotating it for a snug fitting.
(b) Hook a spring balance to the reduction gearmounting bolt head.
(c) Pull the spring balance, and measure tangen-tial force just as the reduction gear starts tomove.
(d) If the tangential force falls out of the specifiedrange, adjust the force by changing the tighten-ing force of the adjusting screws.
Note: When turning the adjusting screws, turn the ad-justing screws, right and left, by the sameamount in the same direction in order not to af-fect the bearing preload.
(7) Removing differential case assemblyAfter confirming the differential case preload,remove the differential case from the differentialcarrier.
Note: Put alignment marks across the adjusting screwand the bearing cap.
Unit: N (kgf) [lbf]
Tangential force 14.7 to 29.4(1.5 to 3.0)[3.3 to 6.6]
215934
Tangential forceDecrease
Increase
Tangential force
DecreaseIncrease
215935
Differential caseassembly
Bearing cap
Adjusting screw
215936
7-55
FRONT AXLE AND REDUCTION DIFFERENTIAL
Suggestions for Reassembling Reduction Assembly
(1) Adjusting reduction pinion shims (front side) When reduction gears and pinions are replaced,add or remove shims according to the machiningerror so that total shim thickness meets the stan-dard value (0.8 mm [0.03 in.]).
(a) Check the machining error value marked onthe end face of the reduction pinion.
(b) Calculate shim thickness using the followingformula: Total shim thickness = standard value -(machining error value)
(c) Select appropriate shims from the table belowto match a calculated value.
(2) Installing oil seal
(a) Using a special tool, install the oil seal into thecarrier cover.
Note: Pay attention to the orientation of the oil sealwhen installing.
(b) Apply grease to the oil seal lip.
(3) Applying liquid gasketApply liquid gasket to the joint surfaces when fit-ting the carrier cover to the differential carrier.
Example: If machining error is 0.10 mm (0.004 in.)Total shim thickness = 0.8 mm - (-0.1 mm)
= 0.8 mm + 0.1 mm
= 0.9 mm (0.035 in.)
213708
Shims
Shim thickness Part number
0.10 mm (0.004 in.) 91331-01200
0.20 mm (0.008 in.) 91331-01300
0.50 mm (0.02 in.) 91331-01400
Special toolInstaller 91263-05400
Grease LG2213709
Oil seal
Liquid gasket ThreeBond #1104
213710
7-56
FRONT AXLE AND REDUCTION DIFFERENTIAL
(4) Adjusting reduction pinion shims (rear side)
(a) Drive the tapered roller bearing into the differ-ential carrier cover.
(b) Measure clearance between the end faces ofboth the differential carrier cover and taperedroller bearing.
(c) Measured clearance can be used as a refer-ence when determining shim thickness. Stan-dard value for shim thickness is 1.25 mm(0.049 in.)
(d) Select appropriate shims from the table belowto match the measured value.
(e) Tighten the lock nut to the specified torque.
(f) After assembling the reduction assembly, hookthe spring balance to the input flange.
(g) Pull the spring balance in the tangential direc-tion, and measure tangential force just as theinput flange starts to move.
(h) If the tangential force falls out of the specifiedrange, adjust the force by adjusting shim thick-ness.
213711
Shim thickness Part number
0.05 mm (0.002 in.) 97E27-01400
0.10 mm (0.004 in.) 97E24-00800
0.20 mm (0.008 in.) 97E24-00900
0.50 mm (0.02 in.) 97E27-01100
1.00 mm (0.04 in.) 97E27-01200
Lock nut
Shims
215925
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque294 ± 19.6
(29.98 ± 2.00)[216.97 ± 14.46]
Unit: N (kgf) [lbf]
Tangential force 53.94 to 83.36
(5.5 to 8.5)[12.1 to 18.7]
213712
7-57
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reassembling Suggestions for Reduction Differ-ential Assembly
(1) Adjusting backlash
(a) Turn over the differential carrier, and place thereduction differential assembly facing upward.
(b) Paying attention to the match mark made onthe bearing cap and adjusting screw, reinstallthe differential case to the differential carrier.
(c) Tentatively tighten the bearing cap mountingbolts.
(d) Set a dial gauge on the reduction differentialassembly with its probe positioned at a rightangle to the tooth face of the reduction gear.
(e) Turn the gear back and forth, and read deflec-tion on the dial gauge (backlash).
(f) If the backlash value falls out of the specifiedrange, adjust backlash value by turning theadjusting screw.
Note: When turning the adjusting screws, turn the ad-justing screws, right and left, by the sameamount in the same direction in order not to af-fect the bearing preload.
(2) Checking and adjusting reduction gear tooth con-tact.Check the reduction gear for uneven tooth con-tact, and adjust it, if necessary, by referring to"4.2.4 Adjustment."
(3) Tightening bearing capsAfter checking the tooth contact, tighten the bear-ing cap bolts to the specified torque, and bend thelock plate to clinch the bearing cap.
Differential caseassembly
Bearing cap
Adjusting screw
215936
Unit: mm (in.)
Backlash 0.20 to 0.26(0.008 to 0.010)
213700
213714
Backlash
Backlash
Decrease
Decrease
Increase
IncreaseIncreaseDecrease
Unit: N·m (kgf·m) [lbf·ft]
Bearing cap tightening torque
235 ± 6.8(23.96 ± 0.69)[173.45 ± 5.02]
Tighten to thespecific torque
Lock plate
215937
7-58
FRONT AXLE AND REDUCTION DIFFERENTIAL
(4) Securing lock nut
(a) Lay the reduction differential assembly on itsside.
(b) Secure the reduction pinion lock nut by caulk-ing its head.
(5) Installing cover
(a) Install O-ring to the cover.
(b) Install the cover, and tighten the mounting boltsto the specified torque.
215938
Caulking
Unit: N·m (kgf·m) [lbf·ft]
Tightening torque39.2 ± 3.9
(4.00 ± 0.40)[28.93 ± 2.88]
O-ring
Cover
Tighten to thespecific torque
215939
7-59
FRONT AXLE AND REDUCTION DIFFERENTIAL
4.4.4 AdjustmentAdjusting Reduction Gear Tooth Contact
(1) Apply a thin and even coat of colorant to a fewreduction gear teeth, on both drive and coastsides.
(2) Rotate the reduction gear back and forth by handuntil a contact pattern is located on both sides ofthe gear teeth. (For adjustment, refer to theinstructions on the next page.)
Note: "Toe" or "Heel" contact is determined by checking the contact pattern on the outside (convex side) of the re-duction gear tooth. For "Face" or "Flank" contact, repeat the above adjusting procedure until the correct toothcontact is obtained.
213715
Adjusting reduction gear tooth contactTooth contact condition Adjusting procedure
1
Extends from toe to middle portion, covering 50% or more of tooth length.
Good
2
Strong contact at toe of tooth(Toe)
1. Move gear away from pinion.
2. Move pinion toward gear for correct back-lash by increasing shim thickness.
3
Short contact at heel of tooth(Heel)
1. Move gear toward pinion.
2. Move pinion away from gear for correct backlash by decreasing shim thickness.
4
Strong contact on face or top half (addendum) of tooth (Face)
1. Move pinion toward gear by increasing shim thickness.
2. Move gear away from pinion for correct backlash.
5
Heavy contact on bottom half (dedendum) of tooth (Flank)
1. Move pinion away from gear by decreasing shim thickness.
2. Move gear toward pinion for correct back-lash.
213716
213717 213721
2
1
213718 213722
2
1
213719 213723
1
2
213720 213724
1
2
7-60
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reduction Gear Adjustment
Turn the adjusting screws, right and left, by the sameamount in the same direction to adjust distance fromthe center.
Reduction Pinion Adjustment
Disassemble the reduction assembly, and add orremove pinion shims (front side) as needed.
215940Distance from center
Distance from center
Distance from center
Near
Near
Far
Far
Near Far
213708
Shims
7-61
FRONT AXLE AND REDUCTION DIFFERENTIAL
5. Troubleshooting (Common to Standard and Option Truck)
Condition Possible cause Action
Continuous gear noise during travel
Reduction bevel gear teeth are badly worn or chipped. Replace
Bearing preload too much or too little, or bearings worn excessively Adjust or replace
Hub bearings are damaged. Replace
Uneven teeth contact between reduction pinion and reduction gear Adjust
Irregular noises dur-ing traveling
Reduction of taper roller bearings and/or hub bearings are damaged. Replace
Differential gear teeth are broken, or thrust washers are worn. Replace gears or washers
Foreign substance in axle housing Clean and change oil
Bolts that secure the axle shaft or differential carrier are loosened. Retighten
Abnormal noises when turning a cor-ner
Fit of differential gears in differential case out of specifi-cation due to wear Replace worn parts
Differential gear teeth (pinion gear teeth) are broken, worn, or damaged by piston. Replace defective parts
Overheated reduc-tion case after trav-eling
Bearing is damaged due to excessive preload. Replace bearings and readjust preload.
Backlash between reduction pinion of output shaft and reduction gear may be too small. Adjust teeth contact and backlash
7-62
FRONT AXLE AND REDUCTION DIFFERENTIAL
6. Service DataUnit: mm (in.)
Item All truck model
Wet disc brake assembly
Thickness 1 of mating plate A 2.00 ± 0.08 (0.078 ± 0.003)
Thickness 2 of friction plateA 3.7 ± 0.1 (0.145 ± 0.004)
B 3.3 (0.13)
Thickness 3 of end plate A 3.2 ± 0.1 (0.126 ± 0.004)
Free length 4 of return spring A 24 (0.94)
A: Standard value B: Service limit217216
1
2
4
3
Section A-A
Section B-B
B
A
A
B
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