hyundai hd78 propeller shaft and axle (Мост и Редуктор)

Propeller Shaft andAxle

GeneralSpecification ................................................. PA -2Troubleshooting ............................................ PA -6Generals ....................................................... PA -10Adjustment .................................................... PA -11

Propeller ShaftComponents ................................................. PA -12Removal ....................................................... PA -13Inspection ..................................................... PA -13Front Propeller Shaft

Disassembly ............................................ PA -15Inspection ................................................ PA -16Reassembly ............................................ PA -18

Rear Propeller ShaftDisassembly ............................................ PA -20Inspection ................................................ PA -21Reassembly ............................................ PA -23Installation ............................................... PA -24

Front AxleWheel Hub

Disassembly ............................................ PA -25Inspection ................................................ PA -30Reassembly ............................................ PA -30

Axle and KnuckleComponents ............................................ PA -36Disassembly ............................................ PA -37Reassembly ............................................ PA -40

Wheel AlignmentDescription .............................................. PA -44Inspection ................................................ PA -44

Rear AxleWheel Hub

Components ............................................ PA -49Removal .................................................. PA -50Disassembly ............................................ PA- 52Inspection ................................................ PA -53Reassembly ............................................ PA -53

Axle HousingComponents ............................................ PA -57Disassembly ............................................ PA -58Reassembly ............................................ PA -60

Rear Axle(F302,F320)Adjustment .................................................... PA -63Inspection ..................................................... PA -65Specification ................................................. PA -67Wheel Hub

Components ............................................ PA -69Replacement ........................................... PA -70

Differential Carrier AssemblyComponents ............................................ PA -72Removal .................................................. PA -73Installation ............................................... PA -73Disassembly ............................................ PA -74Inspection ................................................ PA -78Reassembly ............................................ PA -80Adjustment .............................................. PA -85

Differential Carrier AssemblyComponents ................................................. PA -88Removal ....................................................... PA -89Installation .................................................... PA -90Disassembly ................................................. PA -91Reassembly .................................................. PA -93

GeneralSpecificationPropeller Shaft

Item Specification

Type P2 P3 DS3000

Pipe Outer Diameter × Thickness Ø63.5×2.6 Ø88.9×3 Ø88.9×3

Universal Joint Spider Outer Diameter Ø18.3 Ø22.7 Ø22.7

Bearing Cap Outer Diameter Ø30 Ø35 Ø35

Needle roller Bearing Outer Diameter Ø2.5 Ø2.65 Ø2.65

Length 12.3 19.4 19.4

Amount 26 30 30

Slip Joint Spline Diameter Ø38.7 Ø38.7 Ø38.7

Center Bearing Inner Diameter × Outer Diameter 35×72 40×80 40×80

Unit : mmFront Axle

ItemModel

HD65 HD72 HD78

Tread (mm) 1680 1475 1667

Camber 1°±30′ ← ←

Caster 2°30′±30′ ← ←

King Pin Tilting Angle 8°±10′ ← ←

Toe In (mm) 1~3 1~3 ←

King Pin Offset (mm) 26.87 26.87 17.10

King Pin Span (mm) 1508 1318 ←

Steering Angle(°) Inside 44.1~44.3 36~38 44.3~44.5

Outside 33.3~33.5 27~29 30~32

Wheel Offset(mm) 115 115 127

Rear AxleItem Specification

Reduction Type D2H, D3H, D033H, R130HS

Gear Shape Hypoid Gear

Reduction Ratio R130HS : R3.727D033H : R3.417 / R3.727

Differential Gear Shape Straight Bevel Gear

Gear Oil Type API GL-5, SAE 80W/90

Injection Amount 6.2±0.25ℓ

Hub Grease(Left/Right)

Type MS511-33, WBG-2

Injection Amount 330g at each

Service StandardPropeller Shaft

Item Reference Value Limit Value Remedy and Remark

Propeller Shaft Run-out0.1 or less

0.4Repair or replace

0.6

Clearance of Spline Rotational Direction 0.01~0.09 0.3 Replace

Unbalance of Propeller ShaftFront 5g/3000rpm - Adjust Balance Weight

Rear 10g/3000rpm -

Clearance between Spider and Needle Bearing 0.02~0.05 0.1 Replace with spider kit

Clearance of Snap Ring to axis 0.06 or less - Adjust Snap Ring

Unit : mmFront Axle

Item Reference Value(STD Diameter is in []) Limit Value Remedy and Remark

A=122.9±1 A=126 Repair or replace

King Pin Outer Diameter 29.947~29.98 - Replace

Bushing Inner Diameter(After pressed-in) 28~28.033 -

Clearance between King pinand Bushing 0.020~0.086 0.15 Replace the bushing

Vertical clearance of knuckle 0.02~0.1 0.2 Adjust with ShimShim thickness: 0.10, 0.15, 0.20, 0.30

Front Wheel Hub Starting Tor-que (kgf·cm) 0.98~3.45 Nm (10~35kgf·cm, 0.73~2.55 Ib-ft) Adjust

Rear AxleItem Reference Value Limit Value Remedy and Remark

Rear Axle Shaft Bending of shaft center 2 4 Replace

Bending of flange surface 0.03 0.05

Clearance between differential gear and rear ax-le shaft spline portion 0.05~0.15 0.5 Replace

Backlash between the differential gear and pini-on 0.18 ~0.23 0.5

Adjust by differential gear spac-er (when the tooth of differentialgear is damaged, replace the d-ifferential gear).

Backlash between the final drive gear and the fi-nal drive pinion 0.2 ~ 0.28 - Adjust

Run-out of the back surface the final drive gear 0.05 or less 0.05 Replace the carrier assembly

Final drive pinionStarting torque(kgf·m)

D2H,D3H 0.1 ~ 0.2 - Adjust (do not install the outeroil seal)

D033H 0.2 ~ 0.3

Starting torque of Rear wheel hub(kgf.m) 0.2 ~ 0.4 - Adjust (do not install the outeroil seal and axle shaft)

A 0.5 or less 1 Repair or replace

B1 - B2 1.0 or less 5 Replace

Tightening TorquePropeller Shaft

Install Position Tightening Torque

Nm kgf·m Ib.f-ft

Nut for tightening the flange yoke to t-he propeller shaft flange 98~107.8 10~11 72.3~79.5

Lock nut for tightening the companionflange 539.3~608 55~62 397.8~448.4

Center bearing bolt tightening 93.1~102.9 9.5~10.5 68.7~75.9

Front Axle

Install PositionTightening Torque

Nm Kgf·m Ib.f-ft

Tightening Nut for Knuckle Arm 196~294 20~30 144.6~216.9

Tightening Nut for King pin Lock pin 28~38 2.9~3.9 20.9~28.2

Tightening Nut for Shock Absorber 13~17 1.3~1.7 9.4~12.2

Tightening Bolt for Brake Backing Plate 98~137 10~14 72.3~101.2

Tightening Nut for Hub bolt 539~588 55~60 397.8~433.9

Tightening the wheel hub lock nut 1st tightening torque 98~127 10~13 72.3~94.0

2nd tightening torqueafter full loosening 58 6 43.3

Loosening angle aftertightening Approximately 45° <1/8 turns>

Rear AxleInstall Position Tightening Torque

Nm Kgf·m Ib.f-ft

Bolt (for install the final drive gear and the differential case) 226~265 23~27 166.3~195.2

Tightening bolt for bearing cap 69~78 7~8 50.6~57.8

Bolt (for install the side bearing lock plate) 20~26 2.0~2.7 14.4~19.5

Tightening Nut for differential carrier assembly 34~44 3.5~4.5 25.3~32.5

Tightening Bolt for rear brake assembly 98~137 10~14 72.3~101.2

Nut (for install the wheel hub and the rear drum brake):Aft-er tightening, lock using a triangular or pyramid punch 304~382 31~39 224.2~282.0

Tighten the wheel bearinglock nut

1st tightening 98~127 10~13 72.3~94

2nd tightening torque after fullloosening 29~39 3~4 21.6~28.9

Tightening Bolt for rear axle shaft 98~117 10~12 72.3~86.7

Filler plug 59~78 6~8 43.3~57.8

Drain plug 59~78 6~8 43.3~57.8

TroubleshootingPropeller Shaft

Symptom Causes Remedy

Vibration at Pr-opeller Shaft

High Speed The yoke direction is wrong. Rearrange the align mark.

The universal joint needle roller bearing is defective. Replace with the spider kit.

The propeller shaft is bent Replace the propeller shaft.

The dynamic balance of the propeller shaft is incorr-ect. Adjust the dynamic balance.

The flange linking bolt is loosened. Tighten with specified torque.

The ball bearing is worn out or adhered. Replace the ball bearing.

Low Speed The transmission is too fast. Move the shift bar of the trans-mission to proper position.

The axial clearance of the universal joint spider is to-o large. Adjust the clearance by Shim.

The clearance of the slip joint spline is too large. Replace the yoke sleeve or pr-opeller shaft.

AbnormalNoiseat Propeller S-haft

At start The flange linking blot is loosened. Tighten with specified torque.

The tightening bolt for center bearing is loosened. Tighten with specified torque.

The center bearing is weakened or deformed. Replace the rubber

The universal joint needle roller bearing is worn. Replace with the spider kit.

The clearance of the slip joint spline is too large. Replace the yoke sleeve or pr-opeller shaft.

Running with R-egular speed

The axial clearance of the universal joint spider is to-o large. Adjust the clearance by Shim.

The universal joint needle roller bearing is worn. Replace with the spider kit.

The ball bearing is worn out or adhered. Replace the ball bearing.

The lubricant between the bearing and the spline isdefective. Lubricate.

Front AxleSymptom Causes Remedy

Vibration at Steering Wheel Kingpin wear. Replace.

The clearance of kingpin and bushing is too large. Replace the kingpin bushing.

The front wheel hub bearing is adhered, worn or d-efective in rotation. Replace.

The wheel alignment is defective. Adjust

The tie rod end ball stud is too worn out. Replace the tie rod end assembly.

The air pressures of the tires are uneven. Adjust.

The tightening castle nuts for the knuckle arm andthe tie rod arm are loosened. Tighten with the specified torque.

The tightening nut for tie rod ball stud is loosened. Tighten with the specified torque.

The tightening nut for suspension U-bolt is loosen-ed. Tighten with the specified torque.

The vertical clearance between the knuckle and t-he front axle is too large. Adjust the kingpin thrust washer.

Hard to control the steeringwheel

The clearance between the kingpin and the kingpi-n bushing is too large. Replace the kingpin bushing.

The strut ball bearing is adhered, worn or defectiv-e in rotation. Replace the thrust ball bearing.

The tire air pressure is too low. Adjust the air pressure.

The wheel alignment is defective. Adjust.

The grease is deficiency in kingpin. Oil the grease.

Steering wheel does not ret-urn properly.

The front axle parts are too tightened. Tighten with the specified torque.


Steering wheel can not be t-urned.

The rotating angle adjustment is defective. Adjust the rotating angle.

The tie rod is bent. Replace.

Vehicle is drawn to one side. The sizes of the left and right tires are different. Replace with the same size.

The outer diameters of the left and right tires aredifferent. Replace with the same size.

The air pressures of the tires are different. Apply the same air pressure.

The front axle is bent. Replace.

The front spring is damaged or its tension is defec-tive. Replace.

Front tire is worn irregularlyor too early.


The sizes or types of the left and right tires are dif-ferent. Replace with the same size and type.

The tire is not managed properly. Replace the tire position.

Rear Axle

EMTPA5001A-A

General Information

EMTPA5002A-A

Generals

EMTPA5003A

The propeller shaft installing between the transmissionand the rear axle transmits the engine force changed bythe transmission to the final gear of the rear axle. Thepropeller shaft comprises of the front and the rearpropeller shafts. Two or more parts are linked andsupported by wheel base. The propeller shaft having twoor more parts includes a center bearing at the centerportion supported by the frame.

EMTPA5004A

The relative position of the transmission to the rear axleis varying in accordance with the condition of the roadsurface, the vibration during running of the vehicle andthe amount of the load. To compensate the varying of theposition, the propeller shaft includes the universal jointand the slip joint.

EMTPA5005A

AdjustmentUniversal Joint and Boot1. Set the transmission to the neutral position or the N.2. Lift up the vehicle.3. Check that the center bearing moves excessively ormakes an abnormal noise. If there is any problem,replace the propeller shaft.

KMTPA5003A

4. Check that the universal joint boot is torn or shocked.If there is any problem, replace the propeller shaft.

5. Check that the universal joint moves excessively ormakes an abnormal noise. If there is any problem,replace the propeller shaft.

Propeller Shaft Run-out1. Install a dial gauge at the body of the center portionof the front propeller shaft.

2. With rotating the front shaft slowly, check the run-out.And then, check the other side propeller shaft also.

Item Run-out Spec.(mm)

Front Propeller Shaft 0.4 or less

Rear Propeller Shaft 0.4 or less

KMTPA101A

3. If the run-out of the propeller shaft excesses thespecifications, replace the propeller shaft.

Propeller ShaftComponents

SUDPAA004L

1. Front Propeller Shaft2. Rear Propeller Shaft Support3. Rear Propeller Shaft4. Rear Axle

Removal1. Making an align mark (C) to the flange yoke (A) of thefront propeller shaft and the parking brake drum (B),remove the tightening nut (D) of the propeller shaft.

KMTPA111A

2. Remove the tightening bolt (A) of the center bearingbracket.

NOTICEFor the short wheel base, the center bearing is one,while for the long wheel base, the center bearingsare two.

KMTPA112A

3. Making an align mark (C) to the rear axle companionflange (A) and the flange yoke (B) of the rearpropeller shaft, remove the tightening bolt (D) of thepropeller shaft.

KMTPA113A

Inspection1. After checking the clearance between the spider andthe needle roller bearing, if it excesses thespecifications, replace the spider kit.

Clearance between the Spider and the Needle Roller:0.01~0.06mm

EMTPA5007A

2. Measuring the bending at the 50mm around thewelding center portion of the propeller shaft, if itexcesses the specification, replace the propellershaft.

Limit value : 0.4mm or less

EMTPA5008A

Front Propeller ShaftDisassembly

SUDPAA005L

Disassembling Sequence①. Snap Ring②. Needle Roller Bearing3. Flange Yoke4. Universal Joint Spider5. Self Locking Nut6. Companion Package

7. Holder8. Hanger9. Cushion10. Oil Seal Kit(Housing and Oil Seal)11. Packing⑫. Ball Bearing13. Front Propeller Shaft

* For disassembly for the ○ number, refer to thecorresponding contents.

1. Remove the snap ring

CAUTION• Replace the snap ring with new ones after

removal.

EMTPA5010A

2. Remove the needle roller bearing.

EMTPA5011A

3. Remove the ball bearing

EMTPA5012A

Inspection1. Check the clearance between the spider and theneedle roller bearing.

CAUTION• When replace the spider or needle roller

bearing, replace them with the spider kit.

EMTPA5007A

2. Check the clearance of snap ring along to the axisdirection1. Measure the clearance2. Adjust the clearance


removal.• Use the snap rings having the same

thickness at the both sides.

KMTAX5009A

Snap Ring

Thickness Color Code

1.5 No Color

1.55 Yellow

1.6 Blue

1.66 Cyan

EMTPA5013A

3. Measure the bending at the bent center portion of thepropeller shaft.

EMTPA5008A

Reassembly

EMTPA5014A

1. Insert the needle roller bearing by pressing-in.

EMTPA5015A

2. Install the snap ring.

EMTPA5016A

3. Assemble the center bearing.Setting the arrow mark to upward, insert the centerbearing into cushion, and apply adhesion into thegap. Install the housing tightening bolt with setting it'shead to upward.

EMTPA5017A

4. Using a thickness gauge, measure the gap betweenthe snap ring and the groove of the snap ring.

Reference : 0~0.15mmLimit : 0.3mm or less

CAUTION• If the gap excesses the limit value, replace

the snap ring.

EMTPA5030A

5. Apply the grease enough to the grease nipple of theuniversal joint.

Recommended Grease: SELL ALVANIA EP #2

Rear Propeller ShaftDisassembly

SUDPAA006L

Disassembly Sequence①. Snap Ring②. Needle Roller Bearing3. Front Yoke4. Universal Joint Spider5. Packing Retainer6. Shield Packing7. Rear Propeller Shaft8. Sleeve Yoke

For disassembly for the○ number, refer to the corresponding contents.

1. Remove the snap ring.

CAUTION• Do not reuse the snap ring.

EMTPA5010A

2. Remove the needle roller bearing.

EMTPA5011A

Inspection1. Check the clearance between the spider needle rollerbearings.

CAUTION• When replace the spider or needle roller

bearing, replace them with the spider kit.

EMTPA5007A

2. Check the clearance of snap ring along to the axis.1. Measure the clearance.2. Adjust the clearance.


removal.• Use the snap rings having the same

thickness at the both sides.

KMTAX5009A

Snap Ring

Thickness Color Code

1.5 No Color

1.55 Yellow

1.6 Blue

1.65 Cyan

EMTPA5013A

3. Check the bending of the propeller shaft.

EMTPA5008A

EMTPA5019A

4. Check the clearance of spline

EMTPA5020A

EMTPA5021A

Reassembly

SUDPAA007L

①. Snap Ring②. Needle Roller Bearing3. Flange Yoke4. Universal Joint Spider5. Packing Retainer6. Sheild Packing7. Rear Propeller Shaft8. Sleeve Yoke

For assembly for the ○ number, refer to the corresponding contents.

1. Insert the needle roller bearing by pressing-in.

EMTPA5011A

2. Install the snap ring.

EMTPA5016A

Installation1. Setting the aligning mark (C) of the rear axlecompanion flange (A) to that of the flange yoke (B) ofthe rear propeller shaft, tighten the bolt (D) of thepropeller shaft.

Tightening Torque :98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft) : P359~69 Nm (6~7 kgf.m, 43.3~50.6 lb-ft) : P2

KMTPA113A

2. Install the tightening bolt (A) of the center bearingbracket.

Tightening Torque :69~93 Nm (7~9.5 kgf.m, 50.6~68.7 lb-ft)

KMTPA112A

NOTICEFor narrow version, the center bearing is one, whilefor the wide version, the center bearings are two.

3. Setting the aligning mark (C) of the flange yoke (A) ofthe front propeller shaft to that of the parking brakedrum (B), tighten the bolt (D) of the propeller shaft.

Tightening Torque :98~117 Nm (10~12 kgf.m, 72.3~86.7 lb-ft)

KMTPA111A

4. After filling up the recommended grease to thegrease nipple (A) until it leaks out from the oil seal,wipe out the leaked grease completely.

Recommended Grease: ALVANIA EP #2

KMTPA114A

Front AxleWheel HubDisassembly

SUDPAA008L

Disassembly Sequence1. Hub Cap2. Split Pin3. Lock Nut4. Washer5. Wheel Hub and Brake Drum

6. Hub Bolt7. Front Brake Drum8. Front Wheel Hub9. Outer Bearing Inner Race10. Spacer11. Oil Seal

12. Inner Bearing Inner Race13. Inner Bearing Outer Race14. Outer Bearing Outer Race15. Dust Cover16. Front Brake Assembly

1. Place the wooden block (A) at the front and rear sideof the rear wheel.

KMTPA201A

2. Loosen the wheel nut (A). Lift up the axle using agarage jack (B) and support the frame with a safetystand (C).

KMTPA202A

3. After removing the wheel nut (A), remove the wheeland tire (B) from the hub (C).

CAUTIONWhen removing the wheel and tire (B), be carefulthat the hub bolt (D) is not damaged.

KMTPA203A

4. After removing the wheel cap(A), remove the split pin(B) and the lock nut (C).

CAUTIONWhen removing the lock nut (C), be careful thatthe washer and the outer bearing does not falldown to the ground.

KMTPA204A

5. Remove the washer (A), the outer bearing (B) andthe hub assembly (C) from the knuckle (D).

KMTPA205A

6. Tapping evenly the three notch parts on the hub innersurface with a brass bar, removing the oil seal (A),the inner bearing (B) and the inner bearing race (C).

NOTICEWhen using the brass bar, do not tap except thenotch parts (A) located inside of the hub.

KMTPA206A

7. Tapping evenly the three notch parts on the otherside hub inner surface with a brass bar, removing theouter bearing race (A).

KMTPA207A

8. After removing the hub nut (A), remove the drum (C)from the wheel hub (B).

KMTPA208A

[Disk Brake]

SUDPAA009L

Disassembling Sequence1. Hub Cap2. Split Pin3. Lock Nut4. Washer5. Disk Brake Assembly

6. Wheel Hub and Rotor7. Bolt8. Rotor9. Front Wheel Hub10. Hub Bolt11. Outer Bearing Inner Race

12. Oil Seal13. Inner Bearing Inner Race14. Inner Bearing Outer Race15. Outer Bearing Outer Race16. Adaptor17. Dust Cover

1. Place the wooden block (A) at the front and rearsides of the rear wheel.

KMTPA201A

2. Loosen the wheel nut (A). Lift up the axle using agarage jack (B) and support the frame with a safetystand (C).

KMTPA202A

3. After removing the wheel nut (A), remove the wheeland tire (B) from the hub (C).

CAUTIONWhen removing the wheel and tire, be carefulthat the hub bolt is not damaged.

KMTPA203A

4. After removing the grease cap (A), remove the splitpin (B) and the lock nut (C).

KMTPS5990A

5. Remove the washer (D), the outer bearing (E) andthe hub assembly (F) from the knuckle (G).

6. After taking off the disk tightening bolt, remove thedisk assembly from the wheel hub (B).

7. Remove the hub from the knuckle.

Inspection1. Check the cracks and wear on the hub.2. Check the scratch and damage on the brake disk.3. Check for the cracks.4. Check the assembling state of the bearing.

Reassembly[Drum Brake]1. Installing the drum (C) at the wheel hub (B), tightenthe hub nut (A).

Tightening Torque:304~382 Nm (31~39 kgf·m, 224~282 lb-ft)

CAUTIONAfter tightening the hub nut (A), at least 4portions of the groove parts of the stud shouldbe calked.

KMTPA208A

2. By tapping evenly, install the inner bearing race (B)and the outer bearing race (C) at the wheel hub (A).

KMTPA209A

3. Install the inner bearing (B) and the oil seal (C) at thewheel hub (A).

CAUTION• The bearing should be a set with the bearing

race.• Use a new oil seal (C) always.

KMTPA210A

4. Fill the recommended grease in the wheel hub (A)with specified amount.

Recommended Grease:MS511-33

5. Install the washer (A), the outer bearing (B) and thehub assembly (C) at the knuckle (D).


race.

KMTPA205A

6. Install the lock nut (A).1) With rotating the hub assembly (B), tighten the

lock nut (A) fully with the force of 98~117Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,loosen the nut fully.

2) Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 5~9 Nm (6kgf·m, 43.3 lb-ft) and then loosen the nut at45°(1/8 turns).

KMTPA211A

7. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe moving torque by multiplying the tangential forceto the radius.

Moving Torque:0.98~3.4 Nm (0.10~0.35 kgf·m, 0.72~2.51 lb-ft)

KMTPA212A

8. After installing the split pin (B), install the wheel cap(A).

KMTPA213A

9. After installing the wheel and tire (B) to the hub (C),tighten the wheel nut (A).

KMTPA203A

10.After removing the garage jack (B) supporting theaxle and the safety stand (C) supporting the frame,tighten the wheel nut (A) with the specified torque.

Tightening Torque :539~588 Nm (55~60 kgf·m, 397.8~433.9 lb-ft)

KMTPA202A

11.Remove the wooden block (A) from the front and rearsides of the rear wheel.

KMTPA201A

[Disk Brake]1. Installing the disk assembly (A) to the wheel hub (B),tighten the disk tightening bolt (C).

Tightening Torque:57~60 Nm (5.8~6.1 kgf·m, 42~44 lb-ft)

KISE220E

2. Tighten the hub nut to the hub assembly.

CAUTIONAfter tightening the hub nut, at least 4 portionsof the groove parts of the stud should be calked.

3. By tapping evenly, install the inner bearing race (C)and the outer bearing race (E) at the wheel hub (D).

4. Install the inner bearing (B) and the oil seal (A) at thewheel hub (D).


race.• Replace the oil seal(A) with new one after

removal.

KISE210E



6. Install the washer, the outer bearing and the hubassembly at the knuckle.


race.7. Install the lock nut (A).

1. With rotating the hub assembly (B), tighten thelock nut (A) fully with the force of 98~117Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,loosen the nut fully.

2. Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 59 Nm (6 kgf·m,3.31 lb-ft) and then loosen the nut at 45°(1/8turns).

KMTPA5002A

8. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe moving torque by multiplying the tangential forceto the radius.

Starting Torque : 0.98~3.4 Nm (0.10~0.35 kgf·m,0.72~2.5 lb-ft)

KMTPA212A

9. After installing the split pin (A), install the wheel cap.

KMTPS5991A

10.After installing the wheel and tire (B) to the hub (C),tighten the wheel nut (A).

KMTPA5508A

11.After removing the garage jack (B) supporting theaxle and the safety stand (C) supporting the frame,tighten the wheel nut (A) with the specified torque.

Tightening Torque : 539~588 Nm (55~60 kgf·m,397.8~433.9 lb-ft)

KMTPA202A

12.Remove the wooden block (A) from the front and rearsides of the rear wheel.

KMTPA201A

Axle And KnuckleComponents

SUDPAA001L

1. Hub Cap2. Front Wheel Hub3. Knuckle4. Dust Cap5. Kingpin Shim6. Kingpin

7. Thrust Bearing8. Drag Link9. Knuckle Arm10. Tie Rod11. Front Axle

Disassembly[Drum Type]1. Remove the wheel hub. (Refer to the “Wheel HubDisassembly”)

2. After taking off the tightening bolt (A) for brakeassembly, remove the brake assembly (B) from theknuckle (C).

NOTICETie the brake assembly (B) around the relating partswith a wire.

KMTPA301A

3. After taking off the split pin (A) of the drag linktightening bolt and lock nut (B), remove the drag link(C).

KMTPA302A

4. After taking off the split pin (A) of the tie rodtightening bolt and the lock nut (B), remove the tierod (C).

KMTPA303A

5. After taking off the lock pin nut (A) and the washer(B), remove the lock pin (C).

KMTPA304A

6. After taking off the dust cap (A), remove the king pin(B).

KMTPA305A

7. Remove the king pin shim (A) and the dust seal (B).

KMTPA306A

[Disk Type]1. Remove the wheel hub. (Refer to the “Wheel HubDisassembly”)

2. After holding the brake hose with a vise pliers, loosenthe brake hose tightening bolt (A). Remove the brakehose.

KMTBR5536A

3. After taking off the tightening bolt(A) of the brakecaliper, remove the caliper(B).

SUDPAA002L

4. After taking off the tightening bolt of the dust cover,remove the dust cover from the knuckle.

5. After taking off the split pin (A) of the drag linktightening bolt and the lock nut (B), remove the draglink (C).

KMTPA302A

6. After taking off the split pin (A) of the tie rodtightening bolt and the lock nut (B), remove the tierod (C).

KMTPA303A

7. After taking off the lock pin nut (A) and the washer(B), remove the lock pin (C).

KMTPA304A

8. After removing the dust cap (A), remove the king pin(B).

KMTPA305A

9. Remove the king pin bushing (A) and the dust seal(B).

KMTPA306A

Reassembly[Drum Type]1. Install the king pin bushing (A) and the dust seal (B).

KMTPA306A

2. Install the king pin (B) and then, install the dust cap(A).

CAUTIONThe groove portion of the king pin (B) shouldface to inside.

KMTPA305A

3. After installing the lock pin (C), install the lock pinwasher (B) and nut (A).

Tightening Torque :28~38 Nm (2.9~3.9 kgf·m, 21~28 lb-ft)

KMTPA304A

4. After installing the tie rod (C), install the lock nut (B)and split pin (A).

Tightening Torque :69~118 Nm (7~12 kgf·m, 51~87 lb-ft)

KMTPA303A

5. After installing the drag link (C), install the lock nut(B) and split pin (A).


KMTPA302A

6. After install the brake assembly (B) to the knuckle(C), install the tightening bolt (A) for the brakeassembly.


KMTPA301A

7. Install the wheel hub. (Refer to the “Wheel HubAssembly”)

[Disk Type]1. Install the king pin bushing (A) and the dust seal (B).

KMTPA306A

2. Install the king pin (B) and then, install the dust cap(A).

CAUTIONThe groove portion of the king pin (B) shouldface to inside.

KMTPA305A

3. After installing the lock pin (C), install the lock pinwasher (B) and nut (A).

Tightening Torque :28~38 Nm (2.9~3.9 kgf·m, 21~28 lb-ft)

KMTPA304A

4. After installing the tie rod (C), install the lock nut (B)and split pin (A).


KMTPA303A

5. After installing the drag link (C), install the lock nut(B) and split pin (A).


KMTPA302A

6. After install the brake caliper (B), install the calipertightening bolt (A).

Tightening Torque : 98~127 Nm (10~13 kgf·m, 72~94lb-ft)

SUDPAA002L

7. After installing the dust cover (B) to the knuckle (C),install the tightening bolt (A) of the dust cover.

Tightening Torque : 98~137 Nm (10~14 kgf·m, 72~101lb-ft)

8. After installing the brake assembly (B) to the knuckle(C), install the tightening bolt (A) of the brakeassembly.

Tightening Torque : 125~139 Nm (12.7~14.2 kgf·m,92~103 lb-ft)

9. Install the wheel hub. (Refer to the “Wheel HubAssembly”)

Wheel AlignmentDescriptionWhen wheel alignment and steering angle are measured,check that the vehicle has no load or every parts of thefront axle are properly assembled.

CAUTIONBefore the adjustment, check again followings.1. The front wheel is loosened.2. The knuckle is loosened.3. The linkage between the knuckle flange and

knuckle arm is loosened.4. The bolts, the screws or the nuts are loosened.5. The leaf spring is damaged or weakened.6. The tire air pressure is too high or low.7. The adjusted backlash of the steering gear is

proper.InspectionToe-in1. Set the front wheel along with the straight direction.2. Make a mark at the front end of the front wheel. (Themarking point is the middle position of the width andheight of the wheel)

3. Setting the needle height of the toe-in gauge to themarking point of the left and right tire, measure thetoe-in value. Measure the distance (A) between thetwo wheels.

KMTAX5019A

4. Moving the vehicle to forward so that the markingpoint moves backward. Setting the marking point tothe height of the toe-in gauge (i.e. turn 180°), at therear side, measure the distance (B) between the twowheels.

KMTAX5020A

5. The difference between the measured value of rearside (B) and the measured value of front side (A) isthe toe-in value.

Specified Value (B-A): 1~3mm

KHHA850A

6. If the measured toe-in value excesses the specifiedvalue, adjust it by loosening the clamp bolts (B) of theleft and right tie rods (A) and turning the tie rod (A)with a pipe wrench (C).

Tightening Torque of the Clamp Bolt (B):20~29 Nm (2~3 kgf·m, 14~22 lb-ft)

EMTPA5026A

Camber1. Set the front wheel along with the straight direction.2. Remove the wheel hub cap (A).

KMTPA361A

3. Wipe out the grease at the end of the spindle. Installthe self centering plunger of the camber, the casterand the king pin gauge (A) to the wheel hub bysetting them to the center hole of the spindle.

KMTPA362A

4. Set the gauge (A) in horizontal plane. To do that, setthe bubble (in longitudinal direction) of the levelgauge to the zero point.

5. Measure the camber value(B) of the gauge (A). Thecenter line of the bubble is the camber value.

Specified Value : 1°±30′

KMTPA363A

6. By the same method, measure the camber value ofthe opposite wheel.

Kingpin inclination angle and Caster1. To maintain the vehicle in horizontal position, place aplate (B) having the same height with the turn table(A) under the rear tire (C).

KMTPA371A

2. Positioning the two front tires of the vehicle to thecenter of the turn table, pull (set up) the parkingbrake.

CAUTIONIf it is hard to move the vehicle, lift up thevehicle with a jack and place the turn table andthe plate under the front and rear tire.

3. Set the scales of the both turn table to zero point.

4. Turn the tire to be measured to the outward until thescale of the turn table is positioned 20° (A).

KMTPA363A

5. Remove the wheel hub cap (A).

KMTPA373A

6. Wipe out the grease at the end of the spindle. Installthe self centering plunger of the camber, the casterand the king pin gauge (A) to the wheel hub bysetting them to the center hole of the spindle.

7. Set the gauge (A) in horizontal plane. To do that, setthe bubble (in longitudinal direction) of the levelgauge to the zero point.

8. By turning the zero setting screws of the caster (A)under the gauge and the kingpin tilting angle, set thebubble to 0.

CAUTIONFor left side wheel, use the left scale as thekingpin tilting angle scale. For right side wheel,use the right scale as the kingpin tilting anglescale.

9. Turn the wheel 20° again so as to set the scale of theturn table to 0°. Then the center line of the bubbleindicates the kingpin tilting angle value. Measure thecenter line value of the bubble.

Specified Value : 8°±10′

10.By turning the tire to inward, set the scale of the turntable to 20°.

11.Set the gauge (A) in horizontal plane. To do that, setthe bubble (in longitudinal direction) of the levelgauge to the zero point.

12.From the caster scale, read the each pointing scaleof the casters.

Specified Value: 1°±30′

13.By the same method, measure the caster and thekingpin tilting angle values of the opposite wheel.

Steering AngleBefore inspecting the steering angle, complete theinspection of the wheel alignment.1. To maintain the vehicle in horizontal position, place aplate (B) having the same height with the turn table(A) under the rear tire (C).

KMTPA371A

2. Positioning the two front tires of the vehicle to thecenter of the turn table, pull (set up) the parkingbrake.

CAUTIONIf it is hard to move the vehicle, lift up thevehicle with a jack and place the turn table andthe plate under the front and rear tire.

3. Set the scales of the both turn table to 0°.4. Turn the tire to inward. Measure the scale of the turntable.

Specified Value(°) : 40.8~42.8

5. Turn the tire to outward. Measure the scale of theturn table.

Specified Value(°) : 30.8~32.8

6. If the measured value excesses the specified value,tighten or loosen the knuckle stopper bolt (A) at bothsides (LH/RH) to adjust the steering angle.

KMTPA382A

7. After adjusting the steering angle, tighten the nut (A)of the stopper bolt with specified torque.

Tightening Torque :19.6~29.4 Nm (2~3 Kgf·m, 14.4~21.6 lb-ft)

KMTPA383A

Side SlipBefore checking the side slip, complete the inspection ofthe wheel alignment.1. Set the front wheel along with the straight direction.2. Maintaining the position of the front wheel to thestraight direction, drive the vehicle on the slip testerslowly.

CAUTIONWith maintaining the position of the front wheelto the straight direction, pass through the sideslip tester thoroughly. Do not turn the wheel ordo not fall off from the tester.

3. The value indicated on the tester is the side slip. Ifthe side slip excesses the specified value, the wheelalignment should be adjusted.

Specified Value: 3mm/(when going straight per 1m)

Rear AxleWheel HubComponents

SUDPAA003L

1. Brake Pipe2. Bolt3. Rear Axle Shaft4. Outer Oil Seal5. Rear Brake Assembly6. Bolt7. Lock Plate

8. Lock Nut9. Wheel Hub Outer Bearing Inner Race10. Wheel Hub and Drum Assembly11. Inner Oil Seal12. Wheel Hub Outer Bearing Outer Race13. Wheel Hub Inner Bearing Outer Race14. Nut

15. Hub Bolt16. Rear Wheel Hub17. Rear Brake Drum18. Wheel Hub Inner Bearing Inner Race19. Nut

CAUTION• Be careful that the brake lining and the brake

drum inner surface are not contaminated by theoil or grease.

Removal1. Place the wooden block (A) at the front and rearsides of the front wheel.

KMTPA401A

2. Loosen the wheel nut. Lift up the axle with a garagejack (A) and support the frame with a safety stand(B).

KMTPA402A

3. After taking off the wheel nut (A), remove the wheeland tire (B) from the hub (C).


KMTPA403A

4. After taking off the hub bolt (A), remove the axle shaft(B).

NOTICEWhen it is hard to remove the axle shaft (B), inserthub bolts (A) into the removing screw holes (C)evenly.

KMTPA404A

5. Remove the oil seal (A).

KMTPA405A

6. Loosening the tightening bolt (A) for the lock nut,remove the lock washer (B).

KMTPA406A

7. Using the special tool (09527-47000), remove thelock nut (A).

KMTPA407A

8. Remove the rear wheel hub (B) with the outerbearing (C) from the axle housing (A).

CAUTIONBe careful that the outer hub bearing (C) do notdrop down to the ground.

KMTPA408A

Disassembly1. Tapping evenly the three notch parts on the hub innersurface with a brass bar, removing the oil seal (A),the inner bearing (B) and the inner bearing race (C).

KMTPA409A

NOTICEWhen using a brass bar, do not tap except the notchparts (A) located inside of the hub.

KMTPA420A

2. Tapping evenly the three notch parts on the otherside hub inner surface with a brass bar, removing theouter bearing race (A).

KMTPA410A

3. After taking off the hub nut (A), remove the drum (C)from the wheel hub (B).

KMTPA411A

Inspection1. Check that the rotation state is proper after installingthe bearing(A) to the bearing race(B). If it has beenadhered, worn or defective in rotation, replace thebearing(A) and the bearing race (B) in a set.

KMTPA409A

2. If the hub bolt is worn or corroded, remove the hubbolt from the wheel hub and replace it.

Reassembly1. Installing the drum (C) to the wheel hub (B), tightenthe hub nut (A).

CAUTIONAfter tightening the hub nut (A), at least 4portions of the groove parts of the stud shouldbe calked.

Tightening Torque : 304~382 Nm (31~39 Kgf·m,224~282 lb-ft)

KMTPA411A

2. By tapping evenly, install the inner bearing race (B)and the outer bearing race (C) at the wheel hub (A).

KMTPA412A

3. Install the inner bearing (B) and the oil seal (C) at thewheel hub (A).


race.• Replace the oil seal (C) with new ones after

removal.

KMTPA413A



5. Install the rear wheel hub (B) and the outer bearing(C) to the axle housing (A).

CAUTIONThe bearing should be a set with the bearingrace.

KMTPA408A

6. Install the lock nut (A).a. With rotating the hub assembly (B), tighten the

lock nut (A) fully with the force of 98~127 Nm(10~13 kgf·m, 72~94 lb-ft). After that, loosen thenut fully.

b. Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 29~39 Nm (3~4kgf·m, 22~29 lb-ft).

KMTPA211A

7. Setting the lock washer (A) to the spindle groove (B)of the housing, tighten the lock nut tightening bolt (C).

Tightening Torque : 7~11 Nm (0.7~1.1 Kgf.m, 5~8 lb-ft)

KMTPA415A

8. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe starting torque by multiplying the tangential forceto the radius.

Starting Torque : 2~4 Nm (0.2~0.4 Kgf.m, 1~3 lb-ft)

KMTPA212A

9. Install the oil seal (A).

CAUTIONUse a new oil seal (A) always.

KMTPA405A

10.After installing the axle shaft (B), tighten the hub bolt(A) with specified torque.

Tightening Torque : 98~117 Nm (10~12 Kgf.m, 72~87lb-ft)

KMTPA416A

11.After installing the wheel and tire (B) to the hub (C),tighten the wheel nut (A).

KMTPA403A

12.After removing the garage jack (A) supporting theaxle and the safety stand (B) supporting the frame,tighten the wheel nut with the specified torque.

Tightening Torque : 539~588 Nm (55~60 Kgf.m,398~434 lb-ft)

KMTPA402A

13.Remove the wooden block (A) from the front and rearsides of the front wheel.

KMTPA401A

Axle HousingComponents

SUDPAA010L

1. Drain Plug2. Oiling Plug3. Nut4. Bolt5. Reduction and Differential Assembly6. Nut7. Rear Axle Housing

Disassembly1. Place the wooden block (A) at the front and rearsides of the front wheel.

KMTPA401A

2. Loosen the wheel nut. Lift up the axle with a garagejack (A) and support the frame with a safety stand(B).

KMTPA402A

3. After taking off the wheel nut (A), remove the wheeland tire (B) from the hub (C).


KMTPA403A

4. As the same method with the 2~3 steps, remove theopposite side wheel and tire.

5. Support the both hub with a jack (A).

KMTPA501A

6. Making an align mark (C) to the rear axle companionflange (A) and the flange yoke (B) of the rearpropeller shaft, remove the tightening bolt (D) of thepropeller shaft.

KMTPA113A

7. After removing the brake line (A), remove the brakehose clip (B).

NOTICE• If the brake line is rubber hose, remove it after

biting it with vise pliers.• If the brake line is steel pipe, remove the line

with pressing the brake pedal.

KMTPA502A

8. After taking off the tightening nut(A) of the shockabsorber, remove the shock absorber (B).

KMTPA503A

9. After taking off the tightening nut (A) of the U-bolt,remove the U-bolt (B).

KMTPA504A

10.After getting down the jack (A) supporting the bothhub, remove the axle housing (B).

KMTPA505A

Reassembly1. After positioning the axle housing (B) at the rear sideof the vehicle, lift up the jack (A) supporting the bothhubs slowly.

KMTPA505A

2. Setting the center bolt (A) of the leaf spring to thecenter hole (B) of the axle housing, lift up the axlehousing (C) completely.

KMTPA510A

3. After installing the U-bolt (B), tighten the U-bolttightening nut (A) with the specified torque.

Tightening Torque : 226~255 Nm (23~26 kgf·m,166~188 lb-ft)

KMTPA504A

4. After installing the shock absorber (A), tighten theshock absorber tightening bolt (A) with the specifiedtorque.

Tightening Torque : 26~33 Nm (2.7~3.4 kgf·m, 20~25lb-ft)

KMTPA503A

5. After installing the brake hose clip (B), install thebrake line (A).

NOTICE• If the brake line is rubber hose, remove the vise

pliers after installing the line.• If the brake line is steel pipe, release the brake

pedal after installing the line.

Tightening Torque : 25~29 Nm (2.5~3.0 kgf·m, 18~22lb-ft)

KMTPA502A

6. Setting the align marks (C) of the rear axlecompanion flange (A) to the flange yoke (B) of therear propeller shaft, install the tightening bolt (D) ofthe propeller shaft.

Tightening Torque : 98~107.8 Nm (10~11 kgf·m,72.3~79.5 lb-ft)

KMTPA113A

7. Remove the jack (A) supporting the both hub.

KMTPA501A

8. Install the wheel and tire (B) to the hub (C). Tightenthe wheel nut (A).

KMTPA403A

9. After removing the garage jack (A) supporting theaxle and the safety stand (B) supporting the frame,tighten the wheel nut with the specified torque.


KMTPA402A

10.Remove the wooden block (A) from the front and rearsides of the front wheel.

KMTPA401A

11.Bleed the brake system. (Refer to the "Air Bleeding ofBR Group")

Rear Axle(F302,F320)ADJUSTMENTExchange the lubricating oil1. Recommended lubricating oilThe rear axle gear must be applied with hypoid gearoil SAE 80W-90 or SAE 85W-140 GL-5 Quantity: 5.5Lit.In tropical zone: SAE 85W-140 GL-5 for 5.5 LitIn temperate or cold zone: SAE 80W-90 GL-5 for 5.5Lit

2. Time of Change of Lubricating OilFor every 8000 Km travel,inspect the rear axle oillevel and fill as specified.Oil change period for rear axle:1) On completion of running at beginning of vehicle

(2500 Km of travel)2) Every 24000 Km of travel

3. Specific operation for change of lubricating oilThe rear axle oil filler plug is on the axle housing rearcover.The oil should be filled so that the oil level is flushwith the access hole.

NOTICE• Change of Lubricating oil should be carried out in

warm condition.• Be careful not to be hurt by hot oil.• Clear the foreign matter from the oil drain plug.• Clean the health plug.

Connection of brake line and ABS1. Connection of brake line

1) Position the brake tube onto the axle housingtransition boss. Connect one end of it to the teefitting and the other end to brake hose.

2) Before assembling, the line should be tested bycompressed air for any leakage and the cavityshould be cleaned.

2. Connection of ABS (If installed)1) Range of electric resistance of sensor: 1550-1700

ohm.2) When the wheel speed is greater 30 rpm, the

output induced voltage of sensor is ≥0.2V (AC)and the ratio of its max induced voltage to its mininduced voltage should be ≤2.0.

SUDPAA011L

1. HARD PIPE ASSY-LH2. 3-WAY VALVE TRANSITION BRACKET ASSEMBLY (for ABS)3. HOSE (2 for ABS)4. HARD PIPE ASSY-RH5. BOLTBOLT (transition bracket assembly, for ABS)

6. BOLTCLIP

7. WIRE HARNESS ASSEMBLY (left)8. WIRE HARNESS ASSEMBLY(right)9. STRAP10. BREATHER PLUG11. Oil filler plug12. Oil drain plug

NOTICEThe brake tubes 1 and 4 should be mounted asper the steps as given in Fig. which facilitatesassembling and sealing.

SUDPA7038L

On completion of assembling of the completeaxle, oil should be applied as specified.

Test specification for rear axle assemblyFor users having necessary conditions, a rear axle testbed may be used to test the reassembled rear axle. Forusers without those conditions, the rear axle may bemounted onto the vehicle and observed during slowrunning.

WARNINGObserving of the operation state of the rear axlemounted onto the vehicle should be done in a areafar away from the crowd. Pay attention to the safetyof human body and properties of other people andyour own.1. Test scopeDuring the test, check the assembling of the rear axleassembly for complete correctness and check allthreaded connections for correct tightening andlocking. Check the leakage condition of the bondarea and the oil seal. Check the noise of the carrierassembly and braking effect of the wheel brake. Thetest duration is not less than 3 min.

2. The rear axle assembly under test should conform tothe following:1) The gears must be free from any abnormal noise.

When one of the brake drum is applied, knockingor drastic noise is not allowed from thedifferential.

2) No rotating part may come into contact with anystationary part.

3) After the vehicle is stopped, when touching byhand any bearing and oil seal seat, it should becool or slightly warm. The brake drum should notbe subject to overheat.

4) No oil seal, bond area or castings blow hole, etcmay be subject to oil leakage.

3. A defect found in the test may be reconditioned.However, reacceptance is required after thereconditioning.

INSPECTION1. CleaningThe parts may possibly contaminated by dirty oil orsludge. Cleaning of parts is essential. Usual methodsinclude steam cleaning, gasoline cleaning, acid oralkaline solution cleaning, neutral solvent cleaning,trichloroethylene cleaning and magnetic forcecleaning. Some parts may possibly be damagedduring cleaning. Therefore, careful inspection mustbe done during cleaning.1) Metal part

a. GasolineUnlike any other method, gasoline is not ableto penetrate or dissolve sludge. Unless thesurface of part has been precision machined,a metal brush or other tool to remove sludgeand brushing should be done twice.

b. Alkaline treatmentExcellent result can be obtained by usingalkaline treatment to clean steel parts andcastings. Alkaline treatment is not appropriatefor alloy parts.

2) Rubber partsMineral oil cannot be used. Alcohol can be usedfor cleaning or just a piece of clean cloth can beused to wipe off any dirt.

3) Corrosion preventionAfter cleaning all waste oil and grease off the partsurface, a layer of clean oil should be applied onthe surface for corrosion prevention.

2. Inspection1) Before cleaning, the part should be inspected by

using any already prepared measuring apparatusor tool. Decide according to the specifiedmaintenance criteria if the part is suitable forreuse. Any damaged part should be repaired orreplaced as required. If one of paired parts isseriously worn and the assembling clearanceexceeds the specified degree, this part or thepaired parts can be replaced as required. Inprinciple, any paired parts should be replaced in apaired manner.

2) For the view point of preventive maintenance,some parts within repair or wear limit should bereplaced before they exceed the limit.

3) All parts should, as necessary, be carefullyinspected by visual inspection or by means ofNDT such as infrared ray, ultrasonic wave or Xray. The part can be repaired or replaced as

necessary if any abnormality is found duringvisual inspection, such as irregular wear, ironrust, bending, deformation, scratch, crack, partialwear, discoloration, loose fitting , excessive wearof friction liningand etc, deterioration of frictionlining and etc, failure of return spring orattenuation of return force or abnormal noise ofbearing or gear, etc.

4) Any rubber part such as O ring, oil seal or gasket,after disassembled, should be replaced accordingto the situation. All hub oil seals and pinion gearoil seal after disassembled must be replaced.

5) For cleaning of carrier and differential assembly,replace them according to the assembling order.

6) Check the dismounted bearing, gear and anyother parts for any ablation, flaking off, pockmarkor excessive wear. Replacement is necessary ofany such defect.

3. Reconditioning and Replacement

NOTICEIn order to achieve effectively the value of the rearaxle product, it is an effective means to replace anylow-value wear-prone part.For instance, replacement of any worn gasket, bushor oil seal can prevent damage of gear or bearing,etc.Replacement of such parts will not increase the costfor replacement of important parts.1) Steel parts

For paired parts that may not be reconditioned,such as gear, differential and bearing, when anyused or damaged part is rejected, replacement bysuited part is required as well. That is to say, anypaired parts should be replaced in a pairedmanner but not in a single manner.

2) Rubber partsFor rubber parts such as oil seal, replacement isa must once the seal is damaged. In this case,reuse may not be considered.

3) Axle housingAny cracked or bent axle housing should bereplaced at once.

CAUTIONNever try to repair any axle housing bymeans of welding or straightening;otherwise, the axle housing may becomedefective during use of vehicle, possiblycausing serious result.

SPECIFICATIONModel (F320)

Description Specification

Vehicle HD72

Model F320

Engine corresponded D4DA, D4DB, D4DD D4AL, D4DC

Gear ratio 5.428 6.666

Oil spec

Quantity(L) 5.3~5.7

Temperate or frigid zone GL-5 SAE 80W/90

Torrid zone GL-5 SAE 85W/140

Grease NLGI No.2

Brake size(mm) 320 x 85

Shock absorber center distance(mm) 536

Distance of axle housing brake flange(mm) 1188

Cross section of axle housing(mm) 110 x 108

Model (F302)Description Specification

Vehicle HD65

Model F302

Engine corresponded D4AL, D4DC, D4BD

Gear ratio 6.166

Oil spec

Quantity(L) 4.3~4.7

Temperate or frigid zone GL-5 SAE 80W/90

Torrid zone GL-5 SAE 85W/140

TIGHTENING TORQUE

DescriptionSpecification (F320) Specification (F302)

Nm Kgf.m lb-ft Nm

Propeller shaft & Rear axle assembly 98~118 10~12 72~87 ←

Wheel bolt 539~588 55~60 397~434 ←

Pretightening load of pinion bearing 1.5~3 0.2~0.4 1.1~2.2 ←

Pretightening load of differential bearing 2~4 0.2~0.4 1.5~3 ←

Torque of flange nut of pinion 380~420 38.7~42.8 280.3~309.8 330~390

Torque of binding bolt for ring gear and differe-ntial case 240~280 24.5~28.6 177~206.5 ←

Differential case binding bolt 130~170 13~17 96~125 50~80

Torque of differential bearing cap bolt 240~280 24.5~28.6 177~206.5 ←

Torque of binding bolt of adjusting ring lockingpiece 16~30 1.6~3.1 11.8~22.1 ←

Torque of bolt fastening the carrier and axle h-ousing 140~180 14.3~18.3 103~133 ←

Bolt connecting the brake backplate to axle ho-using flange 98~137 10~14 72.3~101 ←

Axle shaft bolt 110~150 11.2~15.3 81~111 ←

Torque of binding bolt of rear axle bearing cag-e 140~180 14.3~18.4 103.3~132.8 ←

Torque of oil charging and drain plugs 100~140 10.2~14.3 73.8~103.3 ←

Binding bolt of brake tube 6~10 0.6~1 4.4~7.4 ←

Binding bolt of 3 way connector 16~30 1.6~3.1 11.8~22.1 ←

Torque of hard tube joint bolt 13~16 1.3~1.6 9.6~11.8 ←

Torque of wheel hub lock nut 180~220 18.4~22.4 132.8~162.3 ←

Torque of lock washer bolt of wheel hub 2~4 0.2~0.4 1.5~3 ←

SERVICE STANDARDItem Specification

Backlash of pinion and ring gear 0.15~0.3 mm

Variation of backlashes for the same pair of gears Not greater than 0.08 mm

Oil capacity of rear axle hypoid gear F320 : 5.5L, F302 : 4.5L

Wheel HubCOMPONENTS1. Part list and exploded view of wheel end part.

SUDPAA012L

1. REAR AXLE ASSY2. SPACING RING3. BRAKE ASSY-LH4. BRAKE ASSY-RH5. NUT6. SPRING WASHER7. BOLT8. INNER OIL SEAL ASSY-HUB9. SPACER10. CUP-BEARING11. CONE & ROLLER ASSY12. DRUM13. GEAR RING-ABS14. NUT (12 for F320 series: 10 for F302 series)15. HUB-RR WHEEL

16. BOLT-HUB,LH (6 for F320 series: 5 for F302 series)17. BOLT-HUB,RH (6 for F320 series: 5 for F302 series)18. CUP-BEARING19. CONE & ROLLER ASSY20. NUT

NUT21. LOCK WASHER22. CROSS GROOVE BOLT23. OUTER OIL SEAL ASSY-HUB24. AXLE SHAFT-RH25. AXLE SHAFT-LH26. BOLT

NOTICENever work under the vehicle when only one jack isused! During repair of the vehicle (inc. axles), makesure the wheels are blocked by using sole timber.Make surethe vehicle will not move even if the brakefails.

REPLACEMENT1. Dismounting of wheel end part

1) Dismounting of axle shaft

WARNINGBefore dismounting the axle shaft, the wheelsshould be blocked by using sole timber andthe parking system should be released.For dismounting, loosen and screw off all theaxle shaft bolt. Use a copper hammer toslightly knock on the center of the tail of theaxle shaft for 2 or 3 times so that the axleshaft flange face is disconnected from thewheel hub joint face. Then pull the axle shaftflange by hand and the axle shaft can bedrawn out.

NOTICEWhen the axle shaft spline part is to passthrough the oil seal, the axle shaft lever partshould be propped by hands and the axle shaftshould be rotated slowly so that they are shift outin parallel and that hub oil seal will not bedamaged and the axle shaft are prevented fromfalling onto the ground and hurting anyone.

2) Dismounting of wheel hubScrew off the bolt 22 and remove the lockingwasher. Screw off the nut 20. Place the palletunder the wheel hub brake drum assembly. Use acopper bar or soft hammer to knock on the outeredge of the brake drum outwards. Remove thewheel hub brake drum assembly.

SUDPA7035L

2. Equipment and adjustment of wheel end part1) Mount the brake assembly onto the flange of axle

housing and tighten the brake backplate bolt to98~137 N.m. Adjust the brake clearance to0.3±0.05mm (Measurement and adjustment canbe done by using a clearance gauge oradjustment can be done on the brake pumpstroke in such a manner that the wheel hub isblocked. Then adjust it in an inverse way forapproximately 4 to 6 turns).

NOTICEMake sure that the inside of the rear axlehousing is clean and free from any iron dust, dirt,cutting edge, burr or any mechanical impurities.

WARNINGBrakes of the same batch should be selected.New brakes, i.e. left and right brakes, must bein consistent color. The old brakes should bethe product on the same axle.

NOTICEDuring assembling, there are marks R (right) andL (left) on the brake backplate. Make sure thatassembling is not done in an inverse way.

2) Assemble the spacing ring 2 onto the axle sleeveso that the inner end face of the spacing ringabuts on the sleeve step.

3) The wheel hub with brake drum assembly mustbe clean inside before mounting. The wheel hubmust be filled with No. 2 lithium grease. Mountthe spacer. Apply small amount of grease at theinternal and external cutting edges of the inner oilseal and press in the wheel hub.

SUDPA7036L

4) Mount the wheel hub with oil seal assembly intothe axle sleeve.Fit over the specing ring. Mount the outer bearinginner race. Screw on the wheel hub nut. At thesame time, adjust the pretightening force of thewheel hub bearing, i.e. tighten the wheel hub nutso that when rotating the wheel hub, thetangential pulling force applied on the wheel hubbolt is 42-52 N. Fit over the lock washer onto theaxle sleeve. Use three cross groove screws tolock the lock washer on the wheel hub nut andtighten it. Mount the wheel hub outer oil seal.

NOTICEAssembling may fail if the thread on the axlesleeve on the axle housing or the thread of theaxle head nut is subject to any damage orcorrosion.

5) Mount the axle shaft. Tighten the axle shaft boltto 180±20 Nm.

NOTICE1. A proper pressing tool should be used for

mounting of the oil seal. An inappropriate toolmay cause damaged oil seal.

2. The oil seal may be prone to damage andshould be placed in the package beforeassembling.

3. When the axle shaft splinepart is to passthrough the oil seal, the axle shaft lever partshould be propped by hands and the axleshaft should be rotated slowly so that theypass through in parallel and that the axleshaft oil seal will not be damaged.

CAUTION1. When assembling the axle assy, the

lubricating oil and grease to lubricatevarious assemblies and parts should be ofthe same grade as for normal service.

2. Never apply any lubricating grease ontothe bearing before assembling. (Thebearing should be lubricated whenassembling.) Dry grease may possiblyprevent normal lubrication of the axleassy., even causing defective oil seal.

Differential Carrier AssemblyCOMPONENTS

SUDPAA013L

1. Nut-flange2. Washer3. O ring4. Flange assy5. Oil seal assypinion6. Outer bearing-pinion7. Bolt8. Bearing cage9. Adjusting shim

10. Inner bearing-pinion11. Split pin12. Pinion13. Pilot bearing14. Adjusting shim15. Bolt16. Bolt17. Diff. carrier18. Adjusting ring

19. Bearing20. Differential case (right)21. Differential side gear shim22. Bolt23. Spring washer24. Lock piece25. Bolt26. Cover27. Differential side gear

28. Differential pinion gear shim29. Differential pinion gear30. Cross shaft31. Ring gear32. Differential case (left)33. Bolt34. Bolt

REMOVALCAUTION

When axle shaft is dismantled, please distinguishleft from right axle shaft, thus mistake will not bemade in re-installation.The carrier is dismantled according to the following steps1. Release and draw out left/right axle shaft.

SUDPA7002L

2. Support the carrier with cart, dismantle 12 boltslinking carrier and rear axle, dismantle the carrierassembly from axle housing.

WARNING1. Don't use hammer to knock on the edge of

axle shaft flange, don't prize axle shaft orscrew by such tools as flat spade!

2. Don't lie under carrier while dismantling orinstalling tightening bolts of carrier. Cartshall be used to transport carrier.

INSTALLATION1. ASSEMBLY OF DIFFERENTIAL CARRIER

CAUTION1. Before carrier is installed, one shall assure

the interior of axle housing has been checkedand cleared utterly

2. On the engagement face between axlehousing and carrier, heavy load sealing gluewill be applied.

SUDPA7003L

1) Install carrier assembly inside axle housing, afterbolt has been tightened, it shall be retightened. Intightening, the torque shall reach the valuerequired in torque table(Table on Bolt Torque isshown in "Tighening torque").

2) Install axle shaft, tighten linking bolt, retightenbolt to the scope required in torque table(Tableon Bolt Torque is shown in "Tighening torque" ).

3) Fill wheel axle with correct lubricating oil.

CAUTIONIf the pinion, ring gear, differential gear andwheel end parts were decomposed, checkedor replaced, before traffic tool is operated,differential gear shall be assured to operatenormally(in addition, wheel on one side canrotate independently and freely).

2. Mounting of pinion assembly1) Place the adjusting shim onto the Diff carrier. The

upper most and bottommost shims should beapplied with sealant on the surface to contact thehousing.

NOTICEIf the gear before disassembly is used, theadjusting shim kept after disassembly of theassembly should be used. If the shims aredamaged, then shims with the same thicknessand quantity should be prepared prior to theassembling. If a new gear is to be mounted, aset of adjusting shims with nominal thicknesscan be mounted first.That not fewer than two shims of 0.1mm and0.2mm should be used. (The nominal thicknessof F320 series adjusting shim is 1.75mm.

2) Mount the pinion assembly onto the carrier.Screw on the attachment bolt to the specifiedtorque. (For the tightening torque see the TorqueTable.)

SUDPA7026L

3. Mounting of differential assembly

NOTICELubricate the differential bearing.1) Mount the differential assembly onto the carrier.

SUDPA7027L

2) Mount the bearing outer races on both sides ofthe differential. Mount the differential bearing capand adjusting ring. Mount but not tighten theattachment bolts of the bearing cap.

3) Use hands to tighten the attachment bolts of thebearing cap. A wrench may be used if it is difficultto tighten the bolts by hands.

NOTICEIt may be difficult to screw on the adjusting ring ifthe ring and the relevant threads are notlubricated.

Up to this point, the preliminary assembling ofthe carrier assembly has been finished. Next, thepretightening load of the differential bearing, thebacklash andcontact pattern of gears should beadjusted.

DISASSEMBLYCAUTION

If pinion and ring gear need to be usedrepetitively,before Diff. Carrier assembly isdecomposed, the contact dent of gear and gear gapshall be checked. Of course, the best result is toacquire good gear contact dent and gear gap byadjustment. If gear is decided to replace at thebeginning, the step can be given up.The steps for replacing pinion and ring gear1. Install Diff. Carrier shell assembly inside repairgauntry, loosen but not dismantle collar nut. BeforeDiff. Carrier assembly is decomposed, mark shall bemade on the left and right bearing cover , so toprevent left and right bearing cover from beingwrongly assembled in reassembling; ditto, theadjusting ring shall also be marked.

SUDPA7004L

2. Dismantle the retainer bolt on the bearing cover ,take down lock piece, loosen the bolt fixing bearingcover, dismantle nut on bearing cover by wrench;dismantle bearing cover and bolt, take out differentialassembly from Diff. Carrier by chain and hoister.

SUDPA7005L

3. Turn over carrier assy, make ring gear assemblyupwardly, dismantle connection bolt between thebearing cage of and carrier, take down pinionassembly by chain and hoister.

SUDPA7006L

CAUTIONBe sure not to damage or lose the adjustmentshim on the bearing cage . If shim cannot surelybe used again, the group number and thicknessof shim shall be made clear, shim shall bereorganized and reassembly.

Dismantle pinion assembly

SUDPA7007L

CAUTIONWhen dismantling flange assembly, don't lay pinionon hard surface.1. Take out flange nut loosened in step 1 of "The stepsfor replacing pinion and ring gear" by special tool,take down flange assembly; then press out pinionand cone & roller assy by special tool. If bearing hasnot be damaged, it is not necessary to dismantle itscup-bearing and cone; if a part will be replaced,corresponding parts shall be replaced. (see Figure 8),the dismantling steps are shown in 2 and 3.

SUDPA7008L

2. Take down the cup-bearing-inner.

SUDPA7009L

3. Take down the cone & roller assy-outer.

SUDPA7010L

4. Dismantle guide bearing of pinion

SUDPA7011L

SUDPA7012L

NOTICEDismantling tools indicated in figure is only asschematic use. Under the premise of not damagingcomponent, a user himself can select tools withsimilar functions for dismantling.

INSPECTIONDETECTION AND MAINTENANCE ON DIFFERENTIAL ASSEMBLY

SUDPA7013L

NOTICE- In the process of dismantling differential assembly,

differential assembly shall be laid on soft surface, soto prevent wheel tooth of ring gear from beingdamaged.

1. Dismantle the linking bolt tightening ring gear anddifferential case, if ring gear doesn’t slide down fromdifferential case, copper bar or soft hammer can beused to slightly knock on the external edge of ringgear, then dismantle ring gear.

SUDPA7014L-1

2. Make assembly mark on the engagement facebetween left and right differential case, dismantle bolttightening and differential case(left and right), takedown the differential case(right).

SUDPA7014L-2

3. Take down side gear shim and side gear.

SUDPA7014L-3

4. Dismantle differential pinion gear and cross shaftassembly, then dismantle shim and differential piniongear from cross shaft.

SUDPA7014L-4

5. Take down side gear shim and side gear.6. Check if bearings on both ends of differential gearhave been damaged or not. If not, it is not necessaryto dismantle bearing; if damaged, the cone & rollerassy and cup-bearing shall all be replaced.

SUDPA7015L

REASSEMBLYASSEMBLY ON DIFFERENTIAL ASSEMBLY

CAUTIONBefore assembling, hyperbolic gear oil shall beapplied on the rotation engagement surface ofdifferential case, side gear, differential pinion gear,support shim and bearing of side gear. (in tropicalzone, applying SAE 85W-140 GL-5; in temperatezone or Frigid zone, applying SAE 80W-90 GL-5 )1. Assemble the cone & roller assy.

SUDPA7016L-1

NOTICEIn order to prevent bearing from being damaged,suitable pressing sleeve shall be applied. Usedcup-bearing is a good option. If the inner diameter ofinner ring is less than the outer diameter of bearingengagement part of differential case, a notch can bemade from bearing shaft upwardly, so to solve thematter.

2. Assemble side gear shim and side gear intodifferential case(left).

SUDPA7016L-2

3. Assemble planetary gear and shim on cross shaft,then assemble them together into differentialcase(left) . Rotate gear, check if gear system may beblocked or not.

SUDPA7016L-3

4. Assemble side gear and side gear shim.5. Assemble differential case(right) according to markon the differential case. Assemble linking bolt ofdifferential case and tighten to correct torque. Rotateside gear to see if gear system may be blocked ornot.

SUDPA7016L-5

6. Assemble ring gear, assemble bolt linking ring gearand differential case, tighten bolt to correct torque.

SUDPA7016L-6

ASSEMBLE AND ADJUST PINION ASSEMBLY

SUDPA7017L

CAUTIONBefore pressing bearing in, a little lubricating oilshall be applied on the out diameter of pinion. (intropical zone, applying SAE 85W-140 GL-5; intemperate zone or Frigid zone, applying SAE 80W-90GL-5 ). Before cone & roller assy of bearing andguide bearing are assembled, suitable pressingsleeve shall be used. (size is basically equivalent tosize of inner ring of bearing, in addition, the innerring of pressing sleeve shall be larger than thediameter of gear axle).1. Assembling components of pinion assembly

1) Before assembling the cup-bearing, check if burrexists on the surface of cup-bearing, if existing,clear away it.Press cup-bearing into bearing cage

SUDPA7018L

2) Pressing pilot bearing into pinion.

SUDPA7019L

2. Adjustment on the pre-tightened force of bearinginside pinion.1) Assemble bearing cage, inside, outside bearing

and pre-tightened shim(not including pinion andoil seal), lay pre-tightened shim between twocone of bearing and along the direction of axis ofbearing.

SUDPA7020L

CAUTIONIf the reassembled bearing of pinion has beenused, new pre-tightened shim shall beapplied. If it is found that pre-tightened shimhas been seriously worn during the period ofdecomposing assembly, the shim shall beabandoned during the period, however, thethickness of the shim shall be measured andrecorded.

2) Assembled system shall be properly oiled andlubricated; 64KN force shall be applied onassembly. Pressing sleeve must be pressed onthe end face of the inner ring of bearing.

3) When 64KN force is applied on assembly, checkrotation torque. Around bearing cage, wind softmetal wire, hang spring balance to pull.Rotationtorque of bearing cage shall be within the scopeof 1.5~3.0 N.m.

CAUTIONAfter having confirmed value of torque, startto rotate bearing cage.

4) If the pre-tightened force of bearing cannot reachthe requirement, adjust the preload of pinionsupport by varying pre-tightened shim. Thickerpre-tightened shim will reduce pre-tightened load,thinner pre-tightened shim will increasepre-tightened load.

SUDPA7021L

NOTICEGenerally, for this kind of adjustment, suitablepreload may not be acquired in one time ofoperation. Preload testing shall be applied ineach assembly and each time of adjustment.After pre-tightened force has reachedrequirement, when pinion assembly isassembled, a pre-tightened shim with size largerthan test value by 0.02~0.03 shall be selected.When shim is assembled on assembly, thesurplus 0.02~0.03 size can just meet thepre-tightened pressure of assembly. Test onpre-tightened force of bearing shall be completedthrough 3~4 times of tests.

3. Final test on pinion bearing for pretightening force1) Assemble the pinion, the bearing and the bearing

cage

SUDPA7022L

2) Fix the bearing cage assembly by means of themethod as given in Fig.1 or 2. Jaw vice method:Use a jaw vice to clamp the bearing saddleassembly (See Fig.1. Use flange nut to fasten theflange. See the tightening toque table for thetightening torque of the flange nut.)Holding down method: By means of continuousforce, use pressing sleeve to hold down the innerrace of outer bearing.

SUDPA7023L

3) Test the pinion bearing for preload.Wind the soft annealed wire around the bearingcage. Hook up the spring balance to pull it. Therotating torque for bearing cageshould bebetween 1.5 and 3.0 N.m.

NOTICEAfter confirming the torque value, start theoperation of turning the bearing cage.

4) If the requirement of bearing pretightening forceis not met, then the pinion assembly should bedisassembled and assembly and commissioningshould be done again as per the procedure asgivenin page 19 in this manual. Adjust thepreload of pinion bearing by changing thepretightening washer. A thicker pretighteningwasher will reduce the pretigthening load while athinner one will increase it.

WARNINGA pretightening washer as supplied by themanufacturer should be used. Never try touse a shim or any washer as made byyourself. Such inappropriate part may causefailure of pretightening load and bearing orgear.

4. Mounting of oil seal and flange1) After adjustment of the pinion bearing cage for

pretightening load, an appropriate tool should beused to press the oil seal onto the pinion bearingcage.

SUDPA7024L

NOTICEAt the point A in the size of the pressing sleeveshould be ensured.

2) Before mounting the flange, make sure that thefitting surface between flange and oil seal is cleanand dry. Mount the flange washer and flange nutand tighten the flange nut to the specified torque.Insert and lock the cotter pin. (See the toquetable for the torque.)

NOTICEAfter tightening and locking the flange nut andcheck the torque of pinion bearing cage, theprocedure to mount the bearing cage assemblyinto the carrier may begin.

5. Requirement and method for reassembly of flange

WARNINGNever use any flange whose fitting surface withthe oil seal is subject to any damage (nick orscratch).The surface fitting with the oil seal, on the flange, isan important interface to prevent foreign dirt fromentering into the axle and to prevent internallubricating oil from leaking outside. The condition ofthe fitting surface with the oil seal, on the flange, is avery important factor for the service life of oil seal. Itis required that oil seal fitting surface on the flangeshould be inspected carefully to check for any sign ofabrasion or damage. This flange should not be usedin case of any visible score or abrasion or any rubbedsurface exceeding the protecting diameter of oil seallip.

SUDPA7025L

NOTICENever use any abrasive paper or abrasive materialto clean the oil seal fitting surface on the flange. Dirtshould be got rid off by using chemical cleaningagent.

6. Replacement of oil sealIt is strongly recommended that mounting should bedone by using an oil seal pressing sleeve. Anappropriate pressing sleeve can allow the oil seal tobe mounted vertically to a proper depth.

NOTICEThe oil seal may be subject to damage before andduring mounting. For mounting of a new oil seal,damage or pollution should be prevented. Beforemounting the new oil seal, the oil seal should beplaced inside the package.A new flange should also be placed in a properprotective device before mounting.

ADJUSTMENT1. Adjustment of pretightening load of differentialbearingAppropriate pretightening load of differential bearingcan ensure proper operation the differential bearingand facilitate correct contact of the pinion and ringgear.

NOTICEBefore the adjustment, check that the adjusting ringscrew thread pair and the driven gear have beencleaned. For adjustment of the pretightening load,the only adjustment item is the differential adjustingring and any other operation has been finished in theabove-mentioned procedures.Tighten the left and right adjusting rings in such away that the axial positions of the adjusting rings onboth sides are approximately the same. Adjust thepretightening load of the differential bearing bymeans of the adjusting rings. The tightening torque torotate the differential assembly should be2.0~4.0Nm.

SUDPA7028L

SUDPA7029L

SUDPA7030L

SUDPA7031L

NOTICEWhen checking the pretightening load of thebearing, the bearing must have been lubricated andchecking must be done after the bearing has rotatedfor several turns.

2. Adjustment of backlash of gearsRotate the left and right adjusting rings to change theaxial position of the ring gear so as to adjust thepinion and ring gear. In order not to change thealready adjusted pretightening load of the differentialbearing, the advance and retreat amount of the leftand right adjusting rings must be equal. Measure thebacklash of the ring gear at the approximatelytrisection point. Backlash should be between 0.15and 0.30 and the backlash variation should not begreater than 0.08.

SUDPA7032L

SUDPA7033L

NOTICEIn order to reduce the backlash of the gear, theadjusting ring of the ring gear on the side with toothshould be loosened for several pitches. Theadjusting ring on the other side should be tightenedfor the same pitches. Reverse operation can becarried in order to increase the backlash.

3. Adjustment of contact pattern of pinion and ring gear

Adjustment of contact pattern of pinion and ring gearContact pattern of ring gear

Adjusting methedConvex side Concave side

Move the ring gear towardsthe pinion.If the backlash is too smallat the moment, move the pi-nion away.

Move the ring gear away fro-m the pinion.If the backlash is too large atthe moment, move the pinio-n towards the ring gear.

Move the pinion towards thering gear.If the backlash is too smallat the moment, move the rin-g gear away.

Move the pinion away from t-he ring gear.If the backlash is too large atthe moment, move the ringgear towards the pinion.

Differential Carrier AssemblyComponents

SUDPAA014L

1. Self Locking Nut2. O-Ring3. Companion Flange4. Dust Cover5. Oil Seal6. Pinion Bearing7. Pinion Bearing Collar8. Pinion Inner Bearing9. Bearing Retainer10. Pinion Driver11. Pinion Pilot Bearing (ONLY D033H)12. Lock Ring (ONLY D033H)

13. A/B Shim14. Bolt15. Spring Washer16. Pin17. Bolt18. Spring Washer19. Differential Collar20. Adjust Screw21. Side Bearing22. Bolt23. Differential Case, LH24. Drive Gear

25. Differential Case RH26. Differential Case Bolt27. Differential Gear28. Differential Gear Washer29. Differential Pinion Washer30. Differential Pinion31. Differential Spider32. Side Bearing Cap33. Lock Plate34. Bolt35. Spring Washer36. Bearing Cap Bolt

CAUTION• The bearing cap and the differential carrier

should be replaced as a set.

Removal1. After removing the drain plug(A), drain out the gearoil.

KMTPA610A

2. After taking off the hub bolt (A), remove the axle shaft(B).

NOTICEWhen it is hard to remove the axle shaft (B), inserthub bolts (A) into the removing screw holes evenly.

KMTPA611A

3. Remove the axle shaft at the opposite side also.4. Making an align mark (C) to the rear axle companionflange (A) and the flange yoke (B) of the rearpropeller shaft, remove the tightening bolt (D) of thepropeller shaft.

KMTPA113A

5. Disassemble the contacting surface between the rearaxle companion flange (A) and the flange yoke (B) ofthe rear propeller shaft.

CAUTIONAs this part is very heavy, be careful theprecautions. Before the working, be sure that itis supported by jack.

KMTPA613A

6. After taking off the differential carrier tightening boltand nut (A), remove the differential carrier assembly(B) from the axle housing (C).

KMTPA614A

Installation1. After installing the differential carrier assembly (B) tothe axle housing (C), tighten the differential carriertightening bolt (A) with the specified torque.

Tightening Torque :49~58.8 Nm (5~6 kgf·m, 36.1~43.3 lb-ft)

KMTPA614A

2. Setting the aligning mark (C) of the rear axlecompanion flange (A) to that of the flange yoke (B) ofthe rear propeller shaft, tighten the bolt (D) of thepropeller shaft.

Tightening Torque :98~107.8 Nm (10~11 kgf·m, 72.3~79.5 lb-ft)

KMTPA113A

3. After installing the axle shaft (B), tighten the hub bolt(A) with the specified torque.


KMTPA611A

4. Install the rear axle shaft of the opposite side.5. Fill in the recommended oil.

Recommended Oil: API GL-5, SAE 80W/90Oil Amount: 4.5±0.25ℓ

KMTPA661A

Disassembly1. Fix the differential carrier (A) at the vise or theworking base.

KMTPA701A

2. Remove the differential carrier bearing cap bolt (A).

KMTPA702A

3. After removing the bearing cap(A), remove the sidebearing nut (B).

KMTPA703A

4. Remove the differential carrier assembly (A) and theside bearing race (B) from the differential carriercollar (C).

KMTPA704A

5. After removing the side bearing (A), remove thedifferential case bolts (B).

KMTPA705A

6. After removing the differential case, remove thedifferential pinion, the differential pinion washer, thedifferential gear, the differential gear washer and thedifferential spider, sequentially.

7. After taking off the tightening bolt of the drive gear,disassemble the differential case and the driver gear.

8. Remove the self locking nut (A) and the companionflange (B).

KMTPA708A

9. Remove the pinion drive (A), the inner bearing (B),the space (C) and the shim (D).

KMTPA709A

10.Remove the oil seal (A) and the outer bearing (B).

KMTPA710A

11.Remove the bearing race (A), the oil stopper (B) andthe outer bearing race (C) from the differential collar.

KMTPA711A

Reassembly1. Install the outer bearing race (C), the oil stopper (B)and the bearing race (A) into the differential collar.

KMTPA711A

2. Install the outer bearing (B) and a new oil seal (A).

KMTPA710A

3. Install the shim (D), the space (C), the inner bearing(B) and the pinion drive (A).

KMTPA709A

4. Install the companion flange and the self locking nut(A).

Tightening Torque :D033H→ 373~471 Nm (38~48 kgf·m, 275~347 lb-ft)R130HS → 196.1~343.2 Nm (20~35 kgf·m,144.6~253.1 lb-ft)

KMTPA708A

5. After assembling the differential case and the drivegear, install the drive gear tightening bolt.


6. After installing the differential pinion, the differentialpinion washer, the differential gear, the differentialgear washer and the differential spider, install thedifferential case.

7. After installing the differential case bolt (B), install theside bearing.

KMTPA705A

8. Install the differential carrier assembly (A) and theside bearing race (B) at the differential carrier collar(C).

KMTPA704A

9. After installing the side bearing nuts (B), install thebearing cap (A).

Tightening Torque : 69~78 Nm (7~8 kgf·m, 51~58 lb-ft)

KMTPA703A

hyundai hd78 propeller shaft and axle (Мост и Редуктор)

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