DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR

(DRY BRAKE)
S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120 FTBCS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005]

PART NO. 1624739

1400 SRM 1245

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!

Drive Axle and Differential Assembly Repair

Table of Contents

TABLE OF CONTENTS
General ............................................................................................................................................................... Drive Axle Repair............................................................................................................................................... Remove and Disassemble .............................................................................................................................. Clean and Inspect .......................................................................................................................................... Assemble and Install ..................................................................................................................................... Differential Repair ............................................................................................................................................. Remove ........................................................................................................................................................... Support Differential Assembly From Differential Housing Assembly................................................... Differential Assembly From Differential Assembly Support.................................................................. Differential Assembly Support From Drop Box....................................................................................... Drive Pinion and Pinion Gear, From Differential Assembly Support .................................................... Disassemble ................................................................................................................................................... Differential Assembly ............................................................................................................................... Drop Box Housing ..................................................................................................................................... Differential Assembly Support ................................................................................................................. Differential Housing.................................................................................................................................. Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Differential Housing.................................................................................................................................. Differential Assembly Support ................................................................................................................. Drop Box Housing ..................................................................................................................................... Differential Assembly ............................................................................................................................... Install ............................................................................................................................................................. Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) .................................................................. Drive Pinion and Pinion Gear Into Differential Assembly Support....................................................... Differential Assembly Into Differential Assembly Support .................................................................... Ring Gear Backlash, Adjust...................................................................................................................... Gear Set, Tooth Contact Pattern Check................................................................................................... Differential Assembly Support Into Differential Housing ...................................................................... Torque Specifications ......................................................................................................................................... This section is for the following models: S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120 FTBCS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) [N005] 1 1 1 4 4 6 6 6 8 10 12 13 13 15 16 17 18 18 18 19 20 21 24 24 27 29 31 32 35 36

2006 HYSTER COMPANY

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

1400 SRM 1245

Drive Axle Repair

General
This section has the repair procedures for the drive axle and differential assembly.

Drive Axle Repair

REMOVE AND DISASSEMBLE WARNING
When putting the lift truck on blocks, make sure the surface is solid, even, and level. Any blocks used to support the lift truck must be solid, one-piece units. 1. Put blocks on each side (front and back) of the steering tires to prevent movement of the lift truck. 2. Raise the lift truck and put blocks under the frame so that the drive wheels do not touch the floor. Put blocks under the counterweight for stability. 3. Remove the mast assembly as described in the section Mast Repairs, 2- and 3-Stage Masts 4000 SRM 1250. 4. Remove the fill plug and O-ring. Discard O-ring. 5. Remove the drain plug and O-ring to drain the oil from the drive axle into a suitable container. Discard O-ring. See Figure 1. 6. Remove the wheels. 7. Disconnect the brake line connecting the master cylinder to the brake manifold located on top of the differential housing assembly. 8. Remove the parking brake cable. Refer to the section Brake System 1800 SRM 1247. 9. Place blocks under the axle assembly and connect slings and lifting device. 10. Place blocks under the transmission to support the transmission while removing the drive axle. 11. Remove the capscrews retaining the drive shaft and remove the drive shaft. 12. Remove the transmission isolator mounting bolt located on top of the assembly. See Figure 7. 1. 2. 3. 4. 5. DIFFERENTIAL HOUSING ASSEMBLY O-RING OIL FILL PLUG OIL DRAIN PLUG O-RING Figure 1. Drain Plug 13. Remove the four mounting capscrews from the drive axle. See Figure 2. 14. Remove blocks and lower the drive axle assembly. Pull axle forward and away from frame. 15. Place blocks under the differential assembly. 16. Remove the axle shafts, hub/brake drum assembly, and back plates. Refer to the section Brake System 1800 SRM 1247. 17. Remove the capscrews and washers retaining the hanger assembly to the internal gear and differential housing. 18. Remove the planetary gear assembly from the differential housing.

Drive Axle Repair

1400 SRM 1245

1. 2. 3. 4. 5. 6. 7.

BRAKE MANIFOLD INPUT SHAFT (YOKE) OUTER SEAL BEARING CONE BEARING CUP INNER SEAL HUB/BRAKE DRUM ASSEMBLY 8. BEARING CUP 9. BEARING CONE

10. 11. 12. 13. 14. 15. 16. 17. 18.

WHEEL BEARING WASHER LOCK PLATE LOCK NUT AXLE SHAFT CAPSCREW CAPSCREW BRAKE ASSEMBLY BRAKE LINE CAPSCREW Figure 2. Drive Axle

19. 20. 21. 22. 23. 24. 25. 26.

WASHER CAPSCREW WASHER HANGER ASSEMBLY INTERNAL GEAR PLANETARY GEAR ASSEMBLY SUN GEAR DIFFERENTIAL HOUSING ASSEMBLY

1400 SRM 1245 19. Remove the internal gear from the differential housing. 20. Remove the sun gear from the differential housing. 21. Remove the outer snap ring retaining the ball bearing. See Figure 3.

Drive Axle Repair 24. Remove pin retaining the thrust washer, planetary gear, spacer, and needle bearings. See Figure 4.

1. 2. 3. 4.

PLANETARY GEAR ASSEMBLY INNER SNAP RING BALL BEARING OUTER SNAP RING Figure 3. Planetary Gear Disassembly/ Assembly

1. 2. 3. 4. 5. 6.

PLANETARY GEAR ASSEMBLY PIN THRUST WASHER SPACER NEEDLE BEARINGS (QTY 48) PLANETARY GEAR

Figure 4. Planetary Gear and Needle Bearings 25. Remove planetary gear, thrust washers, and needle bearings from housing. 26. Remove the 48 needle bearings (24 on each side of spacer) and spacer from the planetary gear. Repeat this step on the remainder planetary gears. 27. Remove the thrust washer from the inside of planetary gear assembly. Repeat Step 19 through Step 27 for the opposite side. See Figure 5.

22. Remove ball bearing. 23. Remove inner snap ring.

CAUTION
When removing the planetary gear, ensure that the needle bearings are not lost. Losing any needle bearing could result in damage to the equipment.

Drive Axle Repair

1400 SRM 1245

ASSEMBLE AND INSTALL

1. Install thrust washer inside the planetary gear assembly. 2. Apply a light coat of grease on the inside of the planetary gear and slowly install 24 needle bearings on each side of the spacer into planetary gear to be flush with the gear face. NOTE: Spacer should split the needle bearings into two separate sections for one planetary gear assembly. 3. Apply a light coat of grease on thrust washer and install the thrust washer on the ends of the planetary gear. 1. PLANETARY GEAR ASSEMBLY 2. THRUST WASHER Figure 5. Planetary Gear Assembly and Thrust Washer 4. Install the thrust washers, planetary gear, and needle bearings as an assembly into the planetary gear assembly. 5. Ensure flat surface of the pin is toward the center of the carrier and install pin in alignment with the planetary gear. Repeat Step 2 through Step 5 for remainder planetary gears. 6. Install inner snap ring to retain pins. 7. Install ball bearing. 8. Install outer snap ring to retain the ball bearing. 9. Install the sun gear in the differential housing. Repeat steps Step 1 through Step 9 for the opposite side. 10. Apply RTV High Performance sealant, Hyster Part No. 1584621 or equivalent, to the mating surface of the internal gear. Install the internal gear on the differential housing. 11. Install planetary gear assembly into the differential housing assembly. 12. Place the hanger assembly in position on the differential housing assembly. Apply Loctite 242 to the capscrews and install capscrews and lockwashers to retain differential housing assembly. Tighten capscrews in sequence shown in Figure 6 to 225 to 248 Nm (166 to 183 lbf ft). Repeat steps Step 10 and Step 11 for the opposite side.

CLEAN AND INSPECT WARNING

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturers recommended safety precautions. 1. Clean all the parts of the drive axle with solvent. 2. Inspect the planetary gears, spacers, needle bearings, and thrust washers for damage. If planetary gears, spacers, needle bearings, or thrust washers show signs of wear or damage, replace the components as needed. 3. Inspect the internal gears for wear and damage. Replace as needed. Clean silicone from mating surfaces. 4. Inspect the sun gear for wear or damage. If the sun gears show signs of wear or damage, replace the sun gear. The splines of the sun gears must not be damaged. 5. Inspect the axle shafts for wear and cracks at the flange, shaft, and splines. If axle shafts show signs of wear or damage, replace the axle shafts. The splines for the axle shafts must not be damaged.

1400 SRM 1245

Drive Axle Repair

Figure 6. Hanger Assembly Tightening Sequence NOTE: Apply Loctite 515 or High Performance RTV Silicone Gasket Maker on the axle shaft flange when installing. 13. Install the back plates, hub/brake drum assemblies, and axle shafts. Refer to the section Brake System 1800 SRM 1247. 14. Connect slings and lifting device to drive axle. NOTE: When installing the drive axle, ensure the drive axle is held with the upper surface of the drive axle against the frame. This will prevent any gap between the frame and the drive axle mount, and will ensure even weight distribution. 15. Position the drive axle in the lift truck. NOTE: It is recommended to use a torque multiplier to achieve the torque specification in Step 16. 16. Install the four mounting capscrews and washers. Tighten the capscrews to 820 to 902 Nm (605 to 665 lbf ft). 17. Place the drive shaft in position and install the retaining capscrews. Tighten the drive shaft capscrews to 50 to 66 Nm (37 to 49 lbf ft). 18. Install the transmission isolator mounting bolt located on top of the assembly. Tighten the bolt to 225 to 250 Nm (166 to 184 lbf ft). See Figure 7. 1. 2. 3. 4. 5. 6. TRANSMISSION DIFFERENTIAL HOUSING ASSEMBLY ISOLATOR, TRANSMISSION WASHER LOCKWASHER CAPSCREW

Figure 7. Transmission to Differential Housing Assembly Mounting Bolts 19. Remove blocks from under the transmission. 20. Install parking brake cable. Make sure the brake cable is routed properly and has no interference. Verify that the parking brake operates properly. Refer to the section Brake System 1800 SRM 1247. 21. Connect the brake line connecting the master cylinder to the brake manifold located on top of the differential housing assembly. NOTE: When tightening the wheel nuts, DO NOT use any lubricant on the studs or nuts. 22. Install the wheel and nuts and tighten the nuts to 610 to 680 Nm (450 to 502 lbf ft). 23. Apply multipurpose grease to new O-ring and install O-ring on the drain plug. 24. Install the O-ring and drain plug, and tighten to 14 to 27 Nm (10 to 20 lbf ft).

Differential Repair 25. Fill the drive axle to the proper level with 7.5 to 8.0 liter (7.9 to 8.4 qt) of SAE 80W-90 gear oil through the fill hole as shown in Figure 8. 26. Apply multipurpose grease to new O-ring and install O-ring on the fill plug. 27. Install the O-ring, fill plug, and tighten to 14 to 27 Nm (10 to 27 lbf ft). 28. Remove the air from the brake system as described in the section Brake System 1800 SRM 1247. 29. Install the mast assembly as described in the section Mast Repairs, 2- and 3-Stage Masts 4000 SRM 1250. 30. Raise the lift truck and remove blocks from under frame and from under the counterweight. Lower the lift truck. 31. Remove the blocks on each side (front and back) of the steering tires. 1. OIL FILL PLUG 2. OIL DRAIN PLUG 3. OIL FILL LEVEL

1400 SRM 1245 32. Operate the lift truck and check for proper operation and leaks.

Figure 8. Oil Fill Level

Differential Repair
REMOVE
For the following repair procedures, the drive axle must be removed and disassembled. Refer to the section Drive Axle Repair.

Support Differential Assembly From Differential Housing Assembly

1. Remove input shaft (yoke). 2. Remove the dust cover. 3. Remove the oil seal. See Figure 9. 4. Remove capscrew and lockwasher retaining brake manifold bracket to the differential assembly support. See Figure 10. 5. Remove brake manifold bracket.

1. 2. 3. 4.

DIFFERENTIAL HOUSING ASSEMBLY OIL SEAL DUST COVER INPUT SHAFT (YOKE) Figure 9. Drive Axle Yoke

1400 SRM 1245 6. Remove capscrews and lockwashers retaining the differential assembly support to the differential housing. Using two of the M8 1.25 40 capscrews removed from the differential assembly support, push the differential assembly support from the differential housing. If the capscrews do not have enough threaded length, use a prybar to finish removing the differential assembly support. 7. Remove differential assembly support from the differential housing assembly. See Figure 10.

Differential Repair

1. 2. 3. 4. 5. 6. 7.

DIFFERENTIAL HOUSING DIFFERENTIAL ASSEMBLY SUPPORT BRAKE MANIFOLD BRACKET LOCKWASHERS CAPSCREWS CAPSCREW LOCKWASHER Figure 10. Differential Housing Assembly Section Disassembly

Differential Repair

1400 SRM 1245

Differential Assembly From Differential Assembly Support

NOTE: Before working on the differential assembly, inspect the hypoid gear set for damage. If inspection shows no damage, the same gear set can be used again. Using a dial indicator, measure the backlash of the gear set and make a record of the dimension. STEP 1. Remove differential assembly support retainer ring cotter pins. Using a retainer ring special tool, Hyster Part No. 1581188, loosen the retainer rings. If necessary, loosen the bearing cap capscrews to allow the retainer rings to turn freely.

1. COTTER PIN 2. RETAINER RING

1. RETAINER RING SPECIAL TOOL

1400 SRM 1245 STEP 2. Remove the retainer rings.

Differential Repair

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. RETAINER RINGS STEP 3. Mark one differential carrier leg and bearing cap to correctly match the parts when assembling differential assembly support. Mark the part using a center punch and hammer. Remove the capscrews and washers retaining the bearing caps. Remove the bearing caps.

1. 2. 3. 4. 5.

DIFFERENTIAL ASSEMBLY SUPPORT BEARINGS BEARING CAPS WASHERS CAPSCREWS

Differential Repair STEP 4. Remove the differential assembly from the differential assembly support.

1400 SRM 1245

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. TAPERED ROLLER BEARING AND CUP 3. DIFFERENTIAL ASSEMBLY

Differential Assembly Support From Drop Box

STEP 1. Remove the capscrews and lockwashers retaining the pinion cover plate. Remove pinion cover plate.

1. 2. 3. 4. 5.

DIFFERENTIAL ASSEMBLY SUPPORT PINION COVER PLATE CAPSCREWS LOCKWASHERS DROP BOX ASSEMBLY

10

1400 SRM 1245

Differential Repair

CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The staked areas can cause damage to the pinion threads, making the pinion unserviceable. NOTE: When removing the pinion, be sure to retain the shims. STEP 2. Use a small, flat chisel to unstake the pinion nut. Remove the pinion nut, washer, bearing cone, and shims.

1. 2. 3. 4. 5. STEP 3. Remove the capscrews, washers, and clamp retaining the drop box housing. Using two of the M8 1.25 50 capscrews removed from the drop box housing, push the drop box housing from the differential assembly support. If the capscrews do not have enough threaded length, use a prybar to finish removing the drop box housing.

DIFFERENTIAL ASSEMBLY SUPPORT SHIMS BEARING CONE WASHER PINION NUT

1. 2. 3. 4. 5.

DIFFERENTIAL ASSEMBLY SUPPORT DROP BOX HOUSING CLAMP LOCKWASHERS CAPSCREWS

11

Differential Repair

1400 SRM 1245

Drive Pinion and Pinion Gear, From Differential Assembly Support

NOTE: When removing the pinion, be sure to retain the shims. STEP 1. Carefully remove pinion assembly from the differential assembly support. Using a press and a bearing puller, remove the shims and inner bearing from the pinion.

1. 2. 3. 4. STEP 2. Remove drive gear and driven gear.

DIFFERENTIAL ASSEMBLY SUPPORT INNER BEARING SHIMS PINION

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. DRIVE GEAR 3. DRIVEN GEAR

12

1400 SRM 1245

Differential Repair

DISASSEMBLE

Differential Assembly
STEP 1. Remove the bearing cups. Using a suitable bearing puller, remove the bearings from the differential assembly.

1. BEARING CUP 2. TAPERED ROLLER BEARING 3. DIFFERENTIAL ASSEMBLY STEP 2. Remove the capscrews retaining the ring gear to the differential assembly. Remove the ring gear.

1. RING GEAR 2. DIFFERENTIAL ASSEMBLY 3. CAPSCREW

13

Differential Repair

1400 SRM 1245

NOTE: Mark each side of the case halves before separating to ensure alignment at reassembly. STEP 3. Remove the capscrews retaining the case halves together and separate the case halves. Inspect the case halves for wear or damage. If wear or damage is present, the entire differential assembly must be replaced.

1. 2. 3. 4. STEP 4. Remove the side gears and thrust washers from the case halves.

CAPSCREWS CASE HALF SPIDER ASSEMBLY CASE HALF

1. 2. 3. 4. 5.

CASE HALF THRUST WASHER SIDE GEAR SPIDER ASSEMBLY CASE HALF

14

1400 SRM 1245 STEP 5. Remove the spherical washers and spider gears from the cross. Inspect the spider gears for wear or damage. Replace as needed.

Differential Repair

1. SPHERICAL WASHER 2. SPIDER GEAR 3. CROSS

Drop Box Housing

STEP 1. Using a bearing puller, remove outer bearing from the drop box housing.

1. OUTER BEARING 2. DROP BOX HOUSING

15

Differential Repair STEP 2. Using a suitable soft drift, remove the bearing cup.

1400 SRM 1245

1. DROP BOX HOUSING 2. BEARING CUP

Differential Assembly Support

STEP 1. Using a suitable soft drift, remove the bearing cup from the differential assembly support.

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. BEARING CUP

16

1400 SRM 1245 STEP 2. Using a bearing puller, remove inner bearing from the differential assembly support.

Differential Repair

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. INNER BEARING

Differential Housing
NOTE: Only remove the breather cap if damaged. STEP 1. Remove breather cap from differential housing.

1. DIFFERENTIAL HOUSING 2. BREATHER CAP

17

Differential Repair

1400 SRM 1245 assembly. If bearings show signs of wear, cracks, or damage, replace with new bearing. Pinion and gears- Inspect the pinion and gears for wear or damage. Gears that are worn or damaged must be replaced. Main differential assembly- Inspect all parts of the main differential assembly for corrosion, wear, or damage. Parts that are damaged must be replaced. Differential Assembly Support- Inspect all parts of the differential assembly support for corrosion, wear, or damage. Parts that are damaged must be replaced. Drop box housing- Inspect all parts of the drop box housing for corrosion, wear, or damage. Parts that are damaged must be replaced. Alignment pins- Inspect all alignment pins for corrosion, wear, or damage. Parts that are damaged must be replaced.

CLEAN AND INSPECT WARNING

Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Clean and inspect the following parts of the differential: Drive axle- Clean the parts of the axle with solvent and dry with compressed air. Inspect all machined surfaces and bearings for wear and damage. Tapered roller bearings- Inspect the cup, cone, rollers, and cage of all tapered roller bearings in the

ASSEMBLE

Differential Housing
STEP 1. Wrap the breather cap threads with approximately 1.5 turns of Teflon tape. Install the breather cap.

1. DIFFERENTIAL HOUSING 2. BREATHER CAP

18

1400 SRM 1245

Differential Repair

Differential Assembly Support

STEP 1. Using a press, press the outer race of the inner bearing into the differential assembly support until it is contacting the bottom of the bore.

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. INNER BEARING STEP 2. Using a press, press the pinion inner bearing cup into the differential assembly support.

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. BEARING CUP

19

Differential Repair

1400 SRM 1245

Drop Box Housing

STEP 1. Using a press, press the outer race of the outer bearing into the drop box housing until it is contacting the bottom of the bore.

1. OUTER BEARING 2. DROP BOX HOUSING STEP 2. Using a press, press the inner cup until it seats on the bottom of the bore.

1. DROP BOX HOUSING 2. INNER CUP

20

1400 SRM 1245

Differential Repair

Differential Assembly
STEP 1. Lubricate both sides of the spherical washers with 80W - 90W gear lube. Install the spider gears and spherical washers onto the cross.

1. SPHERICAL WASHER 2. SPIDER GEAR 3. CROSS STEP 2. Lubricate both sides of the thrust washers with 80W - 90W gear lube. Install the side gears and thrust washers into the differential halves.

1. 2. 3. 4. 5.

CASE HALF THRUST WASHER SIDE GEAR SPIDER ASSEMBLY CASE HALF

21

Differential Repair STEP 3. Place spider assembly into the case halves and assemble the case halves. Apply Loctite 242 to the threads of the capscrews and install the capscrews. Tighten the capscrews in the sequence shown to 125 to 145 Nm (92 to 107 lbf ft).

1400 SRM 1245

1. 2. 3. 4.

CAPSCREWS CASE HALF SPIDER ASSEMBLY CASE HALF

22

1400 SRM 1245 STEP 4. Place the ring gear in position on the differential assembly and install the capscrews. Tighten the capscrews in the sequence shown to 152 to 167 Nm (112 to 123 lbf ft).

Differential Repair

1. RING GEAR 2. DIFFERENTIAL ASSEMBLY 3. CAPSCREW

23

Differential Repair

1400 SRM 1245

CAUTION
Do not damage the bearing rollers or cage when pressing the bearing cones onto the differential assembly. Press on the inner raceway of the cone. STEP 5. Press the bearing cones onto the differential assembly. Install the bearing cups onto the bearing cones.

1. BEARING CUP 2. TAPERED ROLLER BEARING 3. DIFFERENTIAL ASSEMBLY

INSTALL Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)

NOTE: Use this procedure if a new ring gear and pinion set is installed, or if the depth of the pinion has to be adjusted. NOTE: If replacing the center section, use a new standard shim set with nominal thickness of 1 mm for adjusting the depth of the pinion and a new standard shim set with nominal thickness of 1 mm for adjusting the preload. Perform the following procedure until the correct backlash and gear tooth contact pattern is achieved. The pinion is adjusted using shims. If the same bearings, ring gear, and pinion are used, use the original shim set. See Figure 11. If a new bearings, ring gear, and pinion are used, adjust the pinion as described below.

Figure 11. Shim Set Location

24

1400 SRM 1245 Legend for Figure 11 1. 2. 3. 4. PINION STAKE NUT WASHER BEARING, TAIL OUTER SHIM SET (CONTROLS BEARING PRELOAD) 5. GEAR 6. BEARING, HEAD 7. INNER SHIM SET (CONTROLS DEPTH OF PINION) The correct shim set thickness can be found by using the original and new parts. Use the original shim set thickness and the pinion variation number on the original and new pinion. For the location and identification of the number, see Figure 12

Differential Repair 1. Use a micrometer to measure the thickness of each individual shim of the original shim set that was removed from under the pinion carrier. Add the individual thickness together for total thickness. Make a note of the measurement for later use. 2. Check the pinion variation number for the original pinion. See Figure 12. If this number is a plus (+) value, subtract the value from the value in step Step 1. If the pinion variation number is a minus ( ) value, add the number to the value in Step 1. The number shown is in 0.00 inch (+2 = +0.002 in.). The result is the standard thickness for a shim set. NOTE: The value calculated in Step 2 is the thickness of the standard shim set, without a variation. 3. Check the pinion variation number for the new pinion. Add or subtract this number to the standard thickness value of Step 2. Add the number if the value is a plus (+) value. Subtract the number if the value is a minus ( ) value. The result is the correct thickness for the new shim set. See the examples in Table 1 NOTE: The value calculated in Step 3 is the thickness of the new shim set that will be installed. See the examples shown in Table 1.

1. PINION VARIATION NUMBER Figure 12. Pinion Variation Number Find the correct thickness of the mounting distance (inner) shim set as follows:

25

Differential Repair Table 1. Pinion Variation Numbers Examples Examples in.

1400 SRM 1245

mm

NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 12. 1. Original Shim Set Thickness Original Pinion Variation Number = +2 in. (+0.05 mm) Standard Shim Set Thickness New Pinion Variation Number = +5 in. (+0.13 mm) New Shim Set Thickness = 2. Original Shim Set Thickness Original Pinion Variation Number = 2 in. ( 0.05 mm) Standard Shim Set Thickness New Pinion Variation Number = +5 in. (+0.13 mm) New Shim Set Thickness = 3. Original Shim Set Thickness Original Pinion Variation Number = +2 in. (+0.05 mm) Standard Shim Set Thickness New Pinion Variation Number = 5 in. ( 0.13 mm) New Shim Set Thickness = 4. Original Shim Set Thickness Original Pinion Variation Number = 2 in. ( 0.05 mm) Standard Shim Set Thickness New Pinion Variation Number = 5 in. ( 0.13 mm) New Shim Set Thickness = 0.030 0.002 0.028 +0.005 0.033 0.030 +0.002 0.032 +0.005 0.037 0.030 0.002 0.028 0.005 0.023 0.030 +0.002 0.032 0.005 0.027 0.76 0.05 0.71 +0.13 0.84 0.76 +0.05 0.81 +0.13 0.94 0.76 0.05 0.71 0.13 0.58 0.76 +0.05 0.81 0.13 0.68

26

1400 SRM 1245

Differential Repair

Drive Pinion and Pinion Gear Into Differential Assembly Support

STEP 1. Install the drive gear and driven gear.

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. DRIVE GEAR 3. DRIVEN GEAR STEP 2. Install mounting distance (inner) shims, determined in Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion), onto the pinion. NOTE: Ensure the bearing being installed is lubricated with SAE 80W-90W gear oil. Using a press, press the inner bearing onto the pinion and carefully install the pinion assembly into the differential assembly support.

1. 2. 3. 4.

DIFFERENTIAL ASSEMBLY SUPPORT INNER BEARING SHIMS PINION

27

Differential Repair STEP 3. Apply Loctite 515 sealant to the mating surface of the drop box housing. Place the drop box housing in position on the differential assembly support. Install the clamp, washers, and capscrews. Tighten capscrews to 19 to 23 Nm (14 to 17 lbf ft).

1400 SRM 1245

1. 2. 3. 4. 5.

DIFFERENTIAL ASSEMBLY SUPPORT DROP BOX CLAMP WASHERS CAPSCREWS

NOTE: Ensure the bearing being installed is lubricated with SAE 80W-90W gear oil. STEP 4. Install the preload (outer) shims and outer bearing. Install the washer and new pinion nut. Tighten the pinion nut to 530 to 645 Nm (391 to 476 lbf ft) to seat the bearings. Rotate the pinion two revolutions in both directions. Loosen the pinion nut and retighten to 370 to 410 Nm (273 to 302 lbf ft) for the pre-load. Rotate the pinion ten revolutions in both directions. Verify pinion shaft rotating torque is 4.0 to 6.0 Nm (44.2 to 53.1 lbf in). Add or remove preload (outer) shims as necessary to obtain the correct rotating torque.

1. 2. 3. 4. 5.

DIFFERENTIAL ASSEMBLY SUPPORT SHIMS BEARING WASHER PINION NUT

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1400 SRM 1245

Differential Repair

Differential Assembly Into Differential Assembly Support

STEP 1. Place the differential assembly into the differential assembly support.

1. DIFFERENTIAL ASSEMBLY SUPPORT 2. TAPERED ROLLER BEARING AND CUP 3. DIFFERENTIAL ASSEMBLY STEP 2. Place the retainer rings in position in the differential assembly support. Carefully place the bearing caps in the same location as removed. Install the capscrews and washers. Tighten capscrews finger tight. Verify the retainer rings rotate easily and are not cross threaded. Tighten the bearing cap capscrews to 225 to 270 Nm (166 to 199 lbf ft).

1. 2. 3. 4. 5. 6.

DIFFERENTIAL ASSEMBLY SUPPORT RETAINER RING BEARING BEARING CAP WASHER CAPSCREWS

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Differential Repair STEP 3. Using a retainer ring special tool, Hyster Part No. 1581188, adjust the retainer rings in equal rotations so the backlash of the ring gear is 0.15 to 0.20 mm (0.006 to 0.008 in.). See Ring Gear Backlash, Adjust. Tighten each retainer ring one to two notches past the point where the retainer makes contact with the bearing cup. Recheck the backlash. Verify that the rotating torque at the pinion shaft has increased 0.5 to 0.7 Nm (4.4 to 6.2 lbf in). Check the pinion and ring gear tooth contact pattern. See Gear Set, Tooth Contact Pattern Check. Install differential assembly retainer ring cotter pins and bend tabs over. 1. COTTER PIN 2. RETAINER RING

1400 SRM 1245

1. RETAINER RING SPECIAL TOOL STEP 4. Stake the pinion nut with 8 mm spherical punch until a 1 to 2 mm (0.039 to 0.079 in.) gap is between the nut and pinion shaft at two places. Retighten the drop box capscrews to 19 to 23 Nm (14 to 17 lbf ft).

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1400 SRM 1245 STEP 5. Apply RTV High Performance sealant, Hyster Part No. 1584621 or equivalent, to the mating surface of the pinion cover plate. Place the pinion cover plate in position on the drop box and install the washers and capscrews. Tighten the capscrews to 19 to 23 Nm (14 to 17 lbf ft).

Differential Repair

1. 2. 3. 4. 5.

DIFFERENTIAL ASSEMBLY SUPPORT PINION COVER PLATE CAPSCREWS WASHERS DROP BOX

Ring Gear Backlash, Adjust

If the old gear set is installed, adjust the backlash to the setting that was measured before the differential assembly was disassembled. If a new gear set will be installed, adjust the backlash to 0.15 to 0.20 mm (0.006 to 0.008 in.). To adjust/check the backlash, follow the steps outlined below: 1. Install a dial indicator on the mounting flange of the differential as shown in Figure 13. 2. Adjust the dial indicator so that the plunger or pointer is against the tooth surface. See Figure 13. 3. Adjust the indicator to zero. 4. Hold the drive pinion in position. 5. After reading the dial indicator, rotate the ring gear in both directions, against the drive pinion teeth until it contacts the pinion. Measure 3 to 5 places for correct specification. Figure 13. Gear Clearance Check 6. If the backlash reading is within specifications, 0.15 to 0.20 mm (0.006 to 0.008 in.), continue checking tooth contact patterns.

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Differential Repair 7. If the backlash reading is not within specifications, adjust backlash using retainer rings. Continue onto Step 8 through Step 11. 8. Verify that the bearing cap capscrews are only finger tight. NOTE: To increase backlash, move ring gear away from drive pinion. To decrease backlash, move ring gear toward drive pinion. NOTE: When adjusting backlash, move the ring gear only. Do not move the drive pinion. 9. Loosen one bearing adjusting ring one notch, then tighten the opposite ring the same amount. See Figure 14 and Figure 15.

1400 SRM 1245

1. LOOSEN RETAINER RING THIS SIDE 2. DECREASE BACKLASH 3. TIGHTEN RETAINER RING THIS SIDE Figure 15. Backlash Decrease 10. Tighten the bearing cap capscrews to 225 to 270 Nm (166 to 199 lbf ft). Recheck the backlash. 11. Repeat Step 2 through Step 10 until backlash is within 0.15 to 0.20 mm (0.006 to 0.008 in.). 12. Check the tooth contact pattern. See Gear Set, Tooth Contact Pattern Check.

Gear Set, Tooth Contact Pattern Check

1. TIGHTEN RETAINER RING THIS SIDE 2. INCREASE BACKLASH 3. LOOSEN RETAINER RING THIS SIDE Figure 14. Backlash Increase NOTE: The gear clearance can be changed within the limits of 0.15 to 0.20 mm (0.006 to 0.008 in.). NOTE: If the original gear set is installed, adjust the clearance to the original value recorded in Differential Assembly From Differential Assembly Support. If a new gear set is installed, adjust the retainer rings for 0.15 to 0.20 mm (0.006 to 0.008 in.) clearance. Refer to Ring and Pinion Tooth Contact Adjustment.

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1400 SRM 1245 Table 2. Ring and Pinion Tooth Contact Adjustment 1. Apply a colored dye or grease to approximately 12 of the ring gear teeth. 2. Rotate ring gear forward and backward so that the 12 gear teeth go past the drive six times to get to the contact patterns. Repeat if needed to get a clearer pattern. 3. Check the tooth contact pattern on the ring gear. See Table 3 and Table 4. Make sure that the pattern is checked on the side of the tooth where the pinion applies the force in the forward direction.

Differential Repair

Table 3. Correct Tooth Contact The contact area is the center between the top and bottom of the tooth. The contact area is toward the inner circumference of the ring gear. NOTE: Normal pattern during adjustment shown.

The contact area is the center between the top and the bottom of the tooth. The contact area will be almost the full length of the tooth.

NOTE: Wear pattern from operation shown.

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Differential Repair Table 4. Incorrect Tooth Contact The pinion is too far away from the center of the gear. Add shims to move pinion toward ring gear. Check that the clearance is correct. Some movement of ring gear away from pinion may be necessary.

1400 SRM 1245

The pinion is too close to the center of the ring gear. Remove shims to move pinion away from the ring gear. Check that the clearance is correct. Some movement of the ring gear toward the pinion may be necessary.

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1400 SRM 1245

Differential Repair

Differential Assembly Support Into Differential Housing

STEP 1. Apply RTV High Performance sealant, Hyster Part No. 1584621 or equivalent, to the mating surface of the differential assembly support. Place the differential assembly support in position on the differential housing. Install the capscrews, washers, and brake manifold bracket. Tighten capscrews to 66 to 79 Nm (49 to 58 lbf ft).

1. 2. 3. 4. 5. 6. 7. STEP 2. Using a press on the outer diameter of the input shaft oil seal, press the input shaft oil seal into the drop box until the seal is flush with the housing. After installing the oil seal, apply grease to the lip of the oil seal. Install the input shaft (yoke).

DIFFERENTIAL HOUSING DIFFERENTIAL ASSEMBLY SUPPORT BRAKE MANIFOLD BRACKET WASHERS CAPSCREWS CAPSCREWS WASHERS

1. 2. 3. 4.

DIFFERENTIAL HOUSING ASSEMBLY OIL SEAL DUST COVER INPUT SHAFT (YOKE)

Assemble and install the drive axle. Refer to the section Drive Axle Repair.

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Torque Specifications

1400 SRM 1245

Torque Specifications
Axle Shaft Capscrews 90 to 99 Nm (66 to 73 lbf ft) Bearing Cap Capscrews 225 to 270 Nm (166 to 199 lbf ft) Brake Assembly to Axle Mount Capscrews 340 to 375 Nm (250 to 276 lbf ft) Brake Manifold to Differential Housing Capscrews 23 to 28 Nm (17 to 21 lbf ft) Differential Assembly Support to Differential Housing 66 to 79 Nm (49 to 58 lbf ft) Differential Carrier Halves Capscrews 125 to 145 Nm (92 to 107 lbf ft) Differential Drain Plug 50 to 55 Nm (37 to 41 lbf ft) Differential Fill Plug 151 to 166 Nm (111 to 122 lbf ft) Drive Shaft Capscrews 50 to 66 Nm (37 to 49 lbf ft) Drop Box Housing Capscrews 19 to 23 Nm (14 to 17 lbf ft) Hanger Assembly to Differential Housing 225 to 248 Nm (166 to 183 lbf ft) Hanger Assembly to Frame 820 to 902 Nm (605 to 665 lbf ft) Pinion Cover Capscrews 19 to 23 Nm (14 to 17 lbf ft) Pinion Gear Capscrews 152 to 167 Nm (112 to 123 lbf ft) Pinion Nut, for Pre-Load 370 to 410 Nm (273 to 302 lbf ft) Pinion Nut, to Seat Bearings 530 to 645 Nm (391 to 476 lbf ft) Transmission Mount Bolt to Differential Housing 225 to 250 Nm (166 to 184 lbf ft) Wheel Nuts 610 to 680 Nm (450 to 502 lbf ft)

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TECHNICAL PUBLICATIONS
1400 SRM 1245 6/06 (3/06) Printed in United Kingdom