DRIVE AXLE AND DIFFERENTIAL DIFFERENTIAL ASSEMBL ASSEMBLY Y REPAIR REPAIR (DRY BRAKE) S4.0, 5.0, 5.50FT ([S80, 100, 120FT]; S80, 100, 120 FTBCS; FTBCS; S120FTPRS) [G004]; H4.0FT5/FT6; H4.5FTS5, 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, fastened, and that the load being lifted is balanced. balanced. Make sure the crane, cables, 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 Disconnect the battery ground cable on internal combustion combustion lift trucks. • Always use correct 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. making repairs. repairs. Replacement Replacement parts • Always use HYSTER APPROVED parts when making 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. • Alwa Always ys fast fasten en a DO NOT OPERA OPERATE TE tag tag to the the cont contro rols ls of of the the unit unit when when makin making g repai repairs rs,, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasolin Gasoline, e, Liq Liquid uid Petrol Petroleum eum Gas (LPG), (LPG), Compre Compresse ssed d Natural Natural Gas (CNG), (CNG), and Diesel Diesel fuel fuel are flammable. flammable. Be sure to follow the necessary necessary safety precautions precautions when handling these fuels and when working on these fuel systems. Batteries generate generate flammable gas when they are being charged. charged. Keep fire and sparks • Batteries 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............................................................................................................................................... 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 Differential Assembly Support From Drop Box............ Box ....................... ....................... ........................ ........................ ........................ ........................ ................ .... Drive Pinion and Pinion Gear, From Differential Assembly Support ............ ........................ ........................ ........................ ................ .... Disassemble ................................................................................................................................................... Differential Assembly ............................................................................................................................... Drop Box Housing Housing ..................................................................................................................................... ..................................................................................................................................... Differential Assembly Support ................................................................................................................. Differential Housing .................................................................................................................................. .................................................................................................................................. Clean and Inspect .......................................................................................................................................... Assemble ........................................................................................................................................................ Differential Housing .................................................................................................................................. .................................................................................................................................. Differential Assembly Support ................................................................................................................. Drop Box Housing Housing ..................................................................................................................................... ..................................................................................................................................... Differential Assembly ............................................................................................................................... Install ............................................................................................................................................................. Pinion Inner Shim Set, Adjust Thickness Thickness (Depth of Pinion) ............ ........................ ........................ ........................ ........................ .................. ...... Drive Pinion and Pinion Gear Into Differential Differential Assembly Assembly Support .......... ...................... ........................ ........................ ..................... ......... Differential Assembly Into Differential Assembly Support .............. .......................... ........................ ........................ ........................ .................. ...... Ring Gear Backlash, Backlash, Adjust...................................................................................................................... Adjust...................................................................................................................... Gear Set, Tooth Contact Pattern Check ................................................................................................... Differential Assembly Support Into Differential Housing ............ Housing ........................ ........................ ........................ ........................ ...................... .......... Torque Specifications .........................................................................................................................................
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
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]
©2006 HYSTER COMPANY COMPANY
i
"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.
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Drive Axle Repair
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
1400 SRM 1245
10. WHEEL BEARING WASHER 11. LOCK PLATE 12. LOCK NUT 13. AXLE SHAFT 14. CAPSCREW 15. CAPSCREW 16. BRAKE ASSEMBLY 17. BRAKE LINE 18. CAPSCREW
Figure 2. Drive Axle
2
19. WASHER 20. CAPSCREW 21. WASHER 22. HANGER ASSEMBLY 23. INTERNAL GEAR 24. PLANETARY GEAR ASSEMBLY 25. SUN GEAR 26. DIFFERENTIAL HOUSING ASSEMBLY
1400 SRM 1245
19. Remove the internal gear from the differential housing. 20. Remove the sun gear from the differential housing.
Drive Axle Repair
24. Remove pin retaining the thrust washer, planetary gear, spacer, and needle bearings. See Figure 4.
21. Remove the outer snap ring retaining the ball bearing. See Figure 3.
1. 2. 3. 4.
PLANETARY GEAR ASSEMBLY INNER SNAP RING BALL BEARING OUTER SNAP RING
1. 2. 3. 4. 5. 6.
Figure 3. Planetary Gear Disassembly/ Assembly
Figure 4. Planetary Gear and Needle Bearings
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.
PLANETARY GEAR ASSEMBLY PIN THRUST WASHER SPACER NEEDLE BEARINGS (QTY 48) PLANETARY GEAR
25. Remove planetary gear, thrust washers, and needle bearings from housing. 26. Remove the 48 needle bearings (24on 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.
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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
CLEAN AND INSPECT WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s 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.
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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 N•m (166 to 183 lbf ft). Repeat steps Step 10 and Step 11 for the opposite side.
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.
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.
NOTE: It is recommended to use a torque multiplier to achieve the torque specification in Step 16.
21. Connect the brake line connecting the master cylinder to the brake manifold located on top of the differential housing assembly.
16. Install the four mounting capscrews and washers. Tighten the capscrews to 820 to 902 N•m (605 to 665 lbf ft).
NOTE: When tightening the wheel nuts, DO NOT use any lubricant on the studs or nuts.
17. Place the drive shaft in position and install the retaining capscrews. Tighten the drive shaft capscrews to 50 to 66 N•m (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 N•m (166 to 184 lbf ft). See Figure 7.
22. Install the wheel and nuts and tighten the nuts to 610 to 680 N•m (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 N•m (10 to 20 lbf ft).
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Differential Repair
1400 SRM 1245
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.
32. Operate the lift truck and check for proper operation and leaks.
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 N•m (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 andremove blocks from under frame and from under the counterweight. Lower the lift truck.
1. OIL FILL PLUG 2. OIL DRAIN PLUG 3. OIL FILL LEVEL
31. Remove the blocks on each side (front and back) of the steering tires.
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
6
1400 SRM 1245
Differential Repair
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.
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
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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.
8
RETAINER RING SPECIAL TOOL
1400 SRM 1245
Differential Repair
STEP 2. Remove the retainer rings.
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
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Differential Repair
1400 SRM 1245
STEP 4. Remove the differential assembly from the differential assembly support.
1. 2. 3.
DIFFERENTIAL ASSEMBLY SUPPORT TAPERED ROLLER BEARING AND CUP DIFFERENTIAL ASSEMBLY
1. 2. 3. 4. 5.
DIFFERENTIAL ASSEMBLY SUPPORT PINION COVER PLATE CAPSCREWS LOCKWASHERS DROP BOX ASSEMBLY
Differential Assembly Support From Drop Box STEP 1. Remove the capscrews and lockwashers retaining the pinion cover plate. Remove pinion cover plate.
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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.
DIFFERENTIAL ASSEMBLY SUPPORT SHIMS BEARING CONE WASHER PINION NUT
1. 2. 3. 4. 5.
DIFFERENTIAL ASSEMBLY SUPPORT DROP BOX HOUSING CLAMP LOCKWASHERS CAPSCREWS
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.
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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.
DIFFERENTIAL ASSEMBLY SUPPORT INNER BEARING SHIMS PINION
STEP 2. Remove drive gear and driven gear.
1. DIFFERENTIAL ASSEMBLY SUPPORT 2. DRIVE GEAR 3. DRIVEN GEAR
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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
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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.
CAPSCREWS CASE HALF SPIDER ASSEMBLY CASE HALF
1. 2. 3. 4. 5.
CASE HALF THRUST WASHER SIDE GEAR SPIDER ASSEMBLY CASE HALF
STEP 4. Remove the side gears and thrust washers from the case halves.
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1400 SRM 1245
Differential Repair
STEP 5. Remove the spherical washers and spider gears from the cross. Inspect the spider gears for wear or damage. Replace as needed.
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
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Differential Repair
1400 SRM 1245
STEP 2. Using a suitable soft drift, remove the bearing cup.
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
Differential Repair
STEP 2. Using a bearing puller, remove inner bearing from the differential assembly support.
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
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 sol vent 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 bearingsin the
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.
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
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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
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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
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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 GE AR 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
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Differential Repair
1400 SRM 1245
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 N•m (92 to 107 lbf ft).
1. 2. 3. 4.
22
CAPSCREWS CASE HALF SPIDER ASSEMBLY CASE HALF
1400 SRM 1245
Differential Repair
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 N•m (112 to 123 lbf ft).
1. RING GEAR 2. DIFFERENTIAL ASSEMBLY 3. CAPSCREW
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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 ad justing 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.
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Figure 11. Shim Set Location
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.
1.
PINION VARIATION NUMBER
Figure 12. Pinion Variation Number Find the correct thickness of the mounting distance (inner) shim set as follows:
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.
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Differential Repair
1400 SRM 1245
Table 1. Pinion Variation Numbers Examples Examples
in.
mm
NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 12. 1.
0.030 0.002
0.76 0.05
0.028 +0.005
0.71 +0.13
0.033
0.84
Original Shim Set Thickness Original Pinion Variation Number = 2 in. ( 0.05 mm)
0.030 +0.002
0.76 +0.05
Standard Shim Set Thickness New Pinion Variation Number = +5 in. (+0.13 mm)
0.032 +0.005
0.81 +0.13
New Shim Set Thickness =
0.037
0.94
Original Shim Set Thickness Original Pinion Variation Number = +2 in. (+0.05 mm)
0.030 0.002
0.76 0.05
Standard Shim Set Thickness New Pinion Variation Number = 5 in. ( 0.13 mm)
0.028 0.005
0.71 0.13
New Shim Set Thickness =
0.023
0.58
0.030 +0.002
0.76 +0.05
Standard Shim Set Thickness New Pinion Variation Number = 5 in. ( 0.13 mm)
0.032 0.005
0.81 0.13
New Shim Set Thickness =
0.027
0.68
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.
3.
4.
26
Original Shim Set Thickness Original Pinion Variation Number = 2 in. ( 0.05 mm)
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
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Differential Repair
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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 N•m (14 to 17 lbf ft).
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 N•m (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 N•m (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 N•m (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.
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DIFFERENTIAL ASSEMBLY SUPPORT SHIMS BEARING WASHER PINION NUT
1400 SRM 1245
Differential Repair
Differential Assembly Into Differential Assembly Support STEP 1. Place the differential assembly into the differential assembly support.
1. 2. 3.
DIFFERENTIAL ASSEMBLY SUPPORT TAPERED ROLLER BEARING AND CUP DIFFERENTIAL ASSEMBLY
1. 2. 3. 4. 5. 6.
DIFFERENTIAL ASSEMBLY SUPPORT RETAINER RING BEARING BEARING CAP WASHER CAPSCREWS
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 N•m (166 to 199 lbf ft).
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Differential Repair
1400 SRM 1245
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 N•m (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
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 N•m (14 to 17 lbf ft).
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1400 SRM 1245
Differential Repair
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 N•m (14 to 17 lbf ft).
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 thebacklash 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
1400 SRM 1245
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. 1. 2. 3.
LOOSEN RETAINER RING THIS SIDE DECREASE BACKLASH TIGHTEN RETAINER RING THIS SIDE
Figure 15. Backlash Decrease 10. Tighten the bearing cap capscrews to 225 to 270 N•m (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. 2. 3.
TIGHTEN RETAINER RING THIS SIDE INCREASE BACKLASH LOOSEN RETAINER RING THIS SIDE
Figure 14. Backlash Increase
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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 .
1400 SRM 1245
Differential Repair
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.
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
1400 SRM 1245
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.
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 N•m (49 to 58 lbf ft).
1. 2. 3. 4. 5. 6. 7.
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)
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).
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 N•m (66 to 73 lbf ft)
Drop Box Housing Capscrews 19 to 23 N•m (14 to 17 lbf ft)
Bearing Cap Capscrews 225 to 270 N•m (166 to 199 lbf ft)
Hanger Assembly to Differential Housing 225 to 248 N•m (166 to 183 lbf ft)
Brake Assembly to Axle Mount Capscrews 340 to 375 N•m (250 to 276 lbf ft)
Hanger Assembly to Frame 820 to 902 N•m (605 to 665 lbf ft)
Brake Manifold to Differential Housing Capscrews 23 to 28 N•m (17 to 21 lbf ft)
Pinion Cover Capscrews 19 to 23 N•m (14 to 17 lbf ft)
Differential Assembly Support to Differential Housing 66 to 79 N•m (49 to 58 lbf ft) Differential Carrier Halves Capscrews 125 to 145 N•m (92 to 107 lbf ft) Differential Drain Plug 50 to 55 N•m (37 to 41 lbf ft) Differential Fill Plug 151 to 166 N•m (111 to 122 lbf ft) Drive Shaft Capscrews 50 to 66 N•m (37 to 49 lbf ft)
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Pinion Gear Capscrews 152 to 167 N•m (112 to 123 lbf ft) Pinion Nut, for Pre-Load 370 to 410 N•m (273 to 302 lbf ft) Pinion Nut, to Seat Bearings 530 to 645 N•m (391 to 476 lbf ft) Transmission Mount Bolt to Differential Housing 225 to 250 N•m (166 to 184 lbf ft) Wheel Nuts 610 to 680 N•m (450 to 502 lbf ft)
