DRIVE UNIT

SECTION DU
CONTENTS
NOTE: SERVICE DATA AND SPECIFICATIONS . . DU-2
This section contains information and General Specifications . . . . . . . . . . . . . . . . DU-2
specifications for both General Overseas Market Tightening Torque . . . . . . . . . . . . . . . . . . . DU-2
(GOM) and North America. Therefore, ensure the TROUBLE DIAGNOSES AND
specifications or procedures you are looking at CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . DU-3
are for the proper area. Trouble Diagnoses . . . . . . . . . . . . . . . . . . . DU-3
PRECAUTIONS AND PREPARATION . . . . DU-4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . DU-4
Special Service Tool . . . . . . . . . . . . . . . . . . DU-4
DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . DU-5
Reduction Gear Assembly . . . . . . . . . . . . . DU-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . DU-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . DU-7
Component Parts . . . . . . . . . . . . . . . . . . . DU-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . DU-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . DU-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . DU-15
SERVICE DATA AND SPECIFICATIONS

General Specifications
A1N1 series
Type Half floating
Reduction gear type Planetary gear
Gear ratio 24.1
Gear oil type SAE 80W / API GL4

Oil capacity (US qt, lmp pt)/one side 0.35 (0.74, 0.62)

Unit weight without traction motor

38 (84)
kg (lb)/one side

Tightening Torque
Unit Nm kg-m ft-lb
Wheel nut 167 - 226 17 - 23 123 - 166
Drive unit fixing bolt 150 - 190 16 - 19 111 - 140
Spacer fixing bolt 19 - 25 2.0 - 2.5 15 - 18
Drain plug 20 - 29 2.1 - 2.9 15 - 21
Filler plug 20 - 29 2.1 - 2.9 15 - 21

DU-2
 TROUBLE DIAGNOSES AND CORRECTIONS

Trouble Diagnoses
Reduction gear
Condition Possible cause Corrective action
Distinguish between oil staining and oil leakage, and locate the point of leak, then take proper corrective action.

• Worn, faulty, or improperly installed oil seal. Repair or replace.

Oil leakage • Loose gear carrier mounting bolts. Retighten, or replace gasket.
• Faulty gasket. Replace gasket.
• Loose filler plug or drain plug. Retighten.
• Worn, faulty, or improperly installed axle hub oil seal. Repair or replace.

Replace any seized or damaged parts. Check related parts for condition. Repair or replace them if necessary.
Seizure • Bearing seizure. Replace.
• Insufficient oil, or use of improper oil. Add or replace as specified.
• Pitted or worn gear tooth surface, or broken tooth. Replace.
• Loose pinion nut, or any other bolts or nuts. Retighten.
Unusual noise
• Insufficient oil, or use of improper oil. Add or change oil as specified.
• Abnormally worn or broken gear. Replace.

DU-3
 PRECAUTIONS AND PREPARATIONS

Precautions
! CAUTION
• When raising or lowering the vehicle using a jack, refer to GI
section for safe operation.
• Be careful not to drop heavy components or parts. Always
use a lifting device.
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• Always clean working area to prevent foreign matter from
getting into parts being assembled or serviced.
• Use a paper rag rather than a cloth when wiping clean
parts. Use of a cloth rag may leave lint or other foreign
matter on parts being wiped.

Special Service Tool

Tool number Description
Tool name
Removing or installing bearing nut

SST
Tool bearing nut

DU-4
 DRIVE UNIT

Reduction Gear Assembly

DU-5
 DRIVE UNIT

Removal
• Remove the carriage.
• Turn the ignition switch OFF, and then disconnect the battery
connector.
• Jack up the vehicle and support it using a piece of wood.
• Remove the following parts.
• Mast (if necessary) (Refer to the LM section)
• Side panel (LH) (Refer to the BF section)
• Floor mat, floorboard (Refer to the BF section)
• Brake pedal (Refer to the BR section)
• PS piping (PS valve side) (Refer to the HD section)
• Mast piping (Refer to the HD section)
• Horn (Refer to the EL section)
• Brake cable, brake piping (drive unit side)
(Refer to the BR section)
• Traction motor cables (Refer to the EL section)
• Tire (Refer to the TR section)
• Drain the gear oil from the drive unit.
• Remove the spacer (between the drive unit and the frame).
• Remove the drive unit with a traction motor as unit.
(Disconnect the connections of the revolution sensor and the
temperature sensor.)
• Remove the motor.

DU-6
 DRIVE UNIT

Installation
Install in the reverse order of removal.

Tightening Torque:
Unit Nm kg-m ft-lb
Drive unit fixing bolt 150 - 190 16 - 19 111 - 140
Spacer fixing bolt 19 - 25 2.0 - 2.5 14 - 18
Drain plug 20 - 29 2-3 14 - 22
Filler plug 20 - 29 2-3 14 - 22

! CAUTION

• Always bleed air from the brake piping.

• When installing the motor to drive unit, be careful not to
damage the oil seal of front bracket at shaft spline and drive
unit.

DU-7
 DRIVE UNIT

Component Parts

DU-8
 DRIVE UNIT

Component Parts (Cont’d)

No Designation Qty No Designation Qty
1 Drive axle hub 1 20 Bearing nut 1
2 Hub bolt 5 21 Retaining ring 6
3 Bearing 1 22 Pinion gear 3
4 Dust seal 1 23 Bearing 3
5 Dust cover 1 24 Retaining ring 3
6 Taper roller bearing 2 25 Snap ring 1
7 Gear carrier 1 26 Second reduction gear 1
8 Air breather 1 27 Rectangular key 1
9 Filler plug 3 28 Snap ring 1
10 Filler plug 1 29 Bearing 1
11 Locking pin 2 30 Snap ring 1
12 Needle bearing 1 31 Reduction gear 1
13 Spacer 1 32 Rectangular key 1
14 Spacer 1 33 Gear cover 1
15 Circular spring 1 34 Bolt 8
16 Ring gear washer 1 35 Bearing 1
17 Bolt 10 36 Input shaft 1
18 Ring gear 1 37 O-ring 1
19 Pinion gear 1 38 Sun gear 1

DU-9
 DRIVE UNIT

Disassembly
! CAUTION

• For disassembly of wet type brake, refer to the BR section.

Gear Cover Removal (33)

Unscrew the 8 bolts (34) on the cover (33). Two of the holes where
the screws are located have a M10 thread: Screw in two bolts (M10
× 1.25, = 30mm), until the gear cover (33) is extracted.

Disassembly Of The Input Shaft (36)

It is possible to remove the input shaft (36) without disassembling it.
Using a rubber hammer take out the input shaft beating it from the
internal side of the cover.
To remove the reduction gear (31) first release the snap ring (30),
then, using an extractor, pull out the reduction gear (31).

Disassembly Of The Sun Gear (38)

NOTE:
Prior to this operation you have to drain the brake chamber oil and
to remove the brake disc unit. Refer to the BR section.

Remove the snap ring (25). To remove the second reduction gear
(26) use an extractor.

DU-10
 DRIVE UNIT

Disassembly (Cont’d)

Disassembly Of The Ring Gear (18) And Of The

Drive Axle Hub (1)

1. In order to pull out the pinion gears (22) and their bearings (23),
remove the retaining ring (24) and use a special extractor.

2. To unscrew the bearing nut (20) a special service tool (SST) is

required; this tool is described on page DU-4.
To remove the drive axle hub (1) place a pipe [diameter = 32 mm
(1.26 in) and diameter = 40mm (1.57 in)] on the centre of the
M30 thread of the hub, and carefully press it out. At this point
slip off the pinion gear (19).

3. Unscrew the 10 bolts (17) and pull out the ring gear (18).

DU-11
 DRIVE UNIT

Assembly
After the worn-out parts have been replaced, to assemble the unit
again follow the disassembling process steps in reverse order.

Assembly Of The Sun Gear (38)

1. Key the bearing (29) in its own slot on the gear cover (33), locking
it with the snap ring (28).

2. Place the sun gear (38) on a chock on the press surface. Insert
the gear cover (33) on the pinion, then using a pipe [diameter =
35 mm (1.38 in) and diameter = 41 mm (1.61 in)] placed on the
bearing (29) inner ring, press down the cover.

3. Place the rectangular key (27) into its own slot and insert the
second reduction gear (26) on the sun gear (38).
Insert the snap ring (25).

Assembling The Ring Gear (18) And The Drive Axle

Hub (1)
1. Insert the cup (outer ring) of the taper roller bearings (6) in their
front and rear housings on the gear carrier (7); insert the cone
(inner ring) of bearing (6) onto the hub (1) -possibly heating it up
to 100°C (212°F)-. Insert the dust seal (4) into its housing in the
hub.
Insert the bearing (3) in its own slot in the hub (1).

2. Introduce the dust cover (5) in its own housing on the gear carrier
(7) the wheel side.
Introduce the pre-assembled hub into the casing, insert the
spacer (13) into the shaft and then place the cone of the bearing
(6), pressure-keying it in.

! CAUTION
• In order to respect the max end play [0.04 mm (0.0016 in)] it
is possible to ask for a kit with calibrated pieces including 2
bearings (6), spacer (13) and all the required spacers.

DU-12
 DRIVE UNIT

Assembly (Cont’d)

3. Insert the ring-gear washer (16) into the ring gear (18) and fix it
introducing the spring (15) in its housing.

4. Place the disc in the gear carrier (7) and tighten the 10 bolts (17)
with a 80 Nm torque wrench setting.
Torque:
80 Nm (8.2 kg-m, 59 ft-lb)

5. Heat the pinion gear (19) up to 80 - 100°C (176°F - 212°F), then

place it onto the hub spline (1) and press it down until the group
is pack-closed; tighten the bearing nut (20) with an adapted key
set at 300 Nm torque wrench, then lay the outer edge low.
Torque:
300 Nm (31 kg-m, 221 ft-lb)

6. Insert the pinion gears pre-mounted with their bearings

(22+23+21+21) into the 3 axes of the pinion carrier (19), then lock
them with the retaining rings (24), one for each pinion gear.

DU-13
 DRIVE UNIT

Assembly (Cont’d)

Assembling The Input Shaft (36)

1. Key the bearing (35) onto the input shaft (36), then place the
rectangular key (32) into its own slot on the shaft, insert the
reduction gear (31), and finally lock all with the snap ring (30).

2. Insert it into the housing in the cover (33).

Assembly Of The Cover (33)

Lay a coat of sealant on the gear carrier contact surface (7) and key
the gear cover (33) onto the casing centring it on the 2 pins (11) and,
using a rubber hammer.
Insert the 8 bolts (34) into their own seats and tighten them at 40
Nm torque wrench setting.
Torque:
40 Nm (4.1 kg-m, 30 ft-lb)

DU-14
 DRIVE UNIT

Inspection

The drive unit is reassembled without oil. For oil filling operations,
follow these specifications:

Use plug (9) for filling, plug (10A) for checking the oil level and plug
(10B) for draining (see the figure).

DU-15
MEMO

DU-16