HMM140001

Drive Axle and Differential

Assembly Repair
H1.5-1.8TX, H2.0TXS [B475];
H2.0-3.5TX [B466]

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 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), 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!

—1—
 GENERAL
This section has the repair procedures for the drive axle and differentialassembly.

DRIVE AXLE REPAIR

[1] 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.
4. Remove the drain plug and drain the oil from the drive axle into a suitable container. See
Figure 1.

� �

1. DRIVE AXLE ASSEMBLY

2. DRAIN PLUG

Figure 1. Drain Plug

—2—
 WARNING
On lift trucks with pneumatic tires, completely remove air from tires before removing them
from lift truck. Air pressure in tires can cause tire and rim parts to explode, which can cause
serious injury or death. Never loosen nuts that hold together inner and outer wheel halves
when there is air pressure in tire.

5. Remove the wheels.

6. Disconnect the brake line connecting the master cylinder to the manifold located on top of the
assembly.

VIEW Y−Y

1. DRIVE AXLE ASSEMBLY 7. CAPSCREWS(S)

2. CAPSCREWS 8. DRIVE SHAFT
3. SENSOR COVER 9. CAPSCREWS
4. CAPSCREW 10. INPUT SHAFT
5. MANIFOLD 11. DRIVE SHAFT COVER
6. PICK UP SENSOR(S) 12. CAPSCREWS

Figure 2. Drive Axle

—3—
 7. Remove the sensor cover on the frame and disconnect the pick up sensor(s) on the top of
the center section.
8. Remove the parking brake cable. Refer to the section Brake System.
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 cover. Remove four capscrews retaining the
drive shaft to the drive axle.
12. Remove the transmission isolator mounting bolt located on top of the assembly.
13. Remove the four mounting capscrews from the frame. See Figure 2.
14. Remove blocks and lower the drive axle assembly and disengage the drive axle assembly
from the transmission.
15. Place blocks under the center section assembly.
16. Remove the axle shafts, hub/brake drum assemblies, and back plates. Refer to the section
Brake System.
17. Remove the capscrews that hold the hanger assembly to the center section housing. Remove
the hanger assembly. Repeat this step on the opposite side.

[2] 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 bear ings and seals for
damage.
3. 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.

[3] Assemble and Install

1. Apply grease to new O-rings and install

O-rings on the hanger assemblies. See
Figure 3.
2. Place the hanger assembly in position
on the center section housing. Apply
Loctite® 242 to the capscrews and install
capscrews to retain hanger assembly.
Tighten capscrews in sequence shown
in Figure 4 96 to 106 N·m (980 to 1080 1. O-RING
2. HANGER ASSEMBLY
kgf·cm) [B475], 225 to 248 N·m (2300 to
2530 kgf·cm) [B466]. Repeat this step on
the opposite side.
Figure 3. Hanger Assembly

—4—
 [B475] [B466]
1. CENTER SECTION ASSEMBLY
2. HANGER ASSEMBLY
3. CAPSCREWS

Figure 4. Hanger Assembly Tightening Sequence

NOTE: Apply Loctite® 515 or ThreeBond #1215 or Equivalent on the axle shaft flange when installing.

3. Install the back plates, hub/brake drum assemblies, and axle shafts. Refer to the section
Brake System.
4. 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 bearing distribution.

5. Position the drive axle in the lift truck.

NOTE: It is recommended to use a torque multiplier to achieve the torque specification in Step 6.

6. Install the four mounting capscrews and washers. Tighten the capscrews to 435-480 N·m (4440
to 4900 kgf·cm).
7. Place the drive shaft in position and install the retaining capscrews. Tighten the drive shaft
capscrews to 31 to 37 N·m (315 to 375 kgf·cm). Install the drive shaft cover.
8. Install the transmission isolator mounting bolt located on top of the assembly. Tighten the bolt
to 85-105 N·m (870 to 1070 kgf·cm). See Figure 5.
9. Remove blocks from under the transmission.
10. Install the 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.
11. Connect the brake line connecting the master cylinder to the manifold located on top of the
assembly.
12. Connect the pick up sensor(s) and install the sensor cover.

—5—
 1. TRANSMISSION
2. CENTER SECTION
FINAL DRIVE HOUSING
3. ISOLATOR, TRANSMISSION
4. WASHER
5. LOCKWASHER
6. MOUNTING BOLT

Figure 5. Transmission to Center Section Housing Mounting Bolt

WARNING
Add air to the tires only in a safety cage. Inspect safety cage for damage before use. When
adding air, use a clip-on chuck with enough hose to let the operator stand clear of the cage.

NOTE: When tightening the wheel nuts, DO NOT use any lubricant on the studs or nuts.

13. Inflate the tires using a safety cage. Install the wheels and nuts and tighten the nuts to
196-216 N·m (2000 to 2200 kgf·cm) <1.0 - 2.0 t COMPACT>, 294-343 N·m (3000 to 3500
kgf·cm) <2.0 - 2.5 t>, 397-485 N·m (4050-4950 kgf·cm) <3.0 - 3.5 t >.
14. Clean the drain plug apply new seal type.
15. Install the drain plug. See Figure 1.
16. Remove the fill plug and fill the drive axle to the proper level as shown in Figure 6, with SAE
80W-90 gear oil through the fill hole. Install the fill plug.
17. Remove the air from the brake system as described in the section Brake System.
18. Install the mast assembly as described in the section Mast Repairs, 2 and 3-Stage Masts.
19. Raise the lift truck and remove blocks from under the frame and from under the
counterweight. Lower the lift truck.
20. Remove the blocks on each side (front and back) of the steering tires.
21. Operate the lift truck and check for proper operation and leaks.

—6—
1. DRIVE AXLE ASSEMBLY
2. CENTER SECTION COVER
3. FILL PLUG

Figure 6. Oil Fill Level

—7—
 DIFFERENTIAL REPAIR

[1] Remove

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

(1) Differential Assembly From Center Section Assembly

STEP 1.
Remove the capscrews retaining the center
section cover and remove cover. Remove
the pick up sensor(s) from the center section
assembly.

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. See the procedure Gear Set,
Tooth Contact Pattern Check. During differential
reassembly, adjust the backlash to the original
recorded dimension when the gear set is installed
into the center section.
1. CENTER SECTION
STEP 2. 2. RETAINER RING
Remove differential assembly retainer ring
cotter pins. Loosen the retainer rings. If
necessary, loosen the bearing cap capscrews Figure 7
to allow the retainer rings to turn freely.

STEP 3.
Mark one differential carrier leg and bearing
cap to correctly match the par ts when
assembling differential assembly. Mark the
parts using a center punch and hammer.
Remove the flange bolts retaining the bearing
caps and remove caps.

STEP 4.
Remove the retainer rings.

STEP 5. 1. CENTER SECTION

Remove the differential assembly. 2. DIFFERENTIAL ASSEMBLY
3. TAPERED ROLLER BEARING AND CUP

Figure 8

—8—
(2) Drive Pinion, Pinion Gear, and Bearings From Center Section

STEP 1.
Remove the capscrews retaining the pinion cover and remove cover.

1 - 2t 2 - 3.5t

1. CENTER SECTION HOUSING 14. PINION NUT

2. RING GEAR 15. PINION
3. DIFFERENTIAL ASSY 16. DOWEL PINS
4. CAPSCREWS 17. DRIVE GEAR
5. TAPER ROLLER BEARINGS 18. RADIAL BALL BEARINGS
6. RETAINER RINGS 19. DROP BOX HOUSING
7. COTTER PINS 20. OIL SEAL
8. SHIMS 21. PINION COVER
9. FRONT BEARING 22. CAPSCREWS
10. DRIVEN GEAR 23. CAPSCREWS
11. SHIMS 24. THRUST SCREW
12. REAR BEARING 25. PLUG
13. WASHER 26. NUT

Figure 9

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.

STEP 2.
Use a small, flat chisel or screwdriver and unstake the pinion nut.
Remove the pinion nut and washer.

—9—
STEP 3.
Remove the capscrews retaining the drop box
housing.

NOTE: Be sure to retain the outer shims after

removal.

1. CENTER SECTION HOUSING

2. DROP BOX HOUSING
3. CAPSCREWS
4. DOWEL PINS
5. THREADED HOLES FOR
REMOVING DROP BOX HOUSING

Figure 10

STEP 4.
Remove the rear bearing, drop box housing,
and outer shims by using two of the M8 × 1.25
× 40 capscrews removed from the drop box
housing. Install capscrews to threaded holes
beside the dowel pins (See Figure 10) and
screw them to push the drop box housing from
the center section and outer bearing away
from the pinion. If the capscrews do not have
enough threaded length, use a prybar to finish
removing the housing.

1. REAR BEARING
2. DROP BOX HOUSING
3. SHIMS
4. PINION
5. CENTER SECTION

Figure 11

— 10 —
 NOTE: When removing the pinion, be sure to retain
the shims.

STEP 5.
Carefully remove pinion assembly from the
center section. Using a press and bearing
puller, remove the shims and inner bearing
from the pinion.

1. CENTER SECTION
2. BEARING
3. SHIMS
4. PINION

Figure 12

STEP 6.
Remove the driven gear and the drive gear.

1. DRIVEN GEAR
2. CENTER SECTION
3. DRIVE GEAR

Figure 13

STEP 7.
Using a press or suitable soft drift, remove the
outer bearing cup.

1. DROP BOX
2. BEARING CUP

Figure 14

— 11 —
STEP 8.
Using a suitable soft drift, remove the pinion
inner bearing cup.

1. CENTER SECTION
2. INNER BEARING CUP

Figure 15

[2] Disassemble

(1)–1 Differential Assembly [B475]

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

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

Figure 16

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

Figure 17

— 12 —
STEP 3.
Remove pin from carrier and shaft. Remove
shaft. Inspect shaft for wear. Replace as
needed.

1. PIN
2. CARRIER
3. SHAFT

Figure 18

STEP 4.
Rotate the side gears until the pinion gears
can be removed from the carrier. Remove
pinion gears. Inspect pinion gears spherical
washers for wear. Replace as needed.

1. CARRIER
2. PINION GEARS
3. SPHERICAL WASHERS

Figure 19

— 13 —
STEP 5.
Remove the side gears and thrust washers
from the carrier.
Inspect the carrier and side gears for wear or
damage. Replace as needed.

1. CARRIER
2. THRUST WASHER
3. SIDE GEAR

Figure 20

(1)–2 Differential Assembly [B466]

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

Figure 21

— 14 —
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

Figure 22
NOTE: Mark each side of the case halves and the
spider before separating to ensure alignment at
reassembly.

STEP 3.
Remove the capscrews retaining the case
halves and spider 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. CAPSCREW
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF

Figure 23

STEP 4.
Remove the side gears and thrust washers
from the differential halves.
Inspect the thrust washers for wear. Replace
as needed.

1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF

Figure 24

— 15 —
STEP 5.
Remove the pinions and spherical washers
from the spider.
Inspect the spider for wear or damage.
Replace as needed.

1. SPHERICAL WASHER
2. PINION
3. SPIDER

Figure 25

(2) Drop Box Housing

STEP 1.
Remove the input shaft oil seal.
Inspect the oil seal for wear or damage.
Replace as needed.

1. DROP BOX
2. OIL SEAL

Figure 26

— 16 —
(3) Center Section

NOTE: Only remove the air breather if they are damaged.

STEP 1.
Remove the air breather.

1. CENTER SECTION HOUSING

2. AIR BREATHER

Figure 27

NOTE: Only remove the brake manifold if it is damaged.

STEP 2.
Remove the capscrew retaining the brake
manifold. Remove the brake manifold.

1. CENTER SECTION
2. BRAKE MANIFOLD
3. CAPSCREW

Figure 28

— 17 —
STEP 3. [B466]
Remove the thrust screw and the plug. Inspect
the plug for wear or damage. Replace as
needed.

1. CENTER SECTION HOUSING

2. THRUST SCREW
3. PLUG
4. NUT

Figure 29

[3] 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 drive axle:

• 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 assembly. If bearings show signs of wear, cracks, or damage, replace with
new bearing.
• Pinions and Gears - Inspect the pinions and gears for wear or damage. Gears that are
worn or damaged must be replaced.
• Differential assembly - Inspect all parts of the main differential assembly for wear or
damage. Parts that are damaged must be replaced.
• Oil Seals and O-rings - Inspect the oil seals and the o-rings in the assembly for wear or
damage. Replace with new parts as needed.

— 18 —
[4] Assemble

(1) Center Section

STEP 1.
Place the brake manifold in position on the
center section. Install the capscrew.

1. CENTER SECTION
2. BRAKE MANIFOLD
3. CAPSCREW

Figure 30

STEP 2.
Wrap the air breather threads with seal tape.
Install the air breather.

1. CENTER SECTION HOUSING

2. AIR BREATHER

Figure 31

— 19 —
(2) Drop Box Housing

STEP 1.
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 seal, apply grease to the lip
of the seal.

1. DROP BOX
2. OIL SEAL

Figure 32

(3)–1 Differential Assembly [B475]

STEP 1.
Lubricate both sides of the thrust washers
with 80W - 90W gear lube. Install the side
gears and thrust washers into the carrier.

1. CARRIER
2. THRUST WASHER
3. SIDE GEAR

Figure 33

— 20 —
STEP 2.
Lubricate both sides of the spherical washers
with 80W - 90W gear lube. Install the pinion
gears and the spherical washers by rotating
the side gears until the pinion gears are in
position.

1. CARRIER
2. PINION GEARS
3. SPHERICAL WASHERS

Figure 34

STEP 3.
Install the shaft into the carrier, through the
pinion gears. Install the pin into the carrier and
shaft.

1. PIN
2. CARRIER
3. SHAFT

Figure 35

— 21 —
STEP 4.
Place the ring gear in position on the differential assembly and install capscrews. Tighten the
capscrews in a cross/diagonal pattern to 152 to 167 N·m (1550 to 1700 kgf·cm).
NOTE: Tightening sequence for ring gear.

1. RING GEAR
2. DIFFERENTIAL ASSEMBLY
3. CAPSCREW

Figure 36 Figure 37

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

Figure 38

— 22 —
(3)–2 Differential Assembly [B466]

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

1. SPHERICAL WASHER
2. PINION
3. SPIDER

Figure 39

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. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF

Figure 40

— 23 —
STEP 3.
Place the 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 (1280 to 1480 kgf·cm).

NOTE: Be sure to match marks on the case halves and spider.

1. CAPSCREW
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF

Figure 41 figure 42

STEP 4.
Place the ring gear in position on the differential assembly and install capscrews. Tighten the
capscrews in a cross/diagonal pattern to 152 to 167 N·m (1550 to 1700 kgf·cm).

1. RING GEAR
2. DIFFERENTIAL ASSEMBLY
3. CAPSCREW

Figure 43 Figure 44

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.

— 24 —
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

Figure 45

[5] Install

(1) 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. 1. PINION NUT
2. WASHER
The pinion is adjusted using shims. If the 3. BEARING
same bearings, ring gear, and pinion are 4. REAR SHIM SET
(CONTROLS BEARING PRELOAD)
used, use the original shim set. See Figure
5. GEAR
46. If new bearings, ring gear, and pinion are 6. BEARING
used, adjust the pinion as described below. 7. FRONT SHIM SET
The correct shim set thickness can be found (CONTROLS DEPTH OF PINION)
by using the original and new parts. Use the
original shim set thickness and the pinion
variation number on the original and new Figure 46. Shim Set Location
pinion. For the location and identification of
the number, see Figure 47.

Find the correct thickness of the mounting

distance (inner) shim set as follows:

1. Use a micrometer to measure the total

thickness of the original shim set that was
removed from under the pinion carrier.
Make a note of the measurement for later 1. PINION VARIATION NUMBER
use.
2. Check the pinion variation number for
the original pinion. See Figure 47. If this Figure 47. Pinion Variation Number

— 25 —
 number is a plus (+) value, subtract the value from the value in Step 1. If the pinion variation
number is a minus (–) value, add the number to the value in Step 1. 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.

Table 1. Pinion Variation Numbers Examples

Examples mm

NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 47.

Original Shim Set Thickness 0.76

1.
Original Pinion Variation Number = +0.05 mm –0.05

Standard Shim Set Thickness 0.71

New Pinion Variation Number = +0.13 mm +0.13

New Shim Set Thickness = 0.84

Original Shim Set Thickness 0.76

2.
Original Pinion Variation Number = –0.05 mm +0.05

Standard Shim Set Thickness 0.81

New Pinion Variation Number = +0.13 mm +0.13

New Shim Set Thickness = 0.94

Original Shim Set Thickness 0.76

3.
Original Pinion Variation Number = +0.05 mm –0.05

Standard Shim Set Thickness 0.71

New Pinion Variation Number = –0.13 mm –0.13

New Shim Set Thickness = 0.58

Original Shim Set Thickness 0.76

4.
Original Pinion Variation Number = –0.05 mm +0.05

Standard Shim Set Thickness 0.81

New Pinion Variation Number = –0.13 mm –0.13

New Shim Set Thickness = 0.68

— 26 —
(2) Drive Pinion, Pinion Gear, and Bearings Into Center Section

STEP 1.
Press the pinion front bearing cup into the
center section.

1. CENTER SECTION
2. INNER BEARING CUP

Figure 48

STEP 2.
Press the outer bearing cup into the drop box
housing.

1. DROP BOX
2. BEARING CUP

Figure 49

STEP 3.
Install mounting distance (inner) shims,
determined in Pinion Inner Shim Set, Adjust
Thickness (Depth of Pinion), and pinion head
bearing on pinion.

1. BEARING
2. MOUNTING DISTANCE
(INNER) SHIMS
3. PINION

Figure 50

— 27 —
STEP 4.
Install the pinion assembly into the center
section housing.

1. CENTER SECTION
2. PINION ASSEMBLY

Figure 51

STEP 5.
Install the drive gear and the driven gear onto
the pinion.

NOTE: Make sure the drive gear and the driven

gear are install in correct orientation. (See Figure 9.)

1. DRIVEN GEAR
2. PINION
3. CENTER SECTION
4. DRIVE GEAR

Figure 52

STEP 6.
Clean the mating surface of the drop box
housing and the center section housing. Apply
sealant, Loctite® 242, Three Bond #1215 or
equivalent, to the mating surface of the drop
box housing.
Place the drop box housing in position on
the center section. Install the capscrews and
tighten to 19 to 23 N·m (200 to 235 kgf·cm).
1. CENTER SECTION
2. DROP BOX HOUSING
3. CAPSCREWS

Figure 53

— 28 —
STEP 7.
Install the preload (outer) shims and rear
bearing. Install the washer and pinion nut. Use
the hanmar to press the rear bearing onto the
pinion.
Tighten the pinion nut to 530 to 645 N·m (5410
to 6580 kgf·cm) to seat the bearings. Loosen
the pinion nut and retighten to 370 to 410 N·m
(3780 to 4180 kgf·cm) for the pre-load. Rotate
the pinion two revolutions in both directions.
Verify pinion shaft rotating torque is 5.9 to
9.8 N·m (60 to 100 kgf·cm). Add or remove
preload (outer) shims as necessary to obtain
ffthe correct rotating torque. 1. CENTER SECTION
2. PRELOAD (OUTER) SHIMS
3. BEARING
4. WASHER
5. PINION NUT

Figure 54
(3) Differential Assembly Into Center Section

STEP 1.
Place the differential assembly into the center
section.

1. CENTER SECTION
2. DIFFERENTIAL ASSEMBLY
3. TAPERED ROLLER BEARING
AND CUP

Figure 55

— 29 —
STEP 2.
Install the bearing caps in the same location
as removed. Install flange bolts. Tighten the
bolts finger tight only.

1. CENTER SECTION
2. BEARING CAP
3. CAPSCREW

Figure 56

STEP 3.
Install the retainer rings.

1. CENTER SECTION
2. RETAINER RING

Figure 57

STEP 4.
Adjust the retainer rings in equal rotations so
the backlash of the ring gear is 0.20 - 0.28
mm [B475], 0.15 - 0.20 mm [B466]. See Ring
Gear Backlash, Adjust.

Tighten the bearing cap flange bolts to 225 to

270 N·m (2300 to 2750 kgf·cm). Recheck the
backlash.
Verify that the rotating torque at the pinion
shaft has increased 0.5 to 0.7 N·m (5 to 7
kgf·cm). Check the pinion and ring gear tooth
contact pattern. See Gear Set, Tooth Contact 1. PINION NUT
2. CENTER SECTION
Pattern Check.
3. RETAINER RING COTTER PINS
Install new retainer ring cotter pins. 4. RETAINER RING

Figure 58

— 30 —
STEP 5.
Stake the pinion nut with 8 mm spherical
punch until contacting the bottom of the
groove on the pinion shaft at two places.
Clean the mating surface of the pinion cover
and the drop box housing. Apply sealant,
Three Bond #1215 or equivalent, to the
mating surface of the pinion cover.
Place the pinion cover in position on the
drop box and install the capscrews. Tighten
the capscrews to 19 to 23 N·m (200 to 235
kgf·cm).
1. CAPSCREW
2. PINION NUT
3. CENTER SECTION

Figure 59

STEP 6. [B466]
Install the plug to the end of the thrust screw.
Apply the oil leak-proof agent on the thread
of the thrust screw. Install the thrust screw to
the center section and hard tighten until the
plug touches to the ring gear. Then return 1/6
to 1/4 rotation (the clearance between the
plug and the ring gear is 0.25 to 0.38 mm).
Tighten the nut to 125 to 150 N·m (1280 to
1530 kgf·cm).

1. CENTER SECTION HOUSING

2. THRUST SCREW
STEP 7. 3. PLUG
I n s t a l l t h e p i ck u p s e n s o r ( s ) w i t h t h e 4. NUT
capscrew(s) to the top of the center section.
Figure 60

STEP 8.
Clean the mating surface of the center
section cover and the center section. Apply
sealant, Loctite® 242, Three Bond #1215 or
equivalent, to the mating surface of the center
section for the center section cover.
Place the center section cover in position and
install capscrews. Tighten capscrews to 19 to
23 N·m (200 to 235 kgf·cm).

1. CENTER SECTION COVER

2. CAPSCREW
3. CENTER SECTION

Figure 61

— 31 —
(4) Ring Gear Backlash, Adjust

If the old gear set is installed, adjust the

backlash to the setting that was measured
b e fo r e t h e d i f fe r e n t i a l a s s e m bl y w a s
disassembled.
If a new gear set will be installed, adjust the
backlash to 0.20 - 0.28 mm [B475], 0.15 - 0.20
mm [B466].
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 62.
2. Adjust the dial indicator so that the plunger
or pointer is against the tooth surface. See
Figure 62. Figure 62. Gear Clearance Check
3. Adjust the indicator to zero.
4. Hold the drive pinion in position.
5. After reading the dial indicator, rotate the
differential and ring gear a small amount
in both directions, against the drive pinion
teeth.
6. I f t h e b a c k l a s h r e a d i n g i s w i t h i n
specifications, 0.20 - 0.28 mm [B475], 0.15
- 0.20 mm [B466], continue checking tooth
contact patterns.
7. If the backlash reading is not within
specifications, adjust backlash using
retainer rings. Continue onto Step 8 1. TIGHTEN RETAINER RING THIS SIDE
through Step 11. 2. INCREASE BACKLASH
8. Verify that the bearing cap capscrews are 3. LOOSEN RETAINER RING THIS SIDE
only finger tight.

NOTE: To increase backlash, move ring gear away Figure 63. Backlash Increase
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 retainer ring 1/4 rotation, then

tighten the opposite retainer ring the same
amount. See Figure 63 and Figure 64.
10. Tighten the bearing cap flange bolts to
225 to 270 N·m (2300 to 2750 kgf·cm).
Recheck the backlash.
11. Repeat Step 2 through Step 10 until
backlash is within 0.20 - 0.28 mm [B475], 1. LOOSEN RETAINER RING THIS SIDE
0.15 - 0.20 mm [B466]. 2. DECREASE BACKLASH
3. TIGHTEN RETAINER RING THIS SIDE
12. Check the tooth contact pattern. See Gear
Set, Tooth Contact Pattern Check.
Figure 64. Backlash Decrease

— 32 —
(5) Gear Set, Tooth Contact Pattern Check

NOTE: The gear clearance can be changed within the limits of 0.20 - 0.28 mm [B475], 0.15 - 0.20 mm
[B466].
NOTE: If the original gear set is installed, adjust the clearance to the original value recorded in Differential
Assembly From Center Section Assembly. If a new gear set is installed, adjust the retainer rings for 0.20 - 0.28
mm [B475], 0.15 - 0.20 mm [B466] clearance. Refer to Ring and Pinion Tooth Contact Adjustment.

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 NOTE: Normal pattern during adjustment shown.
and bottom of the tooth. The contact area is
toward the inner circumference of the ring gear.

The contact area is the center between the top NOTE: Wear pattern from operation shown.
and the bottom of the tooth. The contact area will
be almost the full length of the tooth.

— 33 —
 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.

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

— 34 —
 HMM140001

TORQUE SPECIFICATIONS
Axle Shaft Flange Bolts
52 to 62 N·m (530 to 630 kgf·cm) [B475]
90 to 108 N·m (920 to 1100 kgf·cm) [B466]

Bearing Cap Flange Bolts

225 to 270 N·m (2300 to 2750 kgf·cm)

Brake Assembly to Axle Mount Capscrews

152 to 167 N·m (1550 to 1700 kgf·cm) [B475]
255 to 306 N·m (2600 to 3120 kgf·cm) [B466]

Differential Cover Capscrews

19 to 23 N·m (200 to 235 kgf·cm)

Universal Joint Capscrews

31 to 37 N·m (315 to 375 kgf·cm)

Drop Box Housing Capscrews

19 to 23 N·m (200 to 235 kgf·cm)

Hanger Assembly to Center Section Housing

96 to 106 N·m (980 to 1080 kgf·cm) [B475]
225 to 248 N·m (2300 to 2530 kgf·cm) [B466]

Drive Axle to Frame

435 to 480 N·m (4440 to 4900 kgf·cm)

Pinion Nut, to Seat Bearings

530 to 645 N·m (5410 to 6580 kgf·cm)

Pinion Nut, for Pre-Load

370 to 410 N·m (3780 to 4180 kgf·cm)

Pinion Cover Capscrews

19 to 23 N·m (200 to 235 kgf·cm)

Ring Gear Capscrews

152 to 167 N·m (1550 to 1700 kgf·cm)

Transmission Mount Bolt to Center Section Housing

85 to 105 N·m (870 to 1070 kgf·cm)

Wheel Nuts
196 to 216 N·m (2000 to 2200 kgf·cm) [B475]
294 to 343 N·m (3000 to 3500 kgf·cm) [B466 - 2 to 2.5t]
397 to 485 N·m (4050 to 4950 kgf·cm) [B466 - 3 to 3.5t]

— 35 —