10 - tgidirect.com Service Manual... · Rear axle system Worn rear axle shaft spline ... Models FA and FB REAR AXLE 10-11 1 page 1 ASSEMBLY AND ADJUSTMENT 1. ASSEMBLY AND …

Models FA and FB REAR AXLE 10-1

10

10-81E-14

CHAPTER 10REAR AXLEModels FA and FB

TROUBLESHOOTING...............................................................10 - 2

SPECIAL TOOL .........................................................................10 - 3

WHEEL HUB AND RELATED PARTS ......................................10 - 4

DISASSEMBLY ................................................................10 - 5INSPECTION ....................................................................10 - 8ASSEMBLY AND DISASSEMBLY ...................................10 - 11

DIFFERENTIAL CARRIER ........................................................10 - 15HINO SH13-2 series

Single speedSingle reduction

1 INDEX

Models FA and FB10-2 REAR AXLE

1 page 1

Abnormal noise Bearing system

Worn or damaged pinion bearings ................ Replace bearings

Worn or damaged differentialside bearings ................................................. Replace bearings

Loose pinion bearings ................................... Adjust bearing preload

Loose differential side bearings .................... Adjust bearing preload

Gear system

Inadequate backlash on ring gearand pinion gear .............................................Adjust backlash

Worn thrust washers ..................................... Replace

Worn differential spider ................................. Replace

Worn or damaged ring gear and pinion ........ Replace

Worn or damaged differential side gearsand pinions .................................................... Replace

Loose ring gear tightening bolts .................... Tighten bolts

Inadequate tooth contact of ring gear andpinion gear .................................................... Replace or adjust tooth contact

Worn pinion spIine ........................................ Replace

Rear axle system

Worn rear axle shaft spline ...........................Replace

Worn hub bearings ........................................ Replace

Loose hub bearings ...................................... Adjust bearing preload

Loose differential case tightening bolts ......... Tighten bolts

Oil system, etc.

Insufficient oil ................................................ Add

Poor oil quality ..............................................Change

Abnormal noise of propeller shaft ................. Refer to CHAPTER 9PROPELLER SHAFT

TROUBLESHOOTING

Symptom Possible cause Remedy


1 page 1

SPECIAL TOOL

Prior to starting a rear axle overhaul, it is necessary to have those special tools.

Illustration Tool No. Tool name

09650 - 2050 WHEEL HUB PULLER

09839 - 9401 HUB NUT WRENCH

09650 - 2090 HUB BEARING PULLER

09665 - 1150 ADJUSTER TOOL

09839 - 4104 SOCKET WRENCH

09849 - 1601 HANDLE09849 - 2001

09640 - 1022 PINION DEPTH GAUGE


1 page 1

9

1. Oil seal2. Collar3. Taper roller bearing4. Hub5. Lock washer6. Lock nut7. Lock plate8. Axle shaft9. Hub bolt nut

10. Oil deflector11. Hub bolt12. Wheel nut inner13. Wheel nut outer14. Air breather15. Plug16. Washer17. Rear axle housing assembly18. Differential carrier assembly19. ABS sensor ring

WHEEL HUB AND RELATED PARTS

Fig. 1

SM10-543A

12

3

104

35

67

18

1112

13

14

1516

17

1615

18

19


1 page 1

DISASSEMBLY1. REMOVAL OF WHEELS

NOTE: Be sure to apply wheel stoppers in the frontand rear of the front tires.

Fig. 2

SM10-488

1. Using a socket wrench, loosen the rear wheel nutsa little.

NOTE Do not remove the wheel nuts but leavethem loosened.

Hub bolts and wheel nuts on the right sideof the vehicle have right-hand threads,and those on the left side of the vehiclehave left-hand threads.

Fig. 3

SM10-545

2. Jack up the rear axle, and support the frame withstands.

WARNING When jacking up the rear axle, place a jack cor-

rectly to the axle, and then lift up the axle. Do not get under the vehicle when it is supported

by a jack only. It is very dangerous as the jackmight slip.

Use safety stands which have sufficient strengthand stability to support the vehicle whenever youneed to work under it.

Fig. 4

SM10-346

3. Remove the wheel nuts and remove the wheel fromthe wheel hub and do the same for both outer andinner wheel.

NOTE: In the case of dual rear wheel removal,first remove the outer wheel nuts and theouter wheel. Then remove the inner wheelnuts and the inner wheel.

Do not damage the threads of the hub bolts.Fig. 5

SM10-545


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2. DISASSEMBLY OF WHEEL HUB AND RELATED PARTS1. Remove the brake drum set bolts, and then remove

the drum from the wheel hub.

2. Loosen and remove the bolts, and then remove theaxle shaft.

Fig. 7

SM10-546

3. Remove the oil seal, and then loosen the bolts andremove the lock plate.

Fig. 8

SM10-547

4. Remove the taper roller bearing lock nut using aspecial tool, and then remove the lock washer.

Special Tool: Hub nut wrench (09839 - 9401)

Fig. 9

SM10-548

Fig. 6

SM10-524

WARNING Do not work on brake drum while it is still hot,

this can result in personal injury. The drums are heavy. The rear drum weighs 30

kg (66 Ib). Be careful not to drop them. To assure safety, do this operation with more

than two persons.


1 page 1

5. Using a special tool, remove the wheel hub with theouter taper roller bearing from the axle housing.

Special Tool: Wheel hub puller (09650 - 2050)

WARNING The wheel hub assembly is heavy. The rear wheel

hub assembly weighs 20 kg (44 Ib). Be carefulnot to drop it.

To assure safety, do this operation with morethan two persons.

Fig. 10

SM10-549

6. Using a special tool, remove the inner taper rollerbearing with oil seal collar from the axle housing.

Special Tool: Hub bearing puller (09650 - 2090)Handle (09849 - 2001) or (09849 - 1601)

Fig. 11

SM10-349

8. Remove the wheel brake.Disconnect the brake line, loosen the attaching bolt,and remove the wheel brake assembly from the axlehousing.

Fig. 13

SM10-500

7. Remove the ABS wheel sensor.After removing the harness connector for the ABSwheel sensor and the cable clip, remove the ABSwheel sensor with its holder.

NOTE: Subjecting the wheel sensor to a strongshock can cause internal damage. Do notstrike the wheel sensor with a hammer orbump it against other components.

Fig. 12


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INSPECTION1. INSPECTION OF THE WHEEL HUB

1. Inspect the taper roller bearing with race for burnsor pitting, and replace it if such defects are found.

Fig. 14

SM10-501

2. Inspect the taper roller bearing race for burns, cracks,or brinelling on the raceways, and replace it if suchdefects are seen.

NOTE: The bearing and the bearing race must be re-placed as a set.

Fig. 15

3. Replacement of taper roller bearing race.a. Remove the taper roller bearing race from the hub

bore.

Fig. 16

SM10-551

b. Install the new taper roller bearing race in the hubbore.

Fig. 17

SM10-552

4. Inspect the hub bolts.Replace the bolts if the threads of the bolts are wornor damaged.

Fig. 18

SM10-553

SM10-550


1 page 1

A

Tightening Torque : 4,000 - 4,800 kgcm(290 - 347 lbft)

A : Stake

NOTE: Stake the lock nuts at the two points aftertightened to the specified torque.

5. Replacement of hub bolt.a. Loosen the hub bolt nuts and remove the hub bolts

from the wheel hub.

Fig. 19

SM10-506

Fig. 20

SM10-508

b. Install the new hub bolts in place on the wheel hub.

NOTE: The left and right hub bolts differ, so installthem according to the chart below.

6. Inspect the oil seal collar for wear.If the collar is excessively worn at the point of con-tact with the lip of the oil seal, replace it.

Fig. 21

SM10-509

7. Inspect the axle shaft spline for wear or damage.If the spline is excessively worn or damaged, replacethe shaft.

Fig. 22

SM10-510

Marks on the end Color

RIGHT R gold

LEFT L silver

SM10-507


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8. Inspect the axle tube.If the tube is abnormally worn or damaged at the pointof contact with the lip of the oil seal, replace the axlehousing.

Fig. 23

SM10-511

Fig. 24

9. Sensor ring Visually inspect for any damage or deformation of

the sensor ring or protrusion from the wheel hub, etc. If there is any damage or deformation, replace the

sensor ring. If the sensor ring is protruding from the wheel hub,

push it in using a press board.

Fig. 25

a. Removal of the sensor ringUniformly tap on the periphery of the sensor ringusing a screw driver or the like and remove it slowly.

NOTE: When tapping and removing the sensor ring,be careful not to damage the wheel hub.

SENSOR RINGPRESS BOARD

GAP

Fig. 26

b. Installation of the sensor ring1) Set the sensor ring in the wheel hub and uniformly

push equally using a press board.NOTE: Warming up the sensor ring with warm water

before pushing it in enables the procedureto be carried out smoothly. Never use a gasburner. Doing so can cause the sensor ringto be deformed.

2) After pushing it in, check the axle direction wobbleof the sensor ring.

Standard range: Under 0.2 mm (0.0079 in.)

10. Clamp bushing1. Check that the wheel sensor is firmly secured.2. If the wheel sensor can be pulled out or pushed in

easily, replace the clamp bushing.

Fig. 27

ADHESION


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ASSEMBLY AND ADJUSTMENT1. ASSEMBLY AND ADJUSTMENT OF THE WHEEL HUB

1. Apply wheel bearing grease to the taper roller bearing.

Wheel bearing grease:Refer to RECOMMENDED LUBRICANTS LIST.

Fig. 28

SM10-512

3. Install the oil seal collar and inner taper roller bear-ing on the axle housing.Using a pipe, as shown in Fig. 30, makes the workeasier.

WARNINGWhen hammering, a metal tip may fly off on impact.Wear safety glasses to protect your eyes.

Fig. 30

SM10-513

2. Install the wheel brake assembly to the axle-hous-ing.

NOTE: Refer to CHAPTER 13, SERVICE BRAKE. The installation of the ABS wheel sensor

is not proceeded.

Tightening Torque: 1,500 - 2,000 kgcm(109 - 144 lbft)

Fig. 29

SM10-351

NOTE: This procedure must be performed after theABS wheel sensor has been removed.

5. Install the ABS wheel sensor.After applying a thin film of chassis grease to thewheel sensor body, press the wheel sensor into theclamp bushing (holder) until the tip of the wheel sen-sor and the side surface of the holder become flatand install the holder on the base portion of the axletube and tighten with the specified torque.

Tightening torque: 351 - 527 kg.cm (26 - 38 lbft)

Fig. 31

NOTE: The bolts should be tightened by hand.Never use an impact wrench.

In this condition, the wheel sensor is stilltemporarily installed and should be fi-nally installed after the pre-load adjust-ment of the wheel hub assembly.


1 page 1

4. Apply wheel bearing grease to the wheel hub.

Wheel bearing grease:Refer to RECOMMENDED LUBRICANTS LIST.

Capacity: 420 grams (15 oz) per wheel.

SM10-554

Fig. 32

6. Install the lock washer and lock nut.Tighten the nut to the specified torque using a spe-cial tool while turning the wheel hub.

Special Tool: Hub nut wrench (09839 - 9401)Tightening Torque: 5,000 - 6,000 kgcm

(362 - 433 lbft)

Fig. 34

SM10-556

7. Loosen the lock nut by 1/4 to 1/3 turn using a spe-cial tool. Then strike the wheel hub with a copperhammer.

Special Tool: Hub nut wrench (09839 - 9401)

WARNINGWhen striking, a metal tip may fly off on impact.Wear safety glasses to protect your eyes.

Fig. 35

SM10-557

5. Install the wheel hub and taper roller bearing (outer)on the axle housing.Using a pipe, as shown in Fig. 33, makes the workeasier.

WARNING The wheel hub assembly is heavy. The wheel hub

assembly weighs 20 kg (44 Ib). Be careful notto drop it.

To assure safety, do this operation with morethan two persons.

When hammering, a metal tip may fly off on im-pact. Wear safety glasses to protect your eyes.

Fig. 33

SM10-555

SM-10-548


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8. Measure the wheel bearing preload.Adjust the preload with the lock nut, if it exceeds oris less than specifications.

Turning Torque: 40 - 60 kgcm (2.9 - 4.3 lbft)Standard Preload: 3.6 - 5.4 kg (8.0 - 11.9 lb)

Fig. 36

SM10-598

11. Install the axle shaft in the wheel hub and tightenthe set bolts to the specified torque.

Tightening Torque: 870 - 1,100 kgcm (63 - 79 lbft)

Fig. 39

SM10-560

9. Apply the lock plate and align it with the small screwhole of the nut. If the hole does not align, turn overthe plate. If alignment is still unattainable, turn thelock nut further within the limits of hub turning torqueof 40 - 60 kgcm (2.9 - 4.3 lbft)

Tightening Torque: 85 - 110 kgcm (6.2 - 7.9 lbft)

Fig. 37

SM10-558

10. Install the oil seal on the wheel hub.

Fig. 38

SM10-559


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12. Install the brake drum on the wheel hub and tightenthe drum set bolts.

Tightening Torque: 200 - 400 kgcm (15 - 28 lbft)

WARNING The drums are heavy. The rear drum weighs 30

kg (66 Ib). Be careful not to drop them. To assure safety, do this operation with more

than two persons.Fig. 42

Fig. 40

10. Positioning the ABS wheel sensora. Temporarily remove the brake lining of the wheel

sensor installation side.b. Fully depress the wheel sensor until it makes con-

tact with the wheel sensor ring.c. Restore the brake lining.NOTE: Refer to Chapter 13, SERVICE BRAKE.

Fig. 41

MAKE CONTACT

CLAMPBUSHING

HUB

WHEELSENSOR

SENSORRING


1 page 1

14. Tighten the inner wheel nuts to the specified torqueusing a wheel nut wrench.

Tightening Torque: 4,000 - 4,800 kgcm(290 - 347 Ibft)

NOTE: Wheel hub bolts and nuts on the right sideof the vehicle have right-hand threads, andthose on the left side of the vehicle have left-hand threads.

Fig. 44

SM10-352

13. Install the inner wheel on the wheel hub.Before installation, clean the mounting surface of thedisc wheel and the wheel hub, and the hub bolts andnuts. A loose wheel mounting can result from theseparts not being cleaned. Check the hub bolts andnuts for wear of the threads or damage and the wheeldisc for any cracks or bends. Replace the part if youfind any of these conditions.

a. With the hub bolts aligned with the holes of the wheel,lift the wheel up with a tire lever and mount it overthe hub bolts.

b. Rotating the wheel, install the inner wheel nuts andtighten manually. Make sure that the hub bolts arecentered in the holes.

NOTE: Do not damage the threads of the hubbolts.

Wheel hub bolts and nuts on the right sideof the vehicle have right-hand threads,and those on the left side of the vehiclehave left-hand threads.

WARNINGThe specified torque should be observed for tight-ening wheel nuts. Improperly torqued wheel nutscan cause the wheel to come off while driving. Thiscan result in personal injury and/or property dam-age due to loss of vehicle control.When the vehicle, wheels or wheel nuts are new,the wheel nuts should be checked and tightened tospecified torque at 100, 500, and 1,000 miles sincethey are not well seated. The tightening torqueshould be checked with a proper torque wrench.

Fig. 43

SM10-562


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2. BRAKE SYSTEM AIR BLEEDING AND BRAKE SHOECLEARANCE ADJUSTMENT.1. On completion of the wheel hub and related parts

reassembly, conduct the following.a. Bleed the air from the brake lines according to sec-

tion FINAL CHECK AND ADJUSTMENT in chapterSERVlCE BRAKE.

b. Adjust the brake shoe clearance according to sec-tion INSPECTION AND ADJUSTMENT in chapterSERVICE BRAKE.

Fig. 45

SM10-544

Fig. 46

SM10-563

NOTE: The proper tightening sequence is shownin Fig. 43. Go through the sequence sev-eral times, gradually and evenly increas-ing the torque on each nut each time un-til the specified torque is reached.

When tightening the nuts, apply grease orengine oil to the threads of the studs andnuts.

15. Install the outer wheel on the wheel hub.Installation procedures for outer wheels are the sameas in 13 through 14 above.

Tightening torque: 4,000 - 4,800 kgcm(290 - 347 lbft)

NOTE: Install dual rear wheels with their valve stemspositioned 180 degrees apart to facilitate in-flation.


1 page 1

DIFFERENTIAL CARRIER(HINO SH13-2 series)

1. Flange lock nut2. Flange yoke coupling3. Dust deflector4. Oil seal5. Taper roller bearing6. Bearing cage7. Shim8. Spacer9. Drive pinion

10. Cylindrical roller bearing11. Differential carrier case12. Name plate

13. Adjust nut14. Side spacer (Gear ratio 3.636 only)15. Differential case16. Side gear thrust washer17. Side gear18. Pinion thrust washer19. Pinion20. Spider21. Bearing cap22. Lock plate

2

SM10-492A

Fig. 1

34

5

67

145

15

1617

1819

2022

23 15

135

21

24

13

8

121110

5

9

1

23. Ring gear24. Bolt


1 page 1

REMOVAL1. REMOVAL OF DIFFERENTIAL CARRIER

NOTE: Be sure to apply wheel stoppers in the frontand rear of the front tires.

Fig. 2

SM10-488

1. Disconnect the propeller shaft from the flange at thedifferential carrier.

NOTE: Draw the aligning marks on the flange andyoke before disassembling.

Fig. 3

2. Remove the filler and the drain plug to drain the gearoil from the axle housing.

WARNINGDo not work on differential carrier while it is stillhot.This can result in personal injury.

Fig. 4

SM10-422

3. Remove the bolts, and then pull the axle shafts out.

Fig. 5

SM10-489

4. Use a jack to dismount the differential carrier assem-bly from the axle housing.

WARNING When loosening the tightening bolts of the dif-

ferential carrier, do not place yourself under thedifferential carrier.

Be sure to apply a support before dismountingthe differential carrier assembly.

Fig. 6

SM10-565A

SM10-595A


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DISASSEMBLY1. DISASSEMBLY OF THE DIFFERENTIAL CARRIER

1. Mount the differential carrier assembly on a workstand.

Fig. 7

2. Loosen the bolts, then remove the bearing cap fromthe differential carrier.

NOTE: First apply match marks to the cap and car-rier.

Fig. 8

3. Remove the differential case assembly from the car-rier.

Fig. 9

4. Remove the taper roller bearings at both ends of thedifferential case and the side spacer located on theright side of the differential case for gear ratio 3.636only, by using a puller.

NOTE: Do not change the combination of theassembled taper roller bearing and itsrace.

Always replace the bearings with theiroriginal races.

Fig. 10

SM10-568

5. Loosen the nuts and remove the ring gear from thedifferential case.

NOTE: Be careful not to drop the ring gear from thedifferential case.

Fig. 11

SM10-569

SM10-425B

SM10-426A

SM10-567A


1 page 1

6. Disassemble the differential case.

NOTE: Be sure to check the aligning marks on thedifferential case before disassembly. Re-move the bolts so that the case separates.

8. Loosen the bolts and remove the pinion assembly,and then remove the cylindrical roller bearing fromthe differential carrier.

Fig. 14

SM10-433

9. Remove the lock nut using a special tool.Spread the staking of the nut completely with a chisel,then loosen the nut.

NOTE: Insufficient spread of the staked parts willcause damage to the threads of the drive pin-ion when loosening the nut.

Special Tool: Socket wrench (09839 - 4104)

Fig. 15

SM10-434A SM10-435A

Fig. 12

SM10-453

10. Separate the bearing cage and the pinion gear witha press.

Fig. 16

SM10-573

SM10-570

Fig. 13

SM10-431A

7. Component parts of the differential case assembly.

SM10-572A

FOR GEAR RATIO 3.636 ONLY


1 page 1

12. Remove the retainer ring and then pull out the innerrace for cylindrical roller bearing from the pinion gearusing a puller.

WARNINGThe retainer ring is spring steel and may pop out.Wear safety glasses to protect your eyes.

13. Remove the oil seal and the taper roller bearing outerraces from the cage.

NOTE: At the same time that the bearing is drawnout, the oil seal comes out. Be careful not todeform the oil seal.

Fig. 19

SM10-440

INSPECTION1. INSPECTION OF THE DIFFERENTIAL CARRIER

1. Check the flange coupling spline for wear and dam-age.Replace the coupling if damaged or worn.

Fig. 21

SM10-575

Fig. 18

SM10-439SM10-438

11. Remove the taper roller bearing from the pinion gearusing a puller.

Fig. 17

SM10-574

14. Component parts of the pinion assembly.

Fig. 20

SM10-599


1 page 1

4. Inspect the spider holes and surfaces of the differ-ential case that come in contact with the thrust wash-ers for wear or damage. Replace the case, if dam-aged or worn.

Fig. 24

SM10-577

5. Inspect the pinion for wear or damage and check theamount of wear of the bore with a cylinder gauge.

Fig. 25

SM10-447

Fig. 26

SM10-448

6. Inspect the spider for damage, and check the amountof wear by measuring its journals with a micrometerto determine the spider to pinion clearance.When the clearance is beyond the service limit, re-place it.

Standard clearance: 0.141 - 0.181 mm(0.0056 - 0.0071 in.)

Service limit: 0.4 mm (0.016 in.)

2. Inspect the taper roller bearings, cylindrical rollerbearing and races for burns or pitting.If such defects are found, replace it.

Fig. 22

SM10-444

3. Inspect the drive pinion and ring gear teeth surfacesfor wear, stripping or damage, and replace both partsas a set when defects are found.

NOTE: The drive pinion and ring gear must be re-placed as a set, not individually, because theyare fitted to each other by lapping duringmanufacture.Replacement of only one part does not pro-duce proper tooth contact, and gear strengthdrops excessively.

SM10-576

Fig. 23

SM10-445


1 page 1

8. Measure the pinion backlash by using a dial gaugewith a magnet base.When the backlash is beyond the service limit, re-place the pinion gear and/or side gear.

Assembly standard: 0.20 - 0.60 mm(0.0079 - 0.0236 in.)

Service limit: 0.90 mm (0.0354 in.)

Put the side gear in the differential case so that thechamfering surface of the thrust washer is on thegear side.

Fig. 28

SM10-451

Fig. 29

7. Measure the thickness of the thrust washers on thepinion and side gears. Replace any washer wornbeyond the limit.

Standard Thickness:Side gear 1.9 - 2.1 mm (0.075 - 0.082 in.)Pinion gear 1.5 - 1.7 mm (0.060 - 0.066 in.)

Service Limit:Side gear 1.7 mm (0.067 in.)Pinion gear 1.3 mm (0.051 in.)

Fig. 27

SM10-450SM10-449

9. Measure the backlash of the side gear and pinionwith the cogs of the pinion and side gear in the posi-tion shown in Fig. 29.

A: PinionB: Side gearC: Thrust washer

SM10-269B

A

B

C

A

B

CORRECT

A

B

INCORRECT


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2. Install the ring gear to the differential case.

NOTE: Apply the lock agent (Lock tight) which isequivalent to THREE BOND: 1360K on boltthreads.

Fig. 31

SM10-578

Fig. 32

SM10-455

Fig. 33

SM10-597A

3. Tighten the nuts to the specified torque.


4. Install the side spacer to the right side of the differ-ential case (For gear ratio 3.636 only).Install the two tapper roller bearings, one to each endof the differential case, using a press.

ASSEMBLY1. ASSEMBLY AND ADJUSTMENT OF DIFFERENTIAL

CARRIER1. Assemble the differential case.NOTE: Align the aligning marks on cases.

Apply the adhesive (Lock agent) which isequivalent to THREE BOND: 1360K onthreads.

Tighten the bolts to the specified torque.Tightening Torque: 2,500 - 3,000 kgcm (181- 217 lbft)

Fig. 30

SM10-453SM10-452


1 page 1

7. Using a press, install the taper roller bearing outerraces in the bearing cage.

8. Put the spacer to drive pinion.

Fig. 37

Fig. 38

SM10-463

SM10-582A

Fig. 36

SM10-580 SM10-581

9. Using a press, assemble the bearing cage and ta-per roller bearing on the drive pinion.

Fig. 34

SM10-458

5. Install the cylindrical roller bearing inner race usinga press and install the retainer ring on the end of thedrive pinion.

WARNINGThe retainer ring is spring steel and may pop out.Wear safety glasses to protect your eyes.

6. Using a press, install the inner taper roller bearingto the drive pinion.

SM10-457

Fig. 35

SM10-579


1 page 1

New bearing Re-used bearing

Turning torque 20 - 30 kgcm (1.5 - 2.1 lb.ft) 15 - 25 kgcm (1.1 - 1.8 lbft)

Adjusting spacer thickness 20 differences in thickness from 13.900 to 14.375 mm (0.5473 to 0.5659 in.)each differing by 0.025 mm (0.001 in.)

b. Using a spring balancer.

Turning force: Unit: kg (lb)

New bearing 3.2 - 4.8 (7.1 - 10.5)

Re-used bearing 2.4 - 4.0 (5.3 - 8.8)

Fig. 41

SM10-116

12. When the preload is correct, remove the flange andthen install the new oil seal, flange and flange locknut.Tighten the flange lock nut to the specified torque.

NOTE: Apply wheel bearing grease to the oil seal lip.Wheel bearing grease:

Refer to RECOMMENDED LUBRICANTS LIST.Special Tool: Socket wrench (09839 - 4104)Tightening Torque: 3,800 - 5,100 kgcm (275 - 368 lbft)Fig. 42

SM10-466SM10-487

10. Install the flange on the pinion shaft without oil seal,and then tighten the flange lock nut to the specifiedtorque using a special tool.

Special Tool: Socket wrench (09839 - 4104)Tightening Torque: 3,800 - 5,100 kgcm

(275 - 368 lbft)

11. Measure the preload of the drive pinion bearings.If the preload is out of the specified limits, adjust itas follows.Use a thinner spacer to increase and a thicker oneto decrease preload. When new bearings, use thespacer of 14.175 mm (0.558 in.) at first and meas-ure the preload. This will be helpful to select thespacer for specified preload.Tighten the flange lock nut to the specified torquebefore re-checking.

a. Using a torque wrench.

Fig. 40

SM10-465A

Fig. 39

SM10-464A


1 page 1

14. Install the pinion assembly and the cylindrical rollerbearing on the differential carrier.

NOTE: At this point, align the oil leading hole. Oil leading hole position is upperside at

carrier mount position.

Fig. 44

SM10-583B

15. Measure the drive pinion fitting height (conical dis-tance) by using the pinion depth gauge.If the pinion fitting height is out of the specified value,adjust it with shim.Use a thinner shim to decrease and a thicker shimto increase the pinion fitting height.

Nominal Pinion Fitting Height A: 21.5 mm (0.846 in.)Special Tool: Pinion depth gauge (09640-1022)

Fig. 45

SM10-469

a. Pinion depth gauge setting methodSet the pinion depth gauge onto the master bed,confirm the dimensions B, C, and D, and then setthe dial gauge to 0.Dimension B = Nominal pinion fitting height A

Fig. 46

SM10-059

B C D

Height21.5 mm 27.7 mm 20.3 mm

(0.846 in.) (1.091 in.) (0.799 in.)

b. Use method for the pinion depth gaugeSet the pinion depth gauge as shown in the figureon the left, and read the value of the dial gauge.A : Measuring pinion-fitting height valueE : Engraved value for gear toothing adjustmentF : Adjusting shims

Fig. 47

SM10-059

MASTER BED

E

F

BCD

A

13. Lock the flange lock nut by staking the lip into thepinion shaft slots.

NOTE: More than 1.5 mm (0.059 in.). Stake portion should be fitted in the

groove thoroughly. Staking should be done without rift.

Measure the bearing preload (see preceding page)and record it for TOTAL BEARING PRELOAD MEAS-UREMENT described in step 24 on page 10-30.Fig. 43

SM10-494

1.5 mm

10 mm

SM10-467A


1 page 1

16. Tighten the differential carrier cage bolts to the speci-fied torque.

NOTE: Apply the sealing compound which is equiva-lent to THREE BOND No. 1215 to the fittingfaces of the carrier and the cage.


17. Install and tighten the bearing lock washers with boltand nut, and then stake the lock nut as shown.

Tightening Torque : 190 - 260 kgcm (14 - 18 lbft)A : Stake

18. Mount the differential case assembly on the differ-ential carrier.

19. Install the adjusting nut and bearing cap on the dif-ferential carrier and tighten the cap temporarily withbolts.

NOTE: Align the match marks of the cap and the dif-ferential carrier.

Fig. 49

Fig. 50

Fig. 51

Fig. 52

SM10-493

SM10-585

SM10-472

A

Example: When the engraved value at the surface of thepinion gear is 2 (2 means 0.2 mm).Use shims to adjust so that the dial gaugereading becomes 0.2 mm.(A minus () reading of the dial gauge meansthat the tip of the dial gauge is pulled in.)

Adjusting Shims Thickness: 0.3 mm (0.0118 in.),0.4 mm (0.0157 in.), 0.45 mm (0.0177 in.),0.5 mm (0.0197 in.).

Fig. 48

SM10-470

SM10-567A

SM10-584A


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21. Strike the bearing cap with a copper hammer.

Fig. 54

SM10-588

22. Measure the gear backlash at four points using a dialgauge with a magnet stand. If the measured valueis out of specified value, adjust the gear backlash byturning the adjusting nuts, loosening one side onenotch and tightening the other side one notch.

Assembly Standard: 0.25 - 0.33 mm (0.0099 - 0.0130 in.)Special Tool: Adjuster tool (09665 - 1150)

Fig. 55

SM10-540

23. Inspection of gear tooth contacta. Satisfactory gear tooth contacta) The length of the tooth contact area in the direction

of the tooth trace should be more than half the lengthof L, and the tooth contact area should be at the toeside.

b) Tooth pressure should be distributed evenly over thecontact area of the tooth.

SM10-589

Fig. 56

SM10-72A

NOTE: On new gears there is a blade-applying markfrom lapping. Adjust the contact area to alignwith this mark.

Fig. 57

SM10-478A

DecreaseIncrease

20. Adjust the preload of the side bearing by using aspecial tool.

1) Tighten the adjusting nut on the back side of the ringgear fully, and then loosen it by 1/4 turn + 1 notch.

2) Do the same with the adjusting nut on the ring side.

Special Tool: Adjuster tool (09665 - 1150)

Fig. 53

SM10-587SM10-586


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b) Heel and face contact.

A: Replace (Heel contact)

B: Adjust (Face contact)

A B

Fig. 59

SM10-072C

24. Measure the total preload of the differential carrierbearings.

NOTE: Total preload = Pinion bearing preload (Meas-ured in step 13. on page 10 - 27) + Side bear-ing preload (Refer to tables below).

If the preload is out of the specified limits, adjust itwith the adjusting nuts of the side bearings.Tighten both side adjusting nuts evenly to increaseand loosen them to decrease preload and re-inspectthe gear tooth contact.

Special Tool: Adjuster tool (09665 - 1150)1. Using a torque wrench.

Turning torque: Unit: kgcm (lb.ft)

Gear ratio 3.363 3.636

New 6.0 - 8.9 5.5 - 8.2bearing (0.43 - 0.64) (0.40 - 0.59)

Re-used 4.5 - 7.4 4.2 - 6.8bearing (0.33 - 0.53) (0.30 - 0.49)

Fig. 60

2. Using a spring balancer.

Turning force: Unit: kg (lb)

A Gear ratio 3.363 3.636

New 0.96 - 1.42 0.88 - 1.32125 mm bearing (2.10 - 3.14) (1.94 - 2.91)(4.92 in.) Re-used 0.72 - 1.19 0.66 - 1.10

bearing (1.58 - 2.62) (1.46 - 2.42)

Fig. 61

b. Samples of unsatisfactory engagement.a) Toe and Flank contact.

A: Replace (Toe contact)

B: Adjust (Flank contact)

A B

Fig. 58

SM10-072B

SM10-590A

SM10-591A


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26. Install the lock plate.


Fig. 63

SM10-593

INSTALLATION1. INSTALLATION OF THE DIFFERENTIAL CARRIER

1. Install the differential carrier assembly.NOTE: 1. Apply the sealing compound to the face

of the housing flange.a. The trace of the sealing compound should

be continuous.b. Application should be approximately 3

mm (0.12 in.) width and 4 mm (0.16 in.)away from the edge.

c. The sealing compound should be equiva-lent to THREE BOND#1215.

NOTE: Be careful not to install the differential car-rier upside down. Install the differential car-rier so that the ring gear teeth face to the rightside of the vehicle. Otherwise the vehicle willmove backward while the transmission isshifted into forward gear.

Tightening Torque:M12: 870 - 1,100 kgcm (63 - 79 lbft)M14: 1,100 - 1,500 kgcm (80 - 108 lbft)

4 mm (0.16 in.)

3 mm (0.12 in.)

4 mm (0.16 in.)

Fig. 64

SM10-131

Fig. 65

SM10-594A

25. Tighten the bearing cap bolts to the specified torque.

NOTE: Lock the nuts with lock plate.


Fig. 62

SM10-592

3 mm (0.12 in.)


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4. FILL THE DIFFERENTIAL WITH GEAR OIL.

NOTE: Refer to the RECOMMENDED LUBRICANTLIST.

Oil Capacity: Approx. 3.7 L (3.91 U.S.Qt./3.25 lmp.Qt.)

Fig. 68

SM10-486

3. INSTALL THE AXLE SHAFT.

Tightening Torque: 870 - 1,100 kgcm (63 - 79 lbft)

Fig. 67

SM10-596

2. INSTALL THE PROPELLER SHAFT TO DIFFERENTIALCARRIER FLANGE.1. Align the match marks on the flange and yoke.2. When a propeller shaft yoke is secured by four bolts,

bolt heads must face differential carrier.3. Tighten the bolts to specified torque.Tightening Torque: 650 - 870 kgcm (47 - 62 lbft)

Fig. 66

SM10-595A

INDEXREAR AXLETROUBLESHOOTINGSPECIAL TOOLWHEEL HUB AND RELATED PARTSDISASSEMBLYINSPECTIONASSEMBLY AND ADJUSTMENT

DIFFERENTIAL CARRIER

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