Nissan Forklift Internal Combustion F05 Series Service Repair Manual

SERVICE MANUAL & TECHNICAL BULLETIN MODEL F05 SERIES

PROPELLER SHAFT

& DIFFERENTIAL CARRIER (PD) MODEL F05 SERIES CONTENTS SERVICE DATA AND SPECIFICATIONS UNIVERSAL

JOINT

DIFFERENTIAL

PD- 2 ,

CARRIER

TROUBLE DIAGNOSES AND CORRECTIONS UNIVERSAL

JOINT

DIFFERENTIAL

PD- 2 PD- 2 PD- 3 PD- 3

CARRIER

UNIVERSAL 00INT

PD- 3 PD- 5

DISASSEMBLY

PD- 5

INSPECTION

PD- 5

ASSEMB L Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

PD- 6

DIFFERENTIAL REMOVAL

AND

CARRIER INSTALLATION

PD- 7 PD- 8

DISASSEMBLY

PD- 8

INSPECTION

PD-lO

ASSEMBLY

PD-ll

ADJUSTMENT

PD-14

SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS UNIVERSAL GENERAL

JOINT

INSPECTION

SPECIFICATIONS

AND

ADJUSTMENT

Drive bearing starting torque N.m (kg-cm, in-Ib)

2.0 - 3.9 (20 - 40, 17 - 35)

2

Backlash mm (in) Side gear to pinion mate gear

0.15 - 0.4 (0.0059 - 0.0157)

118 (4.65)

Drive pinion to ring gear

0.2 - 0.28 (0.0079 - 0.0110)

118H

Model Number of joints Distance between yokes

INSPECTION

AND

mm (in)

Total preload (at ring gear mounting bolt) N (kg, Ib)

ADJUSTMENT

Journal free play

mm (in)

Lessthan 0.25 (0.0098)

Journal axial play

mm (in)

Lessthan 0.03 (0.0012)

29 - 49 (3 - 5, 7 - 11)

Side gear thrust washer 1.6 mm

Snap ring thickness

Unit:

(0.063 in)

Pinion gear thrust washer

mm (in)

1.46

(0.0575)

1.50

(0.0591 )

1.54

(0.0606)

1.58

(0.0622)

1.62

(0.0638)

1.700 (0.0669)

1.66

(0.0654)

1.725 (0.0679)

1.6 mm

(0.063 in)

Drive pinion bearing adjusting shim Unit:

mm (in)

1.750 (0.0689) 1.775 (0.0699)

TIGHTENING

TORQUE

Universal joint to differential carrier or transmission

1.800 (0.0709) N.m

kg-m

ft-Ib

78 - 98

8 - 10

58 -72

Pinion height adjusting shim Unit:

mm (in)

Unit type 0.5

(0.020)

1.0

(0.039)

Divided type

DIFFERENTIAL GENERAL

CARRIER

0.1

(0.004)

0.15

(0.0059)

0.5

(0.020)

SPECIFICATIONS

Model Gear ratio For SD33 and P engine For FD6 engine Number of teeth (Ring gear/Drive pinion) For SD33 and P engine For F06 engine Differential gear Number of teeth (Side gear/Pinion mate gear) Oil capacity Q (US qt, Imp qt)

H339

5.285 4.875

37/7 39/8 4 pinions

TIGHTENING

TORQUE N.m

kg-m

ft-Ib

Differential carrier to axle housing

69 - 88

7-9

51 - 65

Side bearing cap bo It

206 - 245

21 - 25

152 -181

Ring gear to differential case

137 - 167

14 -17

101 - 123

Differential case

78 - 98

8 -10

58 - 72

Pilot washer mounting bolt

10 -15

1.0 -1.5

7 - 11

Bearing sleeve mounting bolt

59 - 78

6-8

43 - 58

Drive pinion lock nut

343 - 441

35 - 45

253 - 325

16/10

6.5 (6-7/8, 5-3/4)

PD-2

TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS UNIVERSAL

JOINT Possible cause

Condition Noise when driving

DIFFERENTIAL

Worn or damaged journal bearing.

Replace journal bearing assembly.

Loose universal joint.

Retighten.

CARRIER

Gear carrier failures can be classified as oil leakage, seizure, unusual noise, noisy operation, and damage,

Condition Oil leakage

Seizure

Corrective action

according to the phenomena. Shown below are the trouble phenomena,

Possible cause

their possible causes, and remedies to be taken.

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.

• Loose gear carrier mounting bolts

Retighten, or replace gasket.

•

Faulty gasket

Replace gasket.

•

Loose filler plug or drain plug

Retighten.

• Faulty axle housing O-ring

Replace.

• Worn, faulty, or improperly installed axle shaft oil seal

Repair or replace.

Replace any seized or damaged parts. Check related parts for condition. Repair or replace them if necessary.

• Bearing seizure

Replace.

• Too large preload

Disassemble, adjust or replace.

• Too small backlash

Disassemble and adjust or replace .

•

Add or replace as specified.

Insufficient oil, or use of improper oil

Unusual noise

Before disassembling the gear carrier, make sure that the noise is not being produced in transmission or wheel bearing.

1. When starting off or shifting gears

•

Improper hypoid gear backlash

Readjust.

• Improper differential gear backlash

Readjust.

• Too small drive pinion bearing preload

Readjust.

• Pitted or worn gear tooth broken tooth

surface, or

Replace .

•

Loose pinion nut, or any other bolts or nuts

Retighten.

•

Insufficient oil, or use of improper oil

Add or change oil as specified.

PD-3

TROUBLE DIAGNOSES AND CORRECTIONS

Condition

Possible cause

2. When making a turn

Abnormally worn or broken differential • gear

Replace .

worn or broken thrust wash• Abnormally er

Replace .

• Broken pinion mate shaft

Replace .

• Seized or broken side bearing • Insufficient oil, or use of improper oil

Replace .

Gear noise

Corrective action

Add or change oil as specified .

Perform test carefully as gear noise is often mistaken for engine noise, transmission noise, or wheel bearing noise.

Test method: Check for gear noise in coasting, accelerating, or in fixed-speed driving, or by jacking up the front wheels.

• Improper contact of hypoid gear teeth • Improper hypoid gear backlash Worn, or broken hypoid gear tooth sur• face

Adjust, or replace as a gear set.

• Seized hypoid gear • Improper pinion bearing preload • Seized, or broken pinion bearing • Seized or broken side bearing

Replace as a gear set.

• Loose bolts and nuts

Readjust.

Replace as a gear set .

Readjust.

Replace .

Replace .

Retighten.

PD-4

UNIVERSAL

JOINT

UNIVERSAL JOINT

Journal Center yoke

Grease nipple

Flange yoke

CfJ: N.m (kg-m, ft-lb) FPD103

DISASSEMBL Y 1.

Remove

snap ring from yoke.

2. Lightly tap yoke with a hammer, and remove needle bearing assembly.

When removing journal from yoke, be careful not to damage journal and yoke hole.

INSPECTION Measure free play between bearing assembly and journal.

needle

Free play: Lessthan 0.25 mm (0.0098 in)

FPD104

FPD106

Check yoke hole for sign of wear or damage.

Snap ring, needle bearing assembly and oil seal should also be inspected to see if they are damaged, worn or deformed. Replace if necessary.

PD-5

UNIVERSAL ASSEMBLY To assemble, reverse the order of disassembly. Observe the following.

1. Assemble needle bearing assem. bly. Apply a coat of multi-purpose grease to inside of bearing.

Do not bearing

strike the head of needle directly with a hammer.

2. Adjust journal selecting snap ring.

JOINT axial

play

Journal axial play: Less than 0.03 mm (0.0012 at 98 N (10 kg, 22 Ib)

by

in)/

Select snap rings whose difference in thickness on both sides is within 0.06 mm (0.0024 in).

~

TAxial play

SPD133 FPD107

PD-6

Snap ring thickness

1.46 mm (0.0575 in) 1.50 mm (0.0591 in) 1.54 mm (0.0606 in) 1.58 mm (0.0622 in) 1.62 mm (0.0638 in) 1.66 mm (0.0654 in)

DIFFERENTIAL

CARRIER

DIFFERENTIAL CARRIER

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DIFFERENTIAL

CARRIER

REMOVAL AND INSTAllATION

DIFFERENTIAL

CASE

1. Place matching marks on the left and right side bearing caps and carrier.

2. Loosen the bolts and remove the lock plate locking the adjusting nut from the left and right side bearing caps.

1. Disconnect battery ground cable.

2. Block rear wheels with chocks.

3. Jack up front of truck, and place wood blocks under each side of frame.

WARNING: To insure safety. also place wood blocks under counterweight.

4. Make sure frame is secured on wood blocks.

5. Remove mast assembly and related parts.

Refer to Mast Assembly (Section LM) for removal.

6. Drain oil from differential carrier.

7. Remove drive axle shaft. Refer to Axle Shaft (Section FA) for removal.

8. Support differential carrier with the jack.

9. Separate universal joint from differential carrier.

13. Remove bolts securing gear carrier, and detach differential carrier.

FPDll0

3. Loosen the side bearing cap mounting bolt slightly and remove the adjusting nut.

FPD109

To install, reverse order of removal.

rYJ : Differential carrier to axle

10. Remove plate.

brake

tube

from back

housing 69.88 N'm (7.9 kg-m.

51 - 65 ft-Ib) Axle mounting bracket to frame 608 - 657 N.m (62 - 67 kg.m.

448.485 ft-Ib) Universal joint to differential carrier 78 -98 N'm (8 - 10 kg.m.

58 - 72 ft.lb) Brake tube flare nut 15.18 N.m (1.5 - 1.8 kg-m.

11 - 13 ft-Ib)

DISASSEMBLY 11. Remove bolts securing axle mounting bracket.

12. Carefully remove front axle assembly and differential carrier as a unit.

Before disassembly, thoroughly check ring gear and drive pinion for tooth contact and backlash, drive pinion for preload, and ring gear and differential gear for smooth rotation; and correctly diagnose the cause of malfunction.

PD-8

4. Remove the side bearing cap mounting bolt and remove the left and right side bearing caps.

5. Remove the differential case assembly using a hoist, etc. Be careful that the outer race of the bearing doesn't fall out.

Differential case assem bly

DIFFERENTIAL

CARRIER

6. Loosen the bolts mounting the ring gear to the differential case and remove the ring gear. The bolts are coated with locktite.

Drive

pinion

FPD116

DRIVE

7. Loosen the differential case bolts and separate the case. The bolts are coated with locktite.

PINION

1. Unbend the pilot washer, loosen the two bolts tightening the plate washer and pilot plate.

FPD119

When removing the pilot bearing, always hook the bearing puller to the plate washer. If hooked to the pilot bearing, the bearing side plate may be separated.

5. Clamp the companion flange in a vice, remove the cotter pin and loosen and remove the nut.

FPD117

FPD114

8. Remove the pillIOn gear, thrust washer, pinion shaft, side gear, and side thrust washer.

2. Loosen the bearing sleeve mounting bolts, thread these bolts into the threaded holes as puller bolts and remove the adjusting shim, a-ring, and pilot bearing, as well as the drive pinion assembly from the carrier.

FPD120

6. Remove the spacer, a-ring, and companion flange.

Side thrust washer

--'U Adjusting shim \

Puller bolt FPD118

9. Remove the bearing from the differential case (right and left sides), using a bearing puller.

3. Remove the snap ring from the drive pinion.

4. Remove the pilot bearing and plate washer from the drive pinion, using a bearing puller.

PD-9

FPD121

DIFFERENTIAL 7. Remove the bearing sleeve by pushing the drive pinion with a press.

~

CARRIER

Bearing spacer ~Oilseal

~Shim

Drive pinion

FPD123

FPD122

8.

Remove the bearing spacer and

shim from the drive pinion.

9. Remove the taper roller bearing and oil seal from the bearing sleeve.

10. Remove the taper roller bearing from the drive pinion, using a bearing puller.

11. Remove the taper roller bearing outer race from the bearing sleeve.

INSPECTION Thoroughly clean and check each disassembled part. Repair or replace any damaged or unserviceable part.

Condition and corrective action

Part name Ring gear and drive pinion

If tooth contact is incorrect, check the cause, and adjust to contact • properly when reassembling.

If damage to teeth is very slight, repair by using oil stone .

• worn excessively, or if readjustment is impossible, replace the gears as • Ifa set. damage, or seizure is found on tooth face, replace the gears • asIf acracks, set.

Side gears and pinion gears

damage to tooth surface is very slight, repair by using oil stone .

• IfIf cracks damage is found on tooth face, replace with new one .

• If wear ororseizure • with new one. is found on thrust washer contacting surface, replace

Bearings

Replace if seizure, flaking, wear, rust, or binding or noise in rotation is • found.

Thrust washers

• Replace if seizure, damage, or uneven wear is noted .

Oil seals

Replace if fatigue, damage, or uneven wear is found .

• Do • not reuse any oil seal that has been removed once .

• If wear or damage is noted on the bearing fitting surface replace with

Gear carrier

new one.

Differential case

• Replace the case if wear or crack is found on sliding portion.

PD-10

DIFFERENTIAL ASSEMBLY Notes on reassembling • Be sure to apply clean gear oil to each bearing when reassembling.

• Use care not to confuse R.H. and L.H. side parts when assembling side bearings, adjusting nuts and side bearings.

• Use care also not to misassemble spacers and washers.

• Be sure to use ring gear and drive pinion as a matched set.

Observe the above listed cautionary instructions. Assemble parts in the reverse order of disassembly procedure after making necessary inspection and adjustment on each part.

CARRIER

4. Adjust preload of drive pinion assembly.

1) Insert an adjusting shim of any thickness and spacer onto the drive pinion.

~

Bearing spacer

~Shim Bonding agent FPD127

FPD123

In order to avoid application of excessive preload to bearing, first select a thick adjusting shim, and gradually reduce its thickness until specified preload is obtained.

DRIVE PINION ASSEMBLY 1. Press-fit the outer and inner bearing races to the sleeve with a press.

---FPD125

2. After inserting the plate washer at the drive pinion, press fit the pilot bearing and fit the snap ring to the end of the pinion.

3. Press-fit the taper roller bearing to the drive pinion with a press.

Drive pinion bearing adjusting shim thickness

6.

Install the companion flange.

1.700 mm

(0.0669 in)

1.725 mm

(0.0679 in)

DIFFERENTIAL

1.750 mm

(0.0689 in)

1.775mm

(0.0699 in)

1.800 mm

(0.0709 in)

1. Press-fit side bearing inner race to differential case (L.H.).

2. Install side gear, pinion mate gear and pinion mate shaft together with their thrust washers on one side of differential case.

3. Measure backlash between side gear and pinion mate gear. Use dial gauge as shown.

2) Insert drive pinion into sleeve.

3) Install companion flange, O-ring and washer to drive pinion.

4) Select adjusting shim so that drive pinion starting torque is 2.0 to 3.9 N.m (20 to 40 kg-em, 17 to 35 in-lb) when drive pinion lock nut is tightened to specified torque.

CASE

Do not allow pinion mate shaft to move during measurement.

@ : Drive pinion lock nut 343 - 441 N.m (35 - 45 kg-m, 253 - 325 ft-Ibl Drive pinion starting torque 2.0 - 3.9 N.m

(20 - 40 kg-em, 17 - 35 in-Ibl

Taper roller bearing Drive pinion Piate washer Pilot bearing FPD126

5) After adjusting preload, remove companion flange.

5. After packing the oil seal with grease and three bond No. 50 or equivalent, drive onto the sleeve using an insertion tool.

PD-11

Backlash: 0.15 - 0.4 mm (0.0059 - 0.0157 in)

DIFFERENTIAL If backlash is not within the specified value, replace pinion

gear and side

gear.

4.

Install side gear and thrust washer.

CARRIER

Install ring gear to differential case coat drive gear mounting bolts with locktite and then tighten to the specified torque.

[J) : 137 - 167 N.m (14 - 17 kg-m, 101 - 123 ft-Ib)

FPD133

•

When installing the drive pinion assembly to the carrier, confirm that the pilot bearing enters the carrier smoothly.

If the pilot

FPD130

bearing is forced into the carrier, the side plate of the pilot bearing

5. Press-fit side bearing inner race into differential case (R.H.).

6. Align to matching mark on differential case.

• DIFFERENTIAL

CARRIER

I. Install the O-ring to the drive pinion assembly.

c==:>--

a-ring

may be separated.

Install the unit

type

adjusting

shim at the differential carrier side and sandwich thin shims between thick shims.

3. Align the threaded hole of the plate washer with the hole of the carrier, place the pilot washer onto the pilot plate, tighten together with the plate washer with the bolt, and bend the pilot washer so that the bolt can't turn.

[J) : 10 - 15 N.m (1.0. 1.5 kg-m, 7.11 ft-Ib) FPD131

FPD132

7. Coat differential case mounting bolts with locktite and then tighten to specified torque.

2. Install drive pinion assembly to the differential carrier through an arbitrary thickness adjusting shim (unit type and divided type), and then tighten the sleeve mounting bolts to the specified torque.

[J) : 78 - 98 N'm (8 - 10 kg-m, 58 - 72 ft-Ib)

[J) : 59 - 78 N.m (6 - 8 kg-m, 43 - 58 ft-Ib)

FPDl17

Pinion height adjusting shim thickness Unit type 0.5mm 1.0 mm Divided type 0.10 mm 0.15 mm 0.50 mm

(0.020 in) (0.039 in) (0.0039 in) (0.0059 in) (0.0197 in)

PD-12

DIFFERENTIAL

CARRIER

4. Install the bearing outer race to the differential case assembly and place onto the carrier.

D iff eren tial case assem bly

5. Match the matching marks made at the time of disassembly and temporarily tighten the bearing cap and then match with the pitch of the adjusting nut mounting screw.

6. Install the adjusting nut and tighten up to the end of the bearing.

7. Measure the drive pinion and ring gear backlash with a dial gauge, and adjust with the adjusting nut so that the dial gauge reads 0.2 to 0.28 mm (0.0079 to 0.0110 in).

FPD134

FPD135

1) When backlash is insufficient Loosen the left side adjusting nut and tighten the right side adjusting nut so that the drive gear is moved away from the drive pinion.

2) When backlash is excessive Loosen the right side adjusting nut and then tighten the left side adjusting nut so that the drive gear approaches the drive pinion.

8. After setting the backlash in 7 above, tighten the left and right adjusting nuts equally and adjust so that the bearing preload is 29 to 49 N (3 to 5 kg, 7 to 11 Ib) by starting force of the ring gear mounting bolt.

9. Securely tighten the bearing cap mounting bolt.

PD-13

cD: 206 - 245 N.m (21 - 25 kg-m, 152. 181 ft-Ib)

10. Install the lock plate and fasten with the adjusting nut.

cD: 10-15

N.m (1.0 - 1.5 kg-m, 7 - 11 ft-Ib)

DIFFERENTIAL

CARRIER

ADJUSTMENT HYPOID

•

GEAR

TOOTH

CONTACT

Apply thin coat of a mixture of powdered ferric oxide and oil to three or four teeth of drive gear, and turn drive gear a few turns to

check tooth contact pattern.

• If tooth contact is incorrect, make adjustment by changing thickness of pinion height adjusting shim or

Tooth contact

Phenomenon

by turning side bearing adjusting nut. If tooth contact is correct, wipe a mixture of powdered ferric oxide and oil from gear teeth.

Adjustment

• Correct tooth contact Tooth contact extends about 50 to 60% of tooth toward toe end in unloaded state. (When loaded, tooth contact appears toward heel end of tooth.)

PD197

• Short contact at toe end

PD194

PD160

Contacting face is too small. Break on toe end may result.

Increase thickness of drive pinion adjusting shim to move drive pinion away from ring gear.

• Short contact at heel end

..

--

PD159 PD193

Contacting face is too small. Break on heel end may result.

PD-14

Reduce thickness of drive pinion adjusting shim to move drive pinion toward ring gear.

FRONT AXLE (FA) MODEL F05 SERIES CONTENTS SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS FRONT AXLE REMOVAL

AND

INSTAllATION

FA-2 FA-3

FAA FA-5

DISASSEMBLY

FA-5

INSPECTION

FA-6

ASSEMBLY

FA-6

BEARING

ADJUSTMENT

FA-7

SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS GENERAL

SPECI FICATIONS Full floati ng,

Axle type

Wheel reduction

TIGHTENING

direct oil capacity Q

(US pt, Imp pt)

TORQUE

Item

N.m

kg-m

ft-Ib

Drive axle housing to axle

294 - 343

30 - 35

217 - 253

157 -186

16.19

116 - 137

frame mount tube assembly

1.5 (3-1/8,2-5/8)

Axle mounting

bracket

to

brake back plate

INSPECTION

AND

Wheel hub rotation

ADJUSTMENT

starting

(at hub bolt)

torque N (kg, Ib)

Drive hub to brake drum

177 - 235

18 - 24

130 - 174

Axle mounting

608 - 657

62 - 67

448 - 485

69 -88

7-9

51 - 65

play of wheel bearing

mm (in)

78 -98

8 -10

58 - 72

78 -98

8 -10

58 -72

Brake tube flare nut

15 -18

1.5 -1.8

11 -13

Universal

78.98

8 -10

58 -72

343 - 441

35 -45

253 - 325

441 - 588

45 - 60

325 - 434

539 - 686 588 - 736

55.70 60 -75

398 - 506 434 - 542

to

frame

98 -147 (10 -15, 22 - 33)

Drive axle housing to differential

Axial

bracket

case

0(0) Drive hub to pinion

gear

carrier Wheel cylinder

securing

nut

differential

joint

to

carrier

Road wheel nut I nner side Outer side Single tire Double

tire

I nner nut Outer nut

FA-2

TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS Condition

Probable cause

Corrective action

Unusual noise Before attempting a correction, make sure the noise is coming from the drive shaft-not from the final drive or wheel reduction gear.

Loose axle mounting bracket bolts.

Tighten.

Loose axle tube bolts.

Tighten.

Loose wheel nu ts.

Tighten.

Other retaining parts loose.

Tighten.

Worn or damaged wheel bearing.

Replace.

Wheel bearing not properly adjusted.

Adjust.

Worn sun gear (drive shaft) splines.

Replace.

Insufficient lubrication.

Lubricate.

Loose wheel nu t.

Tighten.

Deformed road wheel.

Replace.

Worn or damaged wheel bearing.

Replace.

Loose axle mounting bracket bolts.

Tighten.

Wheel bearing not properly adjusted.

Adjust.

Improper tire pressure

Adjust.

Worn or damaged axle tube oil seal.

Replace.

Final drive improperly installed.

Replace gasket.

Loose filler or drain plug.

Tighten.

Damaged wheel reduction a-ring.

Replace.

Unstable driving.

Also refer to the Trouble Diagnoses and Corrections in the RA section.

Oil leakage

FA-3

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FA-4

FRONT AXLE REMOVAL AND INSTAllATION

8. Remove bolts securing mounting bracket to frame.

axle

1. Raise front end of lift truck and support frame with a block or safety stand. Refer to Lifting Points and Towing GI section.

2. Remove mast assembly. Refer to Mast (LM section) for removal.

3. Remove front road wheels.

4. Drain oil from differential carrier.

5. Disconnect brake flare nuts from right and left wheel cylinders.

DISASSEMBl Y I. Remove pinion gear carrier from axle hub, and drain oil completely.

')

~

Plug brake tube openings with rubber

)

FDA092

caps to prevent oil from flowing out.

FMA064

9.

Remove axle assembly.

2.

Pull out sun gear (axle shaft).

CAUTION: Be careful not to damage brake tubes and other parts during lifting.

10. To install axle assembly, reverse the order of removal.

6. Separate universal joint from differential carrier.

Differential gear oil capacity: 4£ (8-1/2 US pt, 7 Imp pt) Wheel reduction gear oil capacity: 1.5£ (3-1/8 US pt, 2-5/8 Imp pt)

rj) : Axle mounting bracket to frame 608 - 657 N.m (62 - 67 kg-m, 448 - 485 ft-Ibl Universal joint to differential carrier: 78 - 98 N.m (8 - 10 kg-m, 58 - 72 ft-Ibl Brake tube flare nut 15.18 N.m (1.5 - 1.8 kg-m,

7. Support axle assembly with wire ropes and lifting device.

11 - 13 ft-Ibl Road wheel nut Single tire 441 - 588 N.m (45 - 60 kg-m, 325 - 434 ft-Ibl Double tire Inner nut 539 - 686 N.m (55 - 70 kg-m, 398 - 506 ft-Ibl Outer nut 588.736 N.m (60 - 75 kg-m, 434 - 542 ft-Ibl

FA-5

3. Remove bearing washer and bearing nut.

4. Remove ring gear from axle hub.

FRONT 5. Remove drive axle hub with brake drum assembly.

AXLE

7. Remove dust seal and inner bearing as an assembly by tapping evenly along periphery of bearing with a wooden mallet through a soft pad.

8. Remove wheel bearing outer race.

9. Remove brake assembly.

10. Remove bolts securing drive axle housing to axle tube assemby, and disconnect axle tube assembly.

FDA095 F DA098

II. If brake drum assembly is difficult to remove, remove adjusting hole plug.

Then, keeping adjusting lever pushed

Remove O-ring from axle tube.

INSPECTION

up with two flat-blade screwdrivers, turn adjusting nut in the direction of the arrow by 27 to 40 notches.

Inspection

Corrective action

Stepped wear or cracks on axle shaft splines.

Replace.

Seized, nicked, noisy or rusted wheel bearing or improper rotation of rollers.

Replace.

Cracked or damaged drive wheel hub.

Replace.

Damaged oil seal, dust seal or O-ring.

Replace.

Cracked or damaged axle housing or axle tube assembly.

Replace.

FDA038

I 2 3 4 5 6

Back plate Shoe Adj usting lever Adjusting nut Baffle plate Adjust hole plug

6. Separate drive wheel hub from brake drum assembly.

ASSEMBLY Assemble drive axle in the reverse order of disassembly.

• Drive outer races of wheel bearings evenly into drive wheel hub.

• Install dust seal into wheel hub with its brand and nominal number side facing inside of lift truck.

• Install oil seal into axle tube with its brand and nominal number side facing to the inside of lift truck.

~;: Air bleeder

slit

Check that protruded mark that indicates the position of air bleeding slit faces upward. Then install securely.

FDA099

FDA096

FA-6

FRONT AXLE

liJ : Drive axle housing to axle tube assembly 294 - 343 N.m (30 - 35 kg-m, 217 - 253 ft-Ib) Drive hub to brake drum 177 - 235 N.m (18 - 24 kg-m, 130 - 174 ft-Ib) Axle mounting bracket to brake back plate 157 - 186 N.m (16 - 19 kg-m, 116 - 137 ft-Ib) Drive hub to pinion gear carrier 78 - 98 N.m (8 - 10 kg-m, 58 - 72 ft-Ib)

BEARING ADJUSTMENT Adjust wheel bearing with pinion gear carrier, axle shaft and road wheel removed.

1. Apply a coat of multi-purpose grease to threaded areas of wheel bearing nut and bearing contact surface.

2. Tighten wheel bearing nut until drive wheel hub can no longer be rotated with one hand.

3. From that position, turn back wheel bearing nut approximately 60°.

4. With wheel bearing nut held in that position, turn drive wheel hub two or three rotations so that bearing settles down.

S. Again tighten wheel bearing nut until drive wheel hub no longer rotates with one hand; then turn back approximately 60°.

6. Align protruding part of bearing washer with groove in axle tube and hole in washer with wheel bearing nut hole; then tighten with lock screw.

The above value is when road wheels are not installed and it does not include the "dragging resistance" of brakes.

If rotation starting torque is not within specifications, readjust.

FDA100

When holes are not aligned properly, turn back wheel bearing within 11 ° 08' (equivalent to half the distance between tow adjacent holes in washer) until they align.

7. Turn drive wheel hub back and forth two or three rotations to see if rotation starting torque is within specifications.

Rotation starting torque (Spring scale reading at wheel hub): Lessthan 98 - 147 N (10 - 15 kg, 22 - 33 Ib)

FA-7

8. Measure axial play of drive hub to see if it is within specifications.

Axial play: mm (0 in)

o

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