Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL

1. Structure .................................................................................................. 7-1

1.1 Front Axle ................................................................................................................ 7-1
1.2 Reduction Differential .............................................................................................. 7-2
2. Removal and Installation........................................................................ 7-4
2.1 Front Wheels ........................................................................................................... 7-4
2.2 Front Axle ................................................................................................................ 7-6
2.3 Reduction Differential .............................................................................................. 7-9
3. Disassembly and Reassembly............................................................. 7-10
3.1 Front Axle .............................................................................................................. 7-10
3.2 Reduction Differential ............................................................................................ 7-15
4. Troubleshooting.................................................................................... 7-22
5. Service Data........................................................................................... 7-23

7
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Chapter 7 FRONT AXLE AND REDUCTION DIFFERENTIAL

1. Structure
1.1 Front Axle

6
2

4 3

217085

1 Front wheel hub 4 Front axle housing

2 Frame axle support 5 Backing plate
3 Axle shaft 6 Reduction and differential assembly

The front axle housing 4 is bolted to the transmission

housing.

7-1
FRONT AXLE AND REDUCTION DIFFERENTIAL

1.2 Reduction Differential

14
1 to 2 ton classes 13
12

1
16

15

22

11
17
10
9
8
7
6
5
4
3
2

21
20
23

24
27
29
28
26
25
19
18
17
217205

1 Drive pinion 12 Bearing (rear end) 23 Differential case (slightly differ-

2 Drive pinion front bearing 13 Washer ent shape for 2 ton class)
3 O-ring 14 Nut 24 Ring gear
4 Oil seal 15 Gear carrier 25 Side gear thrust washer
5 Distance piece 16 Knock pin 26 Side gear
6 Pinion height adjust shim 17 Side bearing cap 27 Pinion mate shaft (slightly differ-
7 Drive pinion bearing sleeve 18 Side bearing adjust nut ent shape for 2 ton class)
8 Drive pinion bearing adjust shim 19 Side bearing 28 Mate gear thrust washer
9 Drive pinion rear bearing 20 Lock plate 29 Mate gear (4 pieces for 2 ton
10 O-ring(large) 21 Side bearing cap bolt class)
11 Drive pinion bearing lock nut 22 Gasket

Frame support is bolted to the front axle housing The reduction differential is mounted to the front axle
together with the backing plate of the wheel brake. housing. The input flange carries a drive gear which
While front wheel hub carries a single wheel, a double meshes with the driven gear mounted on the reduction
wheel can be mounted to it with an optional rim. pinion.

7-2
 FRONT AXLE AND REDUCTION DIFFERENTIAL

14
3 ton class 13
12

16

15

22

17

11
10
23 9
8
7
6
5
4
21 3
20 2

24
28
29
27
26
25

19
18
17 217206

1 Drive pinion 11 Drive pinion bearing lock nut 21 Side bearing cap bolt
2 Drive pinion front bearing 12 Bearing (rear end) 22 Gasket
3 O-ring 13 Washer 23 Differential case
4 Oil seal 14 Nut 24 Ring gear
5 Distance piece 15 Gear carrier 25 Side gear thrust washer
6 Pinion height adjust shim 16 Knock pin 26 Side gear
7 Drive pinion bearing sleeve 17 Side bearing cap 27 Pinion mate shaft
8 Drive pinion bearing adjust shim 18 Side bearing adjust nut 28 Mate gear thrust washer
9 Drive pinion rear bearing 19 Side bearing 29 Mate gear
10 O-ring (large) 20 Lock plate

Frame support is bolted to the front axle housing The reduction differential is mounted to the front axle
together with the backing plate of the wheel brake. housing. The input flange carries a drive gear which
While front wheel hub carries a single wheel, a double meshes with the driven gear mounted on the reduction
wheel can be mounted to it with an optional rim. pinion.

7-3
FRONT AXLE AND REDUCTION DIFFERENTIAL

2. Removal and Installation

2.1 Front Wheels

Be sure to use the specified tire from the parts manual

for replacement.

Removal
(1) Wheel nuts
(2) Front Wheels
1

2
217207
Start by
(1) Pull the parking brake lever and block the rear
wheels.
(2) Loosen the wheel nuts by two turns. Then, raise
the front end of the truck using a hoist or the
hydraulic system.
(a) Hoisting
Using slings and eye-bolts at both ends of the
cross member on top of the outer mast, lift the
front end of the truck with a hoist.

209939

(b) Using hydraulic system

Tilt the mast fully backward and place appropri-
ate wood blocks under the mast. Tilt the mast
forward back to raise the front end.

After raising the front end, place wood blocks under

the frame to prevent the truck from falling.

210757

(3) Remove the wheel nuts 1.

(4) Remove the wheel 2.

7-4
 FRONT AXLE AND REDUCTION DIFFERENTIAL

2.1.1 Installation
To install, follow the removal sequence in reverse, pay-
ing attention to the following points.
Wheel nut

(1) Use the specified tire from parts manual.

(2) Make sure the clamping surfaces of the wheel Counterbore
nuts and the counterbores in the rim are free of
dirt.

(1) Install the tire and tighten the wheel nuts.Tighten

each nut until its tapered portion is in full-face con-
217114
tact with the counterbore in the rim.

(2) Lower the truck until the tire touches the floor.
Then tighten the wheel nuts in number sequence,
6 1
in two or three steps, to the specified torque.
Unit: N·m (kgf·m) [lbf·ft] 3

Truck type
Items 2 ton class 4
1 ton class
3 ton class
Tightening 156.9 ± 15.7 377.6 ± 37.8
torque for (16.0 ± 1.6) (38.5 ± 3.9) 5
wheel nuts [115.8 ± 11.6] [278.7 ± 27.9] 2
217115

7-5
FRONT AXLE AND REDUCTION DIFFERENTIAL

2.2 Front Axle

2.2.1 Removal

11

3
10

12 14 13
1
5
6
7
2
210758

Sequence
1 Nuts 8 Brake pipe
2 Fork, Lift bracket 9 Parking brake cable
3 High-pressure hose for lift cylinder 10 Bolt
4 Tilt cylinder pin 11 Bolt, Nut
5 Mast support cap 12 Front axle drain plug
6 Mast 13 Front axle shaft
7 Front Wheels 14 Front axle assembly

Start by: Note: It is not necessary to remove the axle housing

(1) Making the truck ready for supporting the front nor to drain the oil before removing the axle
axle assembly. shaft or disassembling the wheel hub.
(2) Remove the mast. For replacement of the front
axle housing, refer to "Chapter 12 MAST AND
FORKS."
(3) Jack up the truck.
(4) Support the front end of the truck with blocks or
stands at both sides to keep the truck in the hori-
zontal position.

7-6
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Removal

(1) Removing front wheels
Before removing the front wheels, place blocks or
stands under frame and transmission to support it.
(2) Removing parking brake cable
To remove the parking brake cable, remove the
parking brake lever assembly from the dashboard
and disconnect the cable from the lever.
(3) Removing front axle assembly
(a) Remove the mounting bolts on the front axle
assembly.
(b) Move back the supporting forklift truck to
remove the front axle assembly out of the vehi-
cle.

2.2.2 Installation
To install, follow the removal sequence in reverse, pay-
ing attention to the following points:
(1) Tighten the bolt 10 and 11 to the specified torque.

Unit: N·m (kgf·m) [lbf·ft]

116.7 to 157.9
Tightening torque for
(11.9 to 16.1)
bolt 10
[86.1 to 116.5]

Unit: N·m (kgf·m) [lbf·ft]

377.6 ± 37.8
Tightening torque for
(38.5 ± 3.9)
bolt 11
[279 ± 27.9]

(2) After connecting the parking brake cable, make

sure that the brake lever operating effort is within
the specification.

Unit: N (kgf) [lbf]

Truck type
Items
1 ton class 2 ton class 3 ton class
Parking 150 to 200 200 to 250 230 to 250
brake lever (15.3 to 20.4) (20.4 to 25.5) (23.5 to 25.5)
operating [110.7 to [147.6 to [169.7 to
effort 147.6] 184.5] 184.5]

Parking brake warning light

After installation of the parking brake lever, check the Parking
following points: brake lever
(1)The parking brake warning lamp glows when
the parking brake lever is in the "apply" posi-
tion
(2)When the operator leaves the seat with the
parking brake lever remaining in the "release"
position, the Presence Detection System
causes the parking brake warning lamp to flick-
er and the buzzer to sound.
217116

7-7
FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Before installing the mast, bleed trapped air in the

brake fluid circuits. For bleeding, refer to "Chapter
09 BRAKE SYSTEM. "
(4) After installing the mast, make sure that tilt
angles, forward and backward, are correct and
that the lift chains, right and left, are equal in ten-
sion. Refer to "Chapter 12 MAST AND FORKS."
(5) Fill the front axle housing with oil up to the plug
hole level.

(c) Apply the parking brake. Place the transmis-

sion in neutral. Stop the engine and block
wheels.
(d) Raise the lift bracket high enough to gain
access to level/fill plug.
(e) Use blocking under the inner mast to secure
the lift bracket in this position.
217117
(f) Remove the level/fill plug. Maintain lubricant
level to the bottom of the level/fill hole.

Unit: liter (cu.in.)

Truck type
Items 2 ton class
1 ton class
3 ton class
Refill capacity of front axle 4.2 5.0
housing (256.3) (305.1)

217118

7-8
 FRONT AXLE AND REDUCTION DIFFERENTIAL

2.3 Reduction Differential

Be careful when removing and installing the differential

carrier with engine and transmission as they are heavy.

2.3.1 Removal
(1) Remove differential carrier with engine and trans-
mission.
(2) Separate engine from transmission case.
(3) Remove torque converter.
(4) Remove oil pump.
(5) Pull out drive pinion rear end cover.
(6) Remove drive pinion, fixing nut at drive pinion rear
end.
(7) Remove differential carrier mounting bolts and 217103
remove differential carrier from transmission case.

217104
2.3.2 Installation
To install, follow the removal sequence in reverse.
Unit: N·m (kgf·m) [lbf·ft]
Truck type
Items 1 ton class
3 ton class
2 ton class
Tightening
30 to 40
torque for car-
(3.1 to 4.1)
rier to trans-
[22 to 30]
mission
Tightening
torque for dif- 19 to 25 38 to 52
ferential car- (1.9 to 2.5) (3.9 to 5.3)
rier to axle [14 to 18] [28 to 38]
housing
Tightening 275 to 343
torque for drive (28 to 35)
pinion lock nut [203 to 253]

7-9
FRONT AXLE AND REDUCTION DIFFERENTIAL

3. Disassembly and Reassembly

3.1 Front Axle
3.1.1 Disassembly

13
1
14

5 2
6 3
12

7 11
10
#8
#9
210759

Sequence
1 Air bleeder 8 Oil seal retainer (except 1 ton class)
2 Level plug 9 O-ring (except 1 ton class)
3 Drain plug 10 Oil seal
4 Axle shaft 11 Tapered roller bearing
5 Lock ring, Lock nut 12 Oil seal
6 Tapered roller bearing 13 Brake assembly
7 Front wheel hub, Brake drum 14 Frame support, Axle housing

7-10
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Disassembly

(1) Removing lock nut
Use the lock nut wrench (special tool) .

Special tool needed

Pin spanner 91A67-00300

Special tool

210760

(2) Removing front wheel hub

Use the wheel hub puller (special tool).

Special tool needed

1 ton class 64309-40100 Special tool
2 ton and 3 ton classes MH061017

Note: It is not necessary to remove the oil seal from

the hub nor disassemble the oil deflector unless
the seal is defective.

210761

(3) Removing bearing

The inner race of the tapered roller bearing
remains in the axle housing when the hub is
drawn out. Remove this race together with a bear-
ing puller.
Note: Trucks of 1 ton class do not have the seal re-
tainer.

210762

7-11
FRONT AXLE AND REDUCTION DIFFERENTIAL

3.1.2 Inspections after Disassembly

(1) Axle shaft
(a) Looseness of mating splines
Mount the differential bevel gear on the splined
end of the shaft and set a dial indicator as
shown. Rotate the bevel gear in the direction
shown and read the free play (looseness of
mating splines).

Unit: mm (in.)
Free movement 0.07 to 0.15
A
Looseness of mat- (0.0028 to 0.0059)
ing splines 217208
B 0.5 (0.02
A: Standard value B: Repair or service limit

(2) Shaft deflection and flange runout

Deflection of shaft
(a) Set a dial indicator at the middle part of the
axle shaft. Rotate the shaft and read the dial
indicator (deflection of axial shaft).

Unit: mm (in.)
Deflection of axial 0.5 (0.020)
A
shaft maximum
(1/2 of dial indica-
tor reading) B 1.0 (0.039)
A: Standard value B: Repair or service limit Face runout of flange
209949
(b) Set a dial indicator against the flange of the
axle shaft as shown. Rotate the shaft and read
the face runout of flange.
Unit: mm (in.)
Face runout of axle A 0.08 (0.0031)
shaft flange B 0.5 (0.020)
A: Standard value B: Repair or service limit

(3) Axle housing

(a) Check the surfaces of axle housing in contact
with the mast bearing for damage.
(b) Check the entire axle housing for distortion,
dents and other defects. Pay particular atten-
tion to the welds to see if any of the welds are
cracked enough to require repair.

(4) Others
(a) Check the oil seals and retainer for wear or
damage.

7-12
 FRONT AXLE AND REDUCTION DIFFERENTIAL

3.1.3 Reassembly
To reassemble, follow the disassembly sequence in
reverse, paying attention to the following points:

(1) Oil seals

(a) Replace with a new one.
(2) Front wheel hub
(a) Fill grease (Autolex A or equivalent) in the front Grease
wheel hub as shown.
Stuff grease in the roller holder of the tapered
roller bearing (inner) using the palm.
Apply grease to the lip groove of oil seal.

Be careful and do not let grease enter the brake

drums. 210763

(b) Using the installer (special tool), install the

inner race and oil seal retainer of the wheel
hub bearing.

Special tool needed Special tool

Truck type
Items 2 ton class
1 ton class
3 ton class
Installer 64309-12300 91468-00300

210764
(c) Apply sealant (Oil resistant liquid gasket such
as ThreeBond #1104) to the flange surfaces of
the axle shaft. Nut
Lock ring
(3) Hub bearing preload adjustment and lock nut
(a) Install hand-tight with a pin spanner (special Lock bolt
tool).

Special tool needed

Pin spanner 91A67-00300

(b) Rotate the hub and tap its periphery with a soft-
head mallet for snug assembling. 210765
(c) Fully tighten the lock nut to obtain hub bearing
preload within the specified limits.
Note: To check the hub bearing preload, hook a
spring scale on the wheel bolt, then pull to mea-
sure the tangential force of the wheel bolt.

7-13
FRONT AXLE AND REDUCTION DIFFERENTIAL

Unit: N (kgf) [lbf]

Truck type Wheel bolt
Items 2 ton class
1 ton class
3 ton class
Increment from
Hub bearing
when preload is 0.5 to 4.9 (0.05 to 0.5) [0.37 to 3.7]
zero
5.6 to 56 4.5 to 45
Tangential force of
(0.57 to 5.5) (0.46 to 4.6)
wheel bolt
[1.26 to 12.1] [1.01 to 10.1]
210766
(d) Fit the lock ring into place and tighten the lock
bolt.
(e) Check the preload again.

(4) Plug
(a) Tighten the drain plug and level to the specified
torque.

Unit: N·m (kgf·m) [lbf·ft]

83.4 ± 7.8
Tightening torque for drain
(8.5 ± 0.8)
plug
[61.5 ± 5.8]
127.5 ± 9.8
Tightening torque for level
(13.0 ± 1.0)
plug
[94.0 ± 7.2]

7-14
 FRONT AXLE AND REDUCTION DIFFERENTIAL

3.2 Reduction Differential

Start by
(1) Measure the backlash between ring gear and drive pinion.
(2) Check ring gear and differential gear for smooth rotation. And correctly diagnose the cause of malfunction.

3.2.1 Disassembly
differential case
(1) Remove side bearing adjusting nut lock plate.

210672
(2) Loosen side bearing cap bolts and remove adjust-
ing nut with the special tool.
(3) Remove side bearing caps
Note: Make cap on one side so that it can be easily
replaced in the correct position.
(4) Remove differential case assembly with side
bearing outer races.
Note: Do not confuse R. H. side and L.H. side bearing
outer races.
210673
(5) Remove side bearing inner races with the tool.
Note: 1. Do not remove side bearing unless absolutely
necessary
2. To prevent damage to bearing, engage puller
paws with groove.
3. Be careful not to mix-up the parts for the right
hand side with parts from the left hand side.

210674
(6) Remove ring gear by loosening ring gear bolts.
Tap ring gear off from differential case using soft-
head mallet.
(7) Remove differential case mounting bolts and sep-
arate differential case at center portion (2, 3 ton
classes).

210675

7-15
FRONT AXLE AND REDUCTION DIFFERENTIAL

(8) Drive out the pinion mate shaft lock pin with the
tool from ring gear side (1 ton class).

93A67-00100

210676

(9) Draw out pinion mate shaft and remove pinion

mate gears, side gears and thrust washers (1 ton
class).
Put marks on gear and thrust washer so that they
can be reinstalled in their original positions from
which they were removed.

210677

Drive pinion
(1) Remove snap ring on drive pinion front end (3 ton
class). Drive pinion Snap ring

Bearing
support plate

210678

(2) Remove drive pinion sleeve from differential car-

rier.

210679

7-16
 FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Remove drive pinion bearing lock nut by using

drive pinion lock nut replacer.

93A67-00200

93A67-00300
210680

(4) Remove front bearing inner race complete drive

pinion from drive pinion sleeve.
(5) Remove bearing outer races on both sides and
remove oil seals from drive pinion sleeve.

210681

(6) Using press, remove bearing inner race from

drive pinion .

210682

7-17
FRONT AXLE AND REDUCTION DIFFERENTIAL

3.2.2 Inspection and Repair

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

Part name Condition and corrective action

Ring gear and drive pinion ŒIf tooth contact is incorrect, check the cause, and adjust to contact properly
when reassembling.
ŒIf damage to teeth is very slight, repair by using oil stone.
ŒIf worm excessively, or if readjustment is impossible, replace the gears as a
set.
ŒIf cracks, damage or seizure is found on tooth face, replace the gears as a
set.
Side gears and pinion mate gears ŒIf damage to tooth surface is very slight, repair by using oil stone.
ŒIf cracks or damage is found on tooth face, replace with a new one.
ŒIf wear or seizure is found on thrust washer contacting surface, replace with
a new one.
Bearings ŒReplace if seizure, flaking, wear, rust, binding or noise in rotation is found.
Thrust washers ŒReplace if seizure, damage, or uneven wear is noted.
Oil seals ŒReplace if fatigue, damage, or uneven wear is noted.
ŒDo not reuse any oil seal that has been removed once.
Gear carrier ŒIf wear or damage is noted on the bearing fitting surface, replace with a new
one.
Differential case ŒReplace the case if wear or cracks are found on sliding portion.

7-18
 FRONT AXLE AND REDUCTION DIFFERENTIAL

3.2.3 Reassembly
To reassemble, follow the disassemble sequence in
reverse.

(1) Arrange shims, washers and the like to install cor-

rectly.
(2) Thoroughly clean the surfaces on which shims,
washers, bearings and bearing caps are to be
installed.
(3) Apply gear oil when installing bearings.
(4) Pack recommended multi-purpose grease cavity
between lips when fitting oil seal.
Differential case
(1) Install pinion mate gears and, side gears together
with their thrust washers onto differential case.
(2) Fit pinion mate shaft (1 ton class).
Note: Pay attention to direction and position of lock
pin hole.
(3) Measure backlash between side gear and pinion
mate gear using dial gauge.

Unit: mm (in.)
0.15 to 0.20
Backlash A
(0.0059 to 0.0079) 210683
A: Standard value

(4) If out of specification, change side gear thrust

washers so that specified backlash can be
obtained.

(5) Strike the pinion mate shaft lock pin into pin hole Punch
using a punch (1 ton class).

210684

(6) Place the ring gear on the differential case.

Tighten bolts in a diagonal sequence, lightly tap-
ping bolt head with a hammer.
Unit: N·m (kgf·m) [lbf·ft]
196 to 226
Tightening torque for ring
(20 to 23)
gear bolt
[145 to 167]

217209

7-19
FRONT AXLE AND REDUCTION DIFFERENTIAL

(7) Assemble differential case, and tighten bolts in

diagonal sequence (2, 3 ton classes).
Unit: N·m (kgf·m) [lbf·ft]
Truck type
Items 2 ton class
3 ton class
Tightening torque for
74 to 81 (7.5 to 8.3) [55 to 60]
differential case bolt

217210

Differential carrier
(1) Insert oil seal into drive pinion bearing sleeve.
Note: Apply chassis grease to oil seal lip. Be careful
not to install oil seal in reverse.
(2) Press-fit each outer race of front and rear bear-
ings into drive pinion bearing sleeve.
(3) Install front bearing, O-ring, distance piece and
drive pinion bearing sleeve, adjusting shims and
rear bearing to drive pinion.
Unit: N·m (kgf·m) [lbf·ft]
1.8 to 2.3
Drive pinion starting
(0.18 to 0.23)
torque
[1.3 to 0.7]

Unit: N·m (kgf·m) [lbf·ft]

275 to 343
Tightening torque for drive
(28 to 35)
pinion lock nut
[203 to 253]

(4) Install drive pinion sleeve assembly to gear car-

rier.
Unit: N·m (kgf·m) [lbf·ft]
76 to 98
Tightening torque for drive
(7.7 to 10)
pinion sleeve
[56 to 72]

(5) Install differential case assembly with wide bear-

ing outer race on gear carrier.
Note: 1. Use care not to misinstall R.H. and L.H. bear-
ing outer races.
2. Tap bearing outer race with soft-head mallet
to seat it snugly into gear carrier.
(6) Install the bearing cap.
Unit: N·m (kgf·m) [lbf·ft]
Truck type
Items 2 ton class
1 ton class
3 ton class
Tightening torque 78 to 98 89 to 118
for side bearing (8 to 10) (9 to 12)
cap [58 to 72] [66 to 87]

7-20
 FRONT AXLE AND REDUCTION DIFFERENTIAL

3.2.4 Adjustment
Hypoid gear tooth contact
(1) Apply thin coat of marking/lapping compound to
three or four teeth of drive gear, and turn drive
gear a few turns to check tooth contact pattern.
(2) If tooth contact is incorrect, make adjustment by
changing thickness of pinion height adjusting
spacer or by turning side bearing adjusting nut.
If tooth contact is correct, apply a mixture of pow-
dered ferric oxide and oil from gear teeth.

Adjusting reduction gear tooth contact

Tooth contact Procedure
Extends from
toe to middle
portion, cover-
1 Good
ing 50% or
more of tooth
213716 length.
Short contact at 2 1. Move gear away from pinion.
toe of tooth
2. Move pinion toward gear for correct back-
(Toe).
2 lash by increasing shim thickness.
1
213717 213721

Short contact at 2 1. Move gear toward pinion.

heel of tooth
2. Move pinion away from gear for correct
(Heel)
3 backlash by decreasing shim thickness.
1
213718 213722

Heavy contact 1. Move pinion toward gear by increasing shim

1
on face or top thickness.
half (adden-
4 2.Move gear away from pinion for correct back-
dum) of tooth
(Face) 2 lash.
213719 213723

Heavy contact 1 1. Move pinion away from gear by decreasing

on bottom half shim thickness.
(deadened) of
5 2. Move gear toward pinion for correct back-
tooth (Flank) 2 lash.
213720 213724

Note: For "Toe" or "Heel" contact, see the contact pattern on the outside (convex) of the reduction gear tooth. In
the case of "Face" or "Flank" contact, repeat the above adjustment until the correct tooth contact is obtained.

7-21
FRONT AXLE AND REDUCTION DIFFERENTIAL

4. Troubleshooting

Reduction bevel gear teeth badly worn, chipped Replace.

Bearing preload too much or too little, or bearings worn
Readjust or replace.
Continuous gear excessively
noise during travel Hub bearings damaged Replace.
Improper tooth contact between reduction bevel pinion
Adjust.
and reduction gear
Reduction taper roller bearings or
Replace.
hub bearings damaged
Differential gears having broken teeth, or thrust washers
Irregular noises Replace gears or washers.
worn
during traveling
Foreign substance in axle housing Clean and replace oil.
Loosened bolts that secure the axle shaft or differential
Retighten.
carrier
Fit of differential gears in differential case out of specifi-
Abnormal noises Replace worn parts.
cation due to wear
when turning a cor-
ner Differential gear teeth broken or seized worn, or dam-
Replace defective parts.
aged by piston
Overheated reduc- Bearing damage due to excessive preload Replace bearings and readjust preload.
tion case after trav- Backlash between reduction bevel pinion (on output
eling Readjust tooth contact and backlash.
shaft) and reduction bevel gear may be too small

7-22
 FRONT AXLE AND REDUCTION DIFFERENTIAL

5. Service Data
Unit: mm (in.)
Truck type
Item
1 ton class 2 ton class 3 ton class
A 0.08 (0.003)
Face runout of axle shaft flange
B 0.5 (0.020)
Deflection of axle shaft A 0.5 (0.020) or less
(1/2 of dial indicator reading)
B 1.0 (0.039), maximum
N·m
Increment from when preload
(kgf·m) A 0.5 to 4.9 (0.05 to 0.5) [0.37 to 3.7]
is zero
Preload for hub [lbf·ft]
bearing 1 N 5.6 to 54 4.5 to 45
Tangential force of wheel bolt 2 (kgf) A (0.57 to 5.5) (0.46 to 4.6)
[lbf] [1.26 to 12.1] [1.01 to 10.1]
Axle shaft bolt 3 A 98.1 ± 9.8 (10.0 ± 1.0) [72.4 ± 7.2]
145.9 ± 14.6 212.7 ± 21.3
Backing plate bolts 4 A (14.9 ± 1.5) (21.7 ± 2.2)
Tightening [107.6 ± 10.8] [156.9 ± 15.7]
torque Axle support nuts 5 A 377.6 ± 37.8 (38.5 ± 3.9) [279 ± 27.9]
N·m
(kgf·m) 156.9 ± 15.7 377.6 ± 37.8
[lbf·ft] Wheel nuts 6 A (16.0 ± 1.6) (38.5 ± 3.9)
[115.8 ± 11.6] [278.7 ± 27.9]
Level plug 7 A 127.5 ± 9.8 (13.0 ± 1.0) [94.0 ± 7.2]
Drain plug 8 A 84.3 ± 7.8 (8.5 ± 0.8) [61.5 ± 5.8]

6
1

7
8

217086
A: Standard value B: Repair or service limit

7-23