205-02 Rear Axle Differential PICKUP JMC

205-02-1 Rear Axle / Differential 205-02-1
Section 205-02 Rear Axle / Differential

Applicable Model: Boomday
CONTENTS PAGE
Specifications
Specifications ................................................................................................................................ 205-02-2
Descriptions and Operations
Rear Axle / Differential ................................................................................................................... 205-02-7
Diagnosis and Testing
Rear Axle / Differential ................................................................................................................. 205-02-13
General Procedures
Clearance between Planetary Gear and Planetary Gear Shaft ................................................... 205-02-24
Clearance between Differential Gear and Differential Carrier ..................................................... 205-02-25
Clearance between Differential Gear and Semi-axle Spline ....................................................... 205-02-26
Spot Check and Adjustment of Contact Surface between Driving Gear and Driven Gear .......... 205-02-27
In-vehicle Repair
Driving Gear Flanges and Driving Gear Oil Seal ......................................................................... 205-02-28
Removal and Installation
Rear Axle ..................................................................................................................................... 205-02-29
Differential ................................................................................................................................... 205-02-31
Disassembly and Assembly
Differential ................................................................................................................................... 205-02-33
2009.06 Boomday
Specifications
Parameter Specifications
Item Specification
7A series rear axle
Applicable vehicle JX1021DSH JX1021SW JX1023SA
Gear ratio 41:10 41:9 41:8
Rear axle model Half-floating axle, main reducer of single-stage hypoid gear
Axle housing model Overall punching and welding, lute model
Main reducer gear Single-stage deceleration, hypoid gear
Differential model Straight bevel gear, two planetary gears
Semi-axle Half-floating
TL-A series rear axle
Applicable vehicle JX1021DSE JX1023DSE
Gear ratio 43:11 41:9
Rear axle model Half-floating axle, main reducer of single-stage hypoid gear
Axle housing model Overall punching and welding, lute model
Main reducer gear Single-stage deceleration, hypoid gear
Differential model Straight bevel gear, four planetary gears
Semi-axle Half-floating
Remarks: Applicable vehicle merely indicates the main corresponding vehicle models of the rear axle.
Lubricants, Sealers, Adhesives
Item Specification
Sealing adhesives 352 anaerobic
Flange sealers Ultra-black 1598 silicone rubber
Sealers HZ-1213 oil-proof silicone
Sealers Lotite 587
Lubricants 2# lithium base
Hypoid gear lubricants APL GL-5 80W-90
2009.06 Boomday
Specifications
Parts Specifications
Item Specification
7A series rear axle
Axle housing section φ76 × 4.5
Gear ratio 41:10, 41:9
Backlash of driving and driven gears 0.18 ~ 0.23mm
TL-A series rear axle
Axle housing section φ76 × 5
Gear ratio 43:11, 41:9
Backlash of driving and driven gears 0.18 ~ 0.23mm
Shim Selection Table (194 mm)
Driving
Gear +10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10
Grade
Dial
Counting
0.081 2.18
0.082 2.18 2.20
0.083 2.18 2.20 2.24
0.084 2.18 2.20 2.24 2.26
0.085 2.18 2.20 2.24 2.26 2.28
0.086 2.18 2.20 2.24 2.26 2.28 2.32
0.087 2.18 2.20 2.24 2.26 2.28 2.32 2.34
0.088 2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36
0.089 2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38
0.090 2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42
0.091 2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44
0.092 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46
0.093 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48
0.094 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52
0.095 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54
0.096 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56
0.097 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56
0.098 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56
2009.06 Boomday
Specifications
0.099 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56

0 2.42 2.44 2.46 2.48 2.52 2.54 2.56
0.001 2.44 2.46 2.48 2.52 2.54 2.56
0.002 2.46 2.48 2.52 2.54 2.56
0.003 2.48 2.52 2.54 2.56
0.004 2.52 2.54 2.56
0.005 2.54 2.56
0.006 2.56
Shim Selection Table(220 mm)
Driving
Gear +10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10
Grade
Dial
Counting
0.073 1.94 1.96
0.074 1.94 1.96 1.98
0.075 1.94 1.96 1.98 2.00
0.076 1.94 1.96 1.94 1.96 1.98 2.00
0.077 1.96 1.98 1.98 2.00 2.02 2.04
0.078 1.94 1.96 1.98 2.00 2.00 2.02 2.04 2.06
0.079 1.94 1.96 1.98 2.00 2.02 2.02 2.04 2.06 2.08
0.080 1.94 1.96 1.98 2.00 2.02 2.04 2.06 2.04 2.06 2.08 2.10
0.081 1.96 1.98 2.00 2.02 2.04 2.06 2.08 2.08 2.10 2.12 2.14
0.082 1.98 2.00 2.02 2.04 2.06 2.08 2.10 2.10 2.12 2.14 2.16
0.083 2.00 2.02 2.04 2.06 2.08 2.10 2.12 2.12 2.14 2.16 2.18
0.084 2.04 2.06 2.08 2.10 2.12 2.14 2.16 2.14 2.16 2.18 2.20
0.085 2.06 2.08 2.10 2.12 2.14 2.16 2.18 2.18 2.20 2.22 2.24
0.086 2.08 2.10 2.12 2.14 2.16 2.18 2.20 2.20 2.22 2.24 2.26
0.087 2.12 2.14 2.16 2.16 2.20 2.22 2.24 2.22 2.24 2.26 2.28
0.088 2.14 2.16 2.18 2.20 2.22 2.24 2.26 2.26 2.28 2.30 2.32
0.089 2.16 2.18 2.20 2.22 2.24 2.26 2.28 2.28 2.30 2.32 2.34
0.090 2.18 2.20 2.22 2.24 2.26 2.28 2.30 2.30 2.32 2.34 2.36
0.091 2.20 2.24 2.26 2.28 2.30 2.32 2.34 2.32 2.34 2.36
0.092 2.24 2.26 2.28 2.30 2.32 2.34 2.36 2.36
2009.06 Boomday
Specifications
0.093 2.26 2.28 2.30 2.32 2.34 2.36

0.094 2.28 2.30 2.32 2.34 2.36
0.095 2.32 2.34 2.36
0.096 2.34 2.36
0.097 2.36
Note: please find the part number in the part catalog against the shim thickness in the preceding table
in case of purchases.
Volume
Item Specification
7A series
Rear axle lubricants 1.6-2 L
TL-A series
Rear axle lubricants 2.5 L
2009.06 Boomday
Specifications
Torque Specifications
7A series
Name Nm
Driving gear flange nuts 193 ± 13
Driven gear attachment bolts 78 ± 8
Differential bearing cap bolts 128 ± 13
Bolt – axle housing 24 ± 4
Stud – axle housing 22 ± 4
Axle housing coupling nut 23 ± 3
Nut – brake soleplate bolt 74 ± 4
Oil-filling plug 43 ± 3
Oil-discharging plug 78 ± 10
TL– A Series
Driving gear flange nuts 402 ± 79
Differential housing attachment bolts 78 ± 8
Driven gear attachment bolts 128 ± 13
Differential bearing cap bolts 152 ± 20
Stay bolt – axle housing 66 ± 7
Axle housing bolt 66 ± 7
Stud – axle housing 66 ± 7
Axle housing coupling nut 47 ± 12
Nut – brake soleplate bolt 74 ± 4
Nut-semi-axle 260 ± 30
Oil-filling plug 43 ± 3
Oil-discharging plug 78 ±10
2009.06 Boomday
Rear Axle / Differential

The rear axle / differential consists of the
following components:
● Half-floating semi-axle supporting form is
adopted for rear axle. With excellent supporting
performance, the rear axle can guarantee the
rigidity and low noise of driving axle operation
and prolong service life.
● The lute-model rear axle housing is shaped by
overall punching and welding.
● The main reducer is the hypoid gear with
single-stage deceleration type.
● 7A model rear axle differential is the straight
bevel gear with two planetary gears.The minus
planetary gear shaft is adopted.
● TL-A model rear axle differential is the straight
bevel gear with four planetary gears.The cross
head planetary gear shaft is adopted.
2009.06 Boomday
Rear Axle Parts Illustration
Item Description Item Description

1 Semi-axle nut 10 Oil seal – semi-axle
2 Lock washer 11 Oil filling plug
3 Bearing 12 Ventilation plug
4 Bearing support 13 Rear axle assembly
5 Oil seal – bearing support 14 Differential assembly
6 Semi-axle 15 Oil discharging plug
7 Brake drum 16 Nut
8 Screw – brake drum 17 Bolt
9 Tire nut assembly 18 Gasket – bearing support
2009.06 Boomday
TL-A Rear Axle Differential Parts Illustration
2009.06 Boomday

1 Flange nut 11 Differential bearing adjustment gasket
2 Flange washer 12 Differential bearing
3 Flange 13 Driven gear
4 Driving gear oil seal 14 Driven gear bolt
5 Driving gear outer bearing 15 Differential housing
6 Telescopic spacer sleeve 16 Differential gear thrust washer
7 Main reducer housing 17 Differential gear
8 Adjustment gasket of the inner bearing 18 Planetary gear
9 Driving gear 19 Planetary gear shaft
10 Driving gear inner bearing
2009.06 Boomday
7A Rear Axle Differential Parts Illustration
2009.06 Boomday

1 Flange nut 12 Driven gear
2 Flange 13 Spring washer
3 Driving gear oil seal 14 Driven gear bolt
4 Driving gear outer bearing 15 Differential housing
5 Elastic spacer sleeve 16 Differential gear thrust washer
6 Main reducer housing 17 Differential gear
7 Inner bearing adjustment gasket 18 Planetary gear
8 Driving gear inner bearing 19 Lockpin – planetary gear shaft
9 Driving gear 20 Planetary gear shaft
10 Differential bearing 21 Thrust sleeve
11 Differential bearing adjustment gasket
2009.06 Boomday
Rear Axle / Differential

Inspection and Confirmation 7 Check technical service bulletin and special
maintenance materials, etc.
The maintenance technician shall acquire an
2. ATTENTION: Repair the vehicle in case
all-round knowledge of the operating principle of evident problems in inspection.
of the transmission system and detect relevant
problems with basic expertise. Carry out a preliminary inspection. Visually
inspect for obvious signs of damage.
The gear driving unit causes noises. Some noises
are bearable and audible at a certain speed and 1 Check transmission shaft.
under different driving conditions. Normal noises ● Whether there are foreign matters.
are amplified under some conditions, such as ● Whether it is damaged, such as tube
worsened road and weather conditions. bending or mass reduction.
The correlative symptoms of the rear axle and ● Whether the universal joint or flexible
transmission system are also common in engine, coupling is worn or damaged.
gear-box, rear wheel bearing and tire. Therefore, 2 Check axle.
related causes must be confirmed at the axle
● Whether there is leakage at the oil disch-
before the maintenance or installation of new
arging plug or oil filling plug.
axle parts.
- Blockage at ventilation holes causes leakage.
The guidelines to diagnose related issues of
power transmission system are shown as below: ● Whether it is damaged, such as cracks,
semi-axle bending or sunken rear back.
● Seek and verify the consumer concern.
● Whether fasteners are lost.
● Launch investigation.
3 Check for other suspicious parts / systems.
● Road test.
● Check whether the universal joint of
● Detect related causes.
semi-axle assembly is damaged, and the
● Check parts. extension sleeve is torn.
1. Seek and verify the consumer concern. ● Check for intactness of the suspension
1 When was the problem noticed for the first spring, shock absorber and suspension
time? axle sleeve.
2 Does it come out suddenly or gradually? ● Check rear brake parts – line, cable and
3 Is there something special that precedes or brake caliper.
synchronizes it? ● Check whether tires are in sound con-
4 Have the power transmission system been dition and match each other.
fixed earlier or new parts been installed? 3. ATTENTION: Road test must be carried
Check vehicle service record. Notice out for noise and vibration concerned by
whether other parts other than transmission customers.
system have been maintained, such as Vehicle Road Test
brake or suspension.
1 During the road test, the following operation
5 Are there any other conditions that affect or methods are used for diagnosis. The most
change such problem? obvious problems are:
Such as: ● From braking.
● Highway speed. ● Switch between reverse gear and forward
● Road grade. gear.
● Driving mode. ● In case of turning?
● Temperature. - Large-angle turn.
● Vehicle loading or unloading. - Abrupt turn (till stopping).
6 Is the condition continuous or intermittent? ● In case of moving forward?
Will the problem reoccur at any time?
2009.06 Boomday
- Is there an engine torque in case of - Pits or cracks along the gear contacting
accelerating the vehicle with a certain line.
accelerator opening degree?
- Scratches or deformation.
● In case of sliding?
- Color changing.
- Is the vehicle decelerated if the throttle
valve is closed? - Gaps or bumps at gear teeth.
2 Keep records of problems. Record the ● Check backlash, and carry out driving and
vehicle speed range when noise/vibration driven gear mode test and inspection of
occurs. gear meshing point and gear quality.
4. Verify the concern and refer to the Symp-
tom List.
5. If the conclusion of road test blames on
the axle center part (the driven gear and
planetary gear or differential housing),
visually check the axle.
Check axle parts:
1 Remove differential housing cover. Wipe out
axle lubricant with white cloth.
Check the liquid:
● Whether there are foreign matters
● Whether there are metallic particles
● Smell of burning
2 ATTENTION: Do not immediately clear
parts in case of checking the axle.
To clear parts may destruct diagnostic
evidence.
Check axle parts.
● Look for:
- Loose fasteners.
- Dents or obvious teeth or grooves caused
by abrasion.
- Pits or cracks along the gear contacting line.
- Scratches or deformation.
- Color changing.
- Gaps or bumps at gear teeth.
● Clear up the axle for inspection.
- Remove lubricant with the cleaning agent
as much as possible. Wipe up parts or
dry them a compressor.
● Whether there are following items in one
inspection.
- Loose fasteners.
- Dents or obvious teeth or grooves caused
by abrasion.
2009.06 Boomday
Symptom List
Symptoms Possible Causes Measures

Abnormal sound in transmission ● Inappropriate differential gear ● Replace thrust gaskets or
gap. gears.
● Too big gap between driving ● Replace thrust gaskets or
and driven gears. gears.
● Too small preload of driving
● Adjust preload.
gear.
● Abrasion or damage of gas-
● Replace troubled parts.
kets, i.e. differential gears.
● Too low level of gear oil. ● Fill up lubricant.
Lubricant leakage ● Abrasion, looseness or dam-
● Replace oil seal.
age of oil seal.
● Looseness of reducer faste- ● Tighten it up according to the
ning bolt. tightening torque.
● Damage of sealer. ● Recoat the sealer.
● Tight it up according to the
● Looseness of oil discharging
tightening torque or replace
plug or damaged gaskets.
the gaskets.
● Axle housing deformation as
● Adjust or replace axle housing.
a result of overload.
● Blocked or damaged ventil- ● Clean up or replace ventilat-
ation plug. ion plug.
Accuracy Test
Accuracy test A: Rear axle noise when the engine drives the vehicle
Test Conditions Details / Results /Measures

A1: Check oil level height of rear axle gear
Is it enough?
Yes
Go to A2.
No
Add oil to the required level.
A2: Check rear axle gear oil
Is it normal?
Yes
Go to A3.
No
Replace the gear oil.
2009.06 Boomday
Test Conditions Details / Results / Measures

A3: Check clearance between driving gear and driven gear
Is it normal?
Yes
Go to A4.
No
Adjust the interval.
A4: Check axial clearance of driving gear
Is it normal?
Yes
Go to A5.
No
Adjust the driving gear bearing preload.
A5: Check abrasion of driving gear bearing
Is it normal?
Yes
Go to A6.
No
Replace the driving gear bearing.
A6: Check looseness of differential side bearing
Is it normal?
Yes
Go to A7.
No
Adjust the preload.
A7: Check differential side bearing
Is it worn?
Yes
Replace differential side bearing.
No
Go to A8.
2009.06 Boomday

A8: Check driving and driven gears
Is the abrasion or run-out tolerance too great?
Yes
Replace the driving and driven gears concurrently.
No
Recheck.
Accuracy test B: Rear axle noise when the vehicle slides.
Test conditions Details / Results / Measures

B1: Check clearance between brake driving gear and driven gear
Is it normal?
Yes
Go to B2.
No
Adjust the clearance.
B2: Check driving gear
Is it damaged?
Yes
No
Recheck.
Accuracy test C: Intermittent rear axle noise

C1: Check rear axle shaft clearance
Is it normal?
Yes
Go to C2.
No
Replace the rear axle shaft.
C2: Check driving gear
Does it warp?
Yes
No
Go to C3.
2009.06 Boomday

C3: Check differential box bolt
Are there any foreign matters?
Yes
Clear away foreign matters.
No
Recheck.
Accuracy test D: Rear axle noise when the vehicle turns a corner

D1: Check rear axle spline
Is it worn?
Yes
Replace the rear axle.
No
Go to D2.
D2: Check side gear
Is it worn?
Yes
Replace the side gear.
No
Go to D3.
D3: Check differential pinion
Is it worn?
Yes
Replace the differential pinion.
No
Go to D4.
D4: Check differential pin
Is it worn?
Yes
Replace the differential pin.
No
Recheck.
2009.06 Boomday
Accuracy test E: Regular rear axle noise

E1: Check rear axle shaft
Is it bent?
Yes
No
Go to E2.
E2: Check driving gear
Are there any flat spots?
Yes
No
Go to E3.
E3: Check driven gear and bearing
Are there any flat spots and abrasion?
Yes
No
Go to E4.
E4: Check driving gear bearing
Yes
Replace the driving gear bearing.
No
Go to E5.
E5: Check side bearing oil seal
Yes
Replace the side bearing.
No
Recheck.
2009.06 Boomday
Accuracy test F: Rear axle vibration

F1: Check rear wheel hub bearing
Is it worn?
Yes
Replace the rear wheel hub.
No
Go to F2.
F2: Check rear axle shaft
Is it bent?
Yes
No
Recheck.
Accuracy test G: Oil leakage of differential housing

G1: Check gear oil level
Is it too much?
Yes
Adjust the gear oil level.
No
Go to G2.
G2: Check differential oil seal
Is it worn or damaged?
Yes
Replace the oil sealing.
No
Go to G3.
G3: Check differential ventilation plug
Is it blocked?
Yes
Clean the ventilation plug.
No
Go to G4.
2009.06 Boomday

G4: Check differential housing bolt
Is it loose?
Yes
Tighten the bolt to the required torque value.
No
Go to G5.
G4: Check differential housing
1. Is the bolt loose?
2. Is the seal gasket damaged?
Yes
Tighten the bolt to the required torque value or
replace the seal gasket.
No
Go to G5.
G5: Check the locking nut and oil sealing of the differential driving gear
1. Is the nut loose?
2. Is the oil seal damaged?
Yes
Tighten the nut to the required torque value or
replace the oil seal.
No
Recheck.
Accuracy test H: Axle housing leakage

H1: Check oil discharging plug
1. Is the plug loose?
2. Is the gasket damaged?
Yes
Tighten the plug or change the gasket.
No
Go to H2.
H2: Check breather pipe
Is it blocked?
Yes
Clean the breather pipe.
No
Go to H3.
2009.06 Boomday

H3: Check axle housing
Is it broken?
Yes
Replace the axle housing.
No
Go to H4.
H3: Check differential housing
1. Is the bolt loose?
2. Is the sealing gasket damaged?
Yes
Tighten the bolt to the required torque value or
replace the sealing gasket.
No
Recheck.
Accuracy test J: Leakage from the axle housing to inner wheel hub

J1: Check gear oil level
Is it too much?
Yes
Adjust the gear oil level.
No
Go to J2.
J2: Check wheel hub outer oil seal
Is it worn?
Yes
Replace the oil sea.
No
Recheck.
2009.06 Boomday
Accuracy test K: Rear axle power cannot be transmitted to the wheel (the transmission shaft runs
normally)

K1: Check rear axle shaft
Is it broken?
Yes
No
Go to K2.
K2: Check driving and driven gears
Is it broken?
Yes
Replace the driving and driven gears.
No
Go to K3.
K3: Check differential gear box and universal joint cross
Is it broken?
Yes
Replace the differential gear box or universal joint
cross.
No
Recheck.
2009.06 Boomday
General Procedures
Clearance between Planetary Gear and Planetary Gear Shaft

Check the clearance between planetary gear
and planetary gear shaft.
In case of over 0.2 mm clearance, install new
parts.
2009.06 Boomday
General Procedures
Clearance between Differential Gear and Differential Housing

The clearance between differential gear and
differential housing: L = R – r.
parts.
2009.06 Boomday
General Procedures
Clearance between Differential Gear and Semi-axle Spline

Check the clearance between differential gear
and semi-axle spline.
parts.
2009.06 Boomday
General Procedures
Spot Check and Adjustment of Contact Surface between

Drive Gear and Driven Gear
ATTENTION: If trouble is found in contact 3. Contact toe, widen backlash and reduce clea-
surface spot and the clearance is correct, rance sheets.
check the selection of gear clearance
sheet.
The contact surface spot inspection aims to
detect problems of devices before technicians
initially install differential.The contact spots
shall be within the main area of gears. Narrow
or too small periphery gear spots shall be
avoided. The contact surface spot inspection
shall be carried out at the driving side of the
gear. Standard assembly features sounddriving
trace and provides the vehicle with good sliding
performance.
1. Good contact surface. 4. Contact heel, reduce backlash and widen
clearance sheets.
2. Contact low flank, approach dedendum and

reduce clearance sheets. 5. Contact high surface and widen clearance
sheets.
2009.06 Boomday
In-vehicle Repair
Drive Gear Flanges and Driving Gear Oil Seal

Removal 3. Install washers and flange nuts, use
dedicated tools to restrict flange from
1. Set the gearbox at neutral gear, and park revolving.
the vehicle on the lift, refer to section 100-
02 for more information. ● 7A series, tighten to 193 ± 13 Nm.
2. ATTENTION: Mark in the corresponding ● TA-L series, tighten to 402 ± 79 Nm.

places of transmission shaft flange and
rear axle gear flange, and stabilize the
transmission shaft in assembly.
Remove four bolts, and move away the
transmission shaft.
4. Against the aligned marks, retain the

transmission flange and install the bolt on
the rear gear flange.
Tighten to 63 ± 4 Nm.
3. Remove flange nut.
5. Check the axle and apply designated lubr-

icant of specific amount on it. Set down the
4. Remove flange and oil seal. vehicle.
5. Clean oil seal holder.
Installation
1. Lubricate rubber oil seal tip with designated
lubricant. Use proper tools to install rear
axle gear oil seal.
2. Coat a little designated lubricant on rear
axle gear flange and install it.
2009.06 Boomday
Rear Axle
Removal and Installation 1 Remove fastening bolts.
CAUTION: Because suspension fasteners 2 Detach wheel speed sensor.

are key parts, they affect operation of
Fixing torque: 8 Nm.
key parts and systems. In case of failure,
huge maintenance cost arises. New parts
or equivalent parts of the same serial
number must prevail. In case of necessary
installation, inferior or alternate parts
shall not be used. Parts installation must
conform to the designated torque to
ensure the correct fastening of parts.
1. Release the tension of parking brake cable.
Refer to section 206-05 for more information.
2. Set the vehicle at neutral gear, and lift it onto
the rack. Refer to section 100-02 for more
information.
7. Disconnect brake tubing connector.
3. Remove rear tire and tire assembly. Refer
to section 204-04 for more information.
4. Remove brake shoe assembly.
8. Remove rear driving semi-axle, refer to

section 205-05 for more information.
5. Disconnect hand brake cable.
6. Disconnect the wheel speed sensor.
2009.06 Boomday
9. Remove shock absorber. Fixing torque: 100 ± 20 Nm.
Fixing torque: 40 ± 2 Nm
13. Detach rear axle.
10. Use fixing rack to prop frame rail, and use

jack to prop rear axle.
11. Remove four U-shape bolt installation
nuts, lower rack and two U-shape bolts.
1 Remove four nuts.
2 Remove lower rack.
3 Remove two U-shape bolts.
Fixing torque: 67 ± 6 Nm.
14. For installation, reverse the removal proc-

edures.
12. Remove rear leaf spring pin.
2009.06 Boomday
Differential
Differential Parts Illustration

1 Transmission shaft 3 Semi-axle
2 Main reducer
Material Specifications
1. Remove oil discharging plug, and drain
rear axle oil.
Description Specification
Flat sealer Ultra-black 1598 silicone rubber 2. ATTENTION: Mark in the corresponding
places of transmission shaft flange and
rear axle gear flange, and stabilize the
transmission shaft in assembly.
2009.06 Boomday
Remove attachment bolt of transmission Tighten connecting nut of axle housing to 23

s h a f t a n d m a i n r e d u c e r, a n d d e t a c h ± 3 Nm.
transmission shaft.
2. Install semi-axle. Rotate semi-axle to make

3. ATTENTION: Detach left and right semi- spline and differential gear fully engage.
axles form the chassis, and draw part of
them from the axle housing respectively. It 3. ATTENTION: Mark in the corresponding
is not necessary to fully draw out the rear places of transmission shaft flange and
axle shaft here, and it is just fine to remove rear axle gear flange, and stabilize the
the main reducer. transmission shaft in assembly.
Remove semi-axle. Install transmission shaft.

Fixing torque: 63 ± 4 Nm.
4. Remove main reducer, attachment bolt of
axle housing and main reducer assembly.
4. Fill gear oil as required.

Installation 7A series: 1.6 ~ 2 L.
1. Install main reducer assembly, coat it with TL-A series: 2.5 L.
sealer and tighten axle housing bolt.
Tighten axle housing bolt to 24 ± 4 Nm.
2009.06 Boomday
Differential
Material Specifications Disassembly
Item Specification 1. Fix differential assembly on the special tools.
Sealing adhesive 352 anaerobic Clamp: 5-8840-0275-0.
Sealer 587 lotite Foundation bed: 5-8840-0003-0.
Special Tools
2. Remove main bearing cover.

1 Make positioning marks on the main bearing
cover and differential housing.
2009.06 Boomday
2 Remove differential bearing outer ring and Special tool: 9-8521-5032-0.

separate left bearing assembly from right bearing
assembly to match inner and outer rings.
6. Remove inner bearing.

3. Remove differential bearing. Use separator and press to remove driving
gear bearing.
Separator: 5-8840-0015-0.
4. Remove flange nut, and use dedicated tools

to clamp driving gears.
Clamp: 5-8840-2157-0.
7. Remove outer ring of inner bearing.
5. Remove driving gears.

Underlay dedicated metal bar at the end
of driving gear, knock metal bar with hand
hammer, and knock out driving gear from main
reducer housing.
2009.06 Boomday
8. Remove outer ring of outer bearing. Use a soft metal bar and a hand hammer to remove
planetary gear shaft.
9. Remove driven gear.

12. Detach differential gear and planetary gear.
In case of dismantling driven gears, guard
against damage to differential gear box and Assembly
driving gears, and do not insert chisel or other 1. Install differential gear.
tools into junction surface.
2. Simultaneously rotate two planetary gears,
and engage them with differential gear. Then
assemble planetary gears.
10. Remove locking pin.

Use aφ5mm punch to punch off pin rod of
locking pin. 3. Install planetary gear shaft.
1 Planetary gear shaft must be aligned with
locking shaft hole of differential before
installation.
11. Remove planetary gear shaft.
2009.06 Boomday
2 Adjust backlash between differential gear and Fixing torque: 110 ± 10 Nm.
planetary gear.
Standard reading: 0.03 ~ 0.08 mm.
Thickness of thrust washer for use.
1.00, 1.05, 1.10 mm
6. Install outer ring of outer bearing.
4. Lock planetary gear shaft.
7. Install outer ring of outer bearing.
5. ATTENTION: Discard old bolts and

install new ones. Note that all bolts are of
left-hand thread.
ATTENTION: In case of installing driven

gears, coat Loctite 271 or an equivalent
on the threaded holes or bolts.
ATTENTION: Replace driving and driven 8. Adjust shimming sheet.

gears concurrently.
Adjust installing distance of driving gears.
ATTENTION: All bolts are of left-hand thread.
1 Use gear oil on inner and outer bearings to
Install driven gears. clean positioning device of driving gear.
Tighten bolts in diagonal order as shown in the
figure.
2009.06 Boomday
Then install positioning gauge with inner and 194mm

outer bearings concurrently.
1 Pilot valve
2 Circular discs (two)
3 Mandrel
4 Adjustment plate
220mm
1 Dial indicator
2 Circular discs (two)
3 Mandrel
4 Adjustment plate
194mm
Tighten nuts to required torque:
1 Pilot valve
194 mm 100 ± 10 Nm
2 Nut and bolt
220 mm 110 ± 10 Nm
4 Adjustment plate
220mm 3 Set the dial indicator to “0”, and place it on the

installation rod of the mandrel. The contact
1 Front pilot valve button shall contact the indicator pad. Press
the dial indicator towards clockwise direction
2 Nut and bolt of the pointer and turn the dial indicator for a
3 Rear pilot valve half circle. Fasten the indicator at the current
position.
4 Adjustment plate
Tighten nuts to required torque:
New bearing 230 Nm

Old bearing 110 Nm
2 Clean differential bearing bore, and install

dial indicator, circular disc and mandrel
concurrently. Install bearing cover and tighten
it to the required torque.
Items Description
1 Dial indicator
2 Mandrel
3 Plunger
4 Adjustment plate
2009.06 Boomday
4 Place the plunger on the adjustment plate, Select shimming sheet against the specification.
and slowly move the mandrel forward and
backward until the maximum deflection
appears on the dial indicator. Then reset the
dial indicator to “0”.
+2
9. ATTENTION: It is forbidden to exert pre-

ssures on the roller bearing rack. Pressure
is exerted exclusively on the inner ring.
5 After “0” position is pinpointed, rotate the Install inner bearing.

mandrel until the indicator does not contact
Place shimming sheet on the driving gear shaft,
the adjustment plate.
with the side facing the driving gear shaft top.
Record the reading of dial indicator pointer. Then use installer and tamp to install inner
bearing on the driving gear.
6 Record reading of pinion scale atop the driving

gear. The reading refers to the distance 10. Install telescopic spacer sleeve.
change required by pinion installation. The
reading with a “cross” sign means that the Discard old telescopic spacer sleeve and install
installing distance shall rise (shimming sheet a new one.
thickness can increase). If the pinion depth 11. ATTENTION: It is forbidden to replace
measures zero, the pinion is a norminal gear. front differential oil seal with rear differen-
tial oil seal.
Install oil seal.
2009.06 Boomday
Use oil seal installer to install new oil seal 220 mm starting torque: 100 ± 30 Nm.
that is soaked in lubricant.
13. Install and adjust shimming sheet.

12. ATTENTION: Discard old flange nut 1 Discard shimming sheet. Install differential
and install a new one.
bearing on differential. Use a guide tube
Install flange nut and washer. to prop differential at the back to avoid
damaging bearing.
1 Coat lubricant on driving gear thread.
2 Use driving gear flange clamp to tighten nut
to the required torque.
194 mm Fixing torque: 205 ± 75 Nm.
Item Description
1 Installer
2 Driving handle
3 Guide tube
3 Pre-tighten driving gear bearing.

- Use a torque wrench to measure bearing
preloading force.
Notice scale reading required for rotating
flange.
- Further tighten it until it reaches the req-
uired starting torque.
194 mm starting torque: 90 ± 25 Nm.
2009.06 Boomday
2 Insert differential and outer ring of bearing 220 mm backlash reading: 0.15 ~ 0.20 mm.
to semi-axle bearing bore.
5 Remove differential bearing.

3 Carry out the operation with two sets of
feeler gauges. Insert a filler block with
sufficient thickness to cram clearances
between outer ring of bearing and
differential. The filler block must be pushed
to the bottom of the bearing bore. Install
dial indicator on differential. The indicator
rod keeps proper angles with teeth of
driving and driven gears.
14. Install differential bearing.

Install differential bearing and selected
shimming sheets concurrently.
4 Adjust thickness of feeler gauge between

both sides until the backlash of driving and
driven gears falls on the required range.
The end gap value is zero. When the
backlash value meets the requirement,
detach the feeler gauge, and determine
thickness of the required shimming sheets.
Thicken each group of the shimming sheets
by 0.5 mm to generate the differential Item Description
bearing preload. Use new shimming sheets
for operation. 1 Installer
194 mm backlash value: 0.13 ~ 0.18 mm. 2 Driving handle

3 Guide tube
2009.06 Boomday
15. Install differential bearing cover.

Align positioning marks which are made
during disassembly.
16. Install differential bearing cover bolts.

2009.06 Boomday

205-02 Rear Axle Differential PICKUP JMC

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205-02-1 Rear Axle / Differential 205-02-1

Section 205-02 Rear Axle / Differential

Lubricants, Sealers, Adhesives

0.099 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56

0.093 2.26 2.28 2.30 2.32 2.34 2.36

Rear Axle / Differential

Rear Axle Parts Illustration

Item Description Item Description

TL-A Rear Axle Differential Parts Illustration

Item Description Item Description

7A Rear Axle Differential Parts Illustration

Item Description Item Description

Rear Axle / Differential

Symptoms Possible Causes Measures

Test Conditions Details / Results /Measures

Test Conditions Details / Results / Measures

Test Conditions Details / Results / Measures

Accuracy test B: Rear axle noise when the vehicle slides.

Test conditions Details / Results / Measures

Accuracy test C: Intermittent rear axle noise

Test Conditions Details / Results / Measures

Test Conditions Details / Results / Measures

Test Conditions Details / Results / Measures

Accuracy test E: Regular rear axle noise

Test Conditions Details / Results / Measures

Accuracy test F: Rear axle vibration

Test Conditions Details / Results / Measures

Accuracy test G: Oil leakage of differential housing

Test Conditions Details / Results / Measures

Test Conditions Details / Results / Measures

Accuracy test H: Axle housing leakage

Test Conditions Details / Results / Measures

Test Conditions Details / Results / Measures

Test Conditions Details / Results / Measures

Test Conditions Details / Results / Measures

Clearance between Planetary Gear and Planetary Gear Shaft

Clearance between Differential Gear and Differential Housing

Clearance between Differential Gear and Semi-axle Spline

Spot Check and Adjustment of Contact Surface between

2. Contact low flank, approach dedendum and

Drive Gear Flanges and Driving Gear Oil Seal

2. ATTENTION: Mark in the corresponding ● TA-L series, tighten to 402 ± 79 Nm.

4. Against the aligned marks, retain the

3. Remove flange nut.

5. Check the axle and apply designated lubr-

5. Clean oil seal holder.

CAUTION: Because suspension fasteners 2 Detach wheel speed sensor.

8. Remove rear driving semi-axle, refer to

5. Disconnect hand brake cable.

6. Disconnect the wheel speed sensor.

9. Remove shock absorber. Fixing torque: 100 ± 20 Nm.

13. Detach rear axle.

10. Use fixing rack to prop frame rail, and use

14. For installation, reverse the removal proc-

12. Remove rear leaf spring pin.

Item Description Item Description

Remove attachment bolt of transmission Tighten connecting nut of axle housing to 23

2. Install semi-axle. Rotate semi-axle to make

Remove semi-axle. Install transmission shaft.