Publication No.

W563-0032E

02
Driving Axle
Model KR063
ｃ2005
◯
PRINTED IN JAPAN
0511 E
 Foreword

Foreword

This service manual explains the disassembly and

reassembly procedures for the driving axles used in
the Tadano rough terrain cranes. This manual applies
to the models listed below.
Before starting repair work, check the model No. in the
nameplate on the unit.
Read the applicable parts catalog, crane service
manual and other reference documents for additional
indispensable information on the crane besides this
manual to carry out correct repair and maintenance.

1. Applicable Crane Model

The table below shows the relationship between the
crane models and the models of axle used.

Axle
Crane model Application Drawing No.
Model Serial No.
FD**** Front 177-000164
GR-120N-1
KR063 Rear (without No-spin) 177-000174
TR-150XL-4 RD****
Rear (with No-spin) 177-000384

[NOTICE]
There is a case that the appearance and so on
differ from the parts for this crane. Although there
is not so much difference in functions and
disassembly procedures, make sure of the serial
number of this crane and the part sales unit
described in the parts catalog before starting
disassembling operations.

Please note that, for product improvement, some

changes may have incorporated in the machine
that are not covered in this manual.

1 W563-0032E
 Foreword
2. Contents
Foreword .................................................. 1
1. Applicable Crane Model.................................... 1
2. Contents ............................................................ 2
Structure .................................................. 4
1. Front differential section.................................... 4
2. Rear differential section .................................... 5
3. Axle section....................................................... 7
3.1 Housing and brake sections ....................... 7
3.2 Axle shaft assy ........................................... 9
3.3 Tie rod end assy ......................................... 9
4. Tightening torque .............................................11
Function ................................................ 12
1. General ........................................................... 12
1.1 Reduction gearing .................................... 12
1.2 Differential ................................................ 12
1.3 Disc brake................................................. 13
2. Standard differential ........................................ 15
3. Operating principle of standard differential ..... 16
4. No-spin differential .......................................... 17
4.1 Structure and configuration of
No-spin type differential ..................... 17
4.2 Spider assy ............................................... 18
4.3 Driven clutch assy .................................... 19
4.4 Spring........................................................... 19
4.5 Side gear .................................................. 19
4.6 Operating explanation (propeller driving
in a straight-forward) .......................... 19
4.7 Operating explanation
(propeller driving in forward turn) ....... 20
2 W563-0032E
Axle Assembly ........................................22
1. Dismounting.....................................................22
1.1 Axle assembly...........................................22
1.2 Draining gear oil........................................22
1.3 Disc brake assy.........................................22
1.4 Axle shaft flange .......................................22
1.5 Wheel hub assy ........................................22
1.6 Tie rod assy...............................................23
1.7 Spindle assy..............................................23
1.8 Axle shaft assy..........................................23
1.9 Knuckle assy.............................................24
1.10 Differential assy.........................................24
2. Disassembly ....................................................24
2.1 Wheel hub assy ........................................24
2.2 Spindle assy..............................................25
2.3 Axle shaft assy..........................................25
2.4 Axle housing assy .....................................25
3. Cleaning...........................................................26
3.1 Metal parts ................................................26
3.2 Rubber parts .............................................26
4. Inspection ........................................................26
4.1 Gear and spline.........................................26
4.2 Oil seal ......................................................26
4.3 Axle shaft ..................................................26
4.4 King pin bushing .......................................26
4.5 Bearing......................................................26
4.6 Service brake ............................................26
4.7 Parking brake............................................26
4.8 Tie rod: straightness..................................26
4.9 Housing bushing .......................................26
4.10 Axle joint....................................................26
5. Reassembly .....................................................27
5.1 Differential assy.........................................27
5.2 Axle housing assy .....................................27
5.3 Axle shaft assy..........................................28
5.4 Knuckle assy.............................................28
5.5 Knuckle spindle.........................................29
5.6 Wheel hub assy ........................................29
5.7 Wheel hub assy ........................................29
5.8 Brake assy ................................................30
5.9 Tie rod .......................................................31
5.10 Lubrication ................................................31
 Foreword

Differential Assembly............................. 32 5. Adjustment.......................................................46

1. Dismounting .................................................... 32 5.1 Adjusting the brake ...................................46
1.1 Differential carrier assy............................. 32 5.2 Connecting the spring chamber................46
1.2 Drive pinion assy ...................................... 32
2. Disassembly.................................................... 33
2.1 Differential carrier assy............................. 33 Adjustment..............................................47
2.2 Standard differential case assy ................ 34 1. Steering angle..................................................47
2.3 No-spin differential case assy .................. 35
2.4 Drive pinion assy ...................................... 35
3. Cleaning .......................................................... 36 Troubleshooting .....................................48
3.1 Metal parts ................................................ 36 1. Noise ............................................................48
3.2 Rubber parts............................................. 36 2. Oil leak ............................................................48
4. Inspection........................................................ 36 3. Defective steering and turning operations .......48
4.1 Differential pinion and spider.................... 36 4. Insufficient braking...........................................49
4.2 Side gear and axle shaft........................... 36 5. Brake drag .......................................................49
4.3 Flange and drive pinion ............................ 36
4.4 Drive pinion and ring gear ........................ 36
4.5 Side gear and differential pinion............... 36 Test for No-spin differential...................50
4.6 Bearing ..................................................... 36 1. Test with wheels jacked up ..............................50
4.7 Others....................................................... 36 2. Test by traveling...............................................51
5. Reassembly .................................................... 37 3. Abnormal conditions during traveling ..............51
5.1 Drive pinion assy ...................................... 37
5.2 Standard differential case assy ................ 38
5.3 No-spin differential case assy .................. 39
5.4 Differential carrier assy............................. 39
5.5 Drive pinion assy ...................................... 40
5.6 Pinion gear backlash adjustment ............. 40
5.7 Inspection and adjustment of
tooth contact pattern........................... 41
5.8 Differential carrier assy............................. 41
6. Lubrication....................................................... 42

Parking Brake ......................................... 43

1. Structure.......................................................... 43
2. Disassembly.................................................... 44
2.1 Removing the brake shoes....................... 44
2.2 Removing the cam shaft........................... 44
3. Check ........................................................... 45
3.1 Checking shoe lining assy........................ 45
3.2 Checking adjuster assy ............................ 45
3.3 Checking cam shaft.................................. 45
3.4 Checking springs ...................................... 45
3.5 Checking support plate assy .................... 45
3.6 Checking brake drum ............................... 45
4. Reassembly .................................................... 45

3 W563-0032E
 Structure

Structure

The axle transmits the driving force from the engine to

the right and left driving wheels as well as it supports
the weight of the vehicle. As it is designed as a
steering drive axle, it is equipped with steering
mechanism such as ball joints and a tie rod for
steering operation.

1. Front differential section Drawing No.: 177-000164

144
114 137 138 115 110 136 109 122 139 116 140 103 105 117

100 135

94 113

33,32 104

34 101,142

102,143

83

89

88

81

99

134

133

71

72

131

128

98 97 93 130 119 92 129 123 124 125-1 125-2 121 120 127

IW563-0031J01
125

4 W563-0032E
 Structure

2. Rear differential section

[NOTICE]
◆The sectional view below shows two types of differential section, namely with and without the no-spin system.

Drawing No.:177-000174
177-000384 [No-spin]

144
106 107 111 115 110 136 109 112 118 108 116 103 105 117

95 135

114 113

104

101,142

102,143

83

89

34 88

33,32 81

100

94

99

134

71

72

98 97 90 119 92 91-1 91-2 93 141

IW563-0031J02
91

5 W563-0032E
 Structure

Exploded view Drawing No.:177-000164 [Front]

177-000174 [Rear]
177-000384 [No-spin]

Final (with no-spin system,optional) 105

117
95 104 142
112
118
143
111
108 103
107
106 138
139
116 T28
109 137 122 T15
34
T30 136
32
33 82
105 102 89
117
140 81

T31 114 134

135 83
113 99 88
94
110 T29
141 100
98
104 144 134 97
115
101 93
99
90
141 91
98
97 91-2
93 71
91-1 119
72 T10 92 T9

131 T11 71 Final (for rear)

72 T10
128 (128-1--128-9)

125

Final (for front) 125-2

125-1
129
130 120
121 T14
124
123 T12

127
119
92 T9
IW563-0032E07

6 W563-0032E
 Structure

3. Axle section Drawing No.:177-000164 [Front]

177-000174 [Rear]
3.1 Housing and brake sections 177-000384 [No-spin]

T-5
46,47 49 67,68 64 54 53 55 56

26,27 28 51 30 29 31
T-20 T-27 T-17 IW563-0032E-01

T-13
39
10-2 8 52 21 9 38 7 6 5 3
10
3-2 3-1 3-3 3-4
10-1

11

14

13

12

15

16

17 18 19 20 22 23 42 37 24 25 IW563-0032E02

7 W563-0032E
 Structure

Exploded view Drawing No.:177-000164 [Front]

177-000174 [Rear]
177-000384 [No-spin]

T-26 T8
55 56 45 2 T16
T24
70
57 69
53

3-2
3-1
For rear axle
177-000174 3-4
177-000384
(optional) 3 3-3

25
T5
49
T-25 145
3-1
64 67,68 146
3-2 T4
7 24
46-47

54 6 T1
51
43 T2
5
65
38,39
28 29
60 30
63
61
62

37 31
23
22
42 40,41 59
8
52
T6 9 7
T7
26,27 21
20
19
12 10-2

4 10-1
T21 14 11 10
13 18 T23
17
16
7 15
T22 T3 IW563-0032E03

8 W563-0032E
 Structure

3.2 Axle shaft assy

24

24-5

24-1 24-2 24-3 24-4 24-6 24-7 24-8 24-9

IW563-0031J05

24-9

24-5

24-4 24-6
24-3 24-8

24-7 24-2

24-1

IW563-0031J08

3.3 Tie rod end assy

T18 T19
62 63 40,41 60,61

IW563-0031J06

9 W563-0032E
 Structure

1.Final drive assy 28.Bolt 70.Plug 110.Bolt

2.Air breather 29.Bolt 71.Spring washer 111.Holdout ring
3.Axle housing assy 30.Nut 72.Bolt 112.Snap ring
3-1.Plug 31.Tie rod 73. ------------------- 113.Bolt
3-2.Bushing 32.Bolt 74. ------------------- 114.Lock plate
3-3.Bushing 33.Bolt 75. ------------------- 115.Bolt
3-4.Axle housing 34.Spring washer 76. ------------------- 116.Nut
4.Snap ring 35. ------------------- 77. ------------------- 117.Washer
5.Shim 36. ------------------- 78. ------------------- 118.Center cam
6.King pin: upper 37.Thrust bearing 79. ------------------- 119.O-ring
7.Bolt 38.Knuckle: left 80. ------------------- 120.Spring washer
8.Spindle 39.Knuckle: right 81.Bolt 121.Nut
9.Bolt 40.Rod end assy: right 82.Nut 122.Spider
10.Hub, wheel pin: right 41.Rod end assy: left 83.Snap ring 123.Bolt
10-1.Hub 42.King pin: lower 84. ------------------- 124.Spring washer
10-2.Wheel pin 43.O-ring 85. ------------------- 125.Flange assy
11.Wheel nut: right 44. ------------------- 86. ------------------- 125-1.Flange
12.Flange 45.Filler plug 87. ------------------- 125-2.Bolt
13.Bolt 46.Brake pipe assy: left 88.Roller bearing 126. -------------------
14.Cover 47.Brake pipe assy: right 89.Retainer 127.Brake drum
15.Bolt 48. ------------------- 90.Oil seal 128.Parking brake assy
16.Lock plate 49.Bolt 91.Flange assy 129.Cover
17.Bearing nut 50. ------------------- 91-1.Flange 130.Oil seal
18.Bearing: hub outer 51.Elbow joint 91-2.Dust cover 131.Bolt
19.Bearing: hub inner 52.Bolt 92.Lock nut 132. -------------------
20.Oil seal 53.Bracket A 93.Taper roller bearing 133.Cage
21.Disc 54.Bracket B 94.Carrier cage 134.Shim
22.Bushing 55.Lock bolt 95.Spider 135.Lock plate
23. Oil seal 56.Lock bolt 96. ------------------- 136.Differential case A
24.Axle shaft assy 57.Pin 97.Spacer 137.Thrust washer
24-1.Yoke 58. ------------------- 98.Shim 138.Thrust washer
24-2.Grease nipple 59.Bolt 99.Taper roller bearing 139.Pinion
24-3.Bearing 60.Nut 100.Drive pinion 140.Side gear
24-4.Snap ring 61.Spring washer 101.Adjusting nut 141.Pinion cage
24-5.Spider assy 62.Nut 102.Taper roller bearing 142.Adjusting nut
24-6.Valve 63.Split pin 103.Differential case B 143.Taper roller bearing
24-7.Dust cover 64.Bolt 104.Bearing cap 144.Bolt
24-8.Spider 65.Nut 105.Bolt 145.Bushing
24-9.Yoke 66. ------------------- 106.Side gear 146.Retainer ring
25.Oil seal 67.Joint assy 107.Spring
26.Disc brake A: left 68.Joint assy 108.Driven clutch
27.Disc brake B: right 69.Gasket 109.Ring gear

10 W563-0032E
 Structure

4. Tightening torque

Tightening torque
Place Remarks
N-m ft-lbf
T1 22.5±2.9 16.6±2.2 Elbow nut
T2 22.5±29.5 16.6-21.8 Flared nut
T3 5.8-10.7 4.3-7.9 LOCTITE 242
T4 15.7-23.5 11.6-17.3 Sleeve nut
T5 31.3-52.9 23.1-39
T6 294-343 217-253
T7 294-343 217-253
T8 11.7-15.6 8.6-11.5 Level plug
T9 638±49 471±36
T10 155 114
T11 132-194 97-143
T12 207-230 153-170
T13 294-343 217-253
T14 155±15 114±11
T15 85-104 63-77
Air breather
T16 6.8-12.7 5-9.4
LOCTITE 242
T17 274-333 202-245
T18 265-343 195-253
T19 60.8-91.2 44.8-67.3
T20 687±30 507±22
T21 7.8-17.6 5.7-13 LOCTITE 242
T22 294-343 217-253 LOCTITE 242
T23 491-589 362-434
T24 83.3±14.7 61.4±10.8 Drain plug
T25 139-171 103-126
T26 197-240 145-177
T27 14.7±1.5 10.8±1.1 Elbow
T28 157±15 116±11
T29 323±20 239±15
T30 216±20 159±15
T31 25.5 18.8

11 W563-0032E
 Function

Function

1. General

1.1 Reduction gearing 1.2 Differential

The reduction gearing consists of the drive pinion
and the ring gear bolted to the differential case.
It transmits the driving force from the propeller
shaft to the axle shafts while changing the force
direction 90 degrees and reducing the speed to
give increased torque.
1. The differential is an arrangement of gears that
allows the right and left driving wheels to turn at
different speeds when the vehicle makes turns
and the two wheels have to travel different
distances. It prevents the tires from dragging.
2. There are two types of differential; one is the
standard type used in ordinary vehicles and the
other is the no-spin type that can automatically
adjust the torque distributed to the right and left
driving wheels.

Drive pinion Ring gear

Spider

Thrust washer
Differential pinion

Thrust washer
Side gear

Axle shaft

Differential case

IW563-0010J011E

12 W563-0032E
 Function

1.3 Disc brake

Tightening torque
1. This is an opposed piston type disc brake. This
brake has two pad assy on both sides of the disc Tightening torque
Sign / Port
plate, and they pinch the disc plate when braking N-m ft-lbf
is applied. T1
284±30 209±22
(Bridge bolt • 11)
2. When brake pressure is applied, the pistons built T2
25.5±3 18.8±2.2
in the caliper push the pad assy at their tips (Bridge bolt • 8)
against the disc plate from both sides to create T3
490±50 361±37
braking force. (Bridge bolt • 10)

3. The piston seal keeps a constant clearance Caliper mounting bolt 687±30 507±22
between the pad assy and the disc plate.

3 18

11,14 10,13 1,2 9 8

T-1 T-3 T-2 16 4 5 12 17 15
A

7 6
A A-A
IW563-0032E04

1.Caliper: Inner LH 6.Ring boot 11.Bolt 16.Thread protector

2.Caliper: Inner RH 7.Piston boot 12.Pad assy 17.Snap pin
3.Caliper: Outer 8.Bleeder screw 13.Washer 18.Body seal
4.Piston 9.Bleeder cap 14.Washer
5.Piston seal 10.Bolt 15.Pin

13 W563-0032E
 Function

Principle of operation The simple check method of pad assy is shown as

follows:
1. When hydraulic pressure is applied Check the pad thickness by inserting a check gauge
as shown below in the check holes in the torque
The pistons exert force to the pad assy by plate.
deforming the piston seals. (Fig. 2)

φ7.5
2
0.
R

φ13

C
38

0.
5
80 IW577-011002

Unit : mm (1 mm = 0.039 in)

[NOTICE]
When one of the pad assy is found to have worn to
the use limit, all the other ones are also worn to the
same limit in most cases.
Replace the pad assy for the right and the left
2. When hydraulic pressure is removed
wheels or even for all the four wheels
simultaneously.
The seals recover the original shape to push the
Thickness of the brake lining of the Pad assy
pistons back, creating clearance between the disc
plate and the pad assy. (Fig. 3 ) Thickness of the brake lining
New parts 14 mm (0.56in)
Use limit 4 mm (0.16in)

The regular check is necessary to prevent from

deteriorating brake function and from the brake
damage since the thickness of the brake lining
exceeding the limit results in serious damage.

Check gauge

3. When pad assy wears

The piston displacement distance increases

beyond the seal deformation limit, and the pistons
Replace the pad assy when this
slip relative to the seals, but when the hydraulic distance becomes zero.
Piston
pressure is removed, the pistons are pulled back
Back plate Pad assy
by the seals through the same distance as before Brake lining
Disc plate IW577-0190E02
the occurance of wear, giving the same
clearances.

●Checking the disc plate

●Checking the pad assy
Check the disc plate for the thickness and
damage. If it is excessively damaged or the
[NOTICE]
thickness is below 10.9 mm (0.43 in), replace the
The brake caliper must be disassembled to check
the remained pad thickness. However, the check disc plate. (Thickness of new disc plate: 12.9 mm
gauge may use to check. (0.51 in))

14 W563-0032E
 Function

2. Standard differential

Drive pinion Ring gear

Spider

Thrust washer
Differential pinion

Thrust washer
Side gear

Axle shaft

Differential case

IW563-0010J011E

In the differential cases, four differential pinions

placed around a spider whose ends are supported
by the differential cases are in mesh with two side
gears that are splined to the end of the axle shafts.
The differential pinions and side gears can rotate
freely.

15 W563-0032E
 Function

3. Operating principle of standard

differential
1. The following figures show the comparison of the
operating conditions, one for traveling straight and
the other for turning.

Drive pinion Ring gear

Spider

Differential pinion

Side gear Outside Inside

When traveling Axle shaft When turning

straight

IW563-0010J012E

2. As shown above, when the vehicle turns a corner,

the differential pinions rotate on their own axes to
absorb the speed difference between the right and
left axle shafts, providing a smooth cornering.

3. This standard differential, however, cannot

provide a straight traveling when the road surface
conditions are different between the right and left
tires.

4. Especially when one of the wheels gets stuck in

the mud or runs on a frozen road surface, etc., it
may slip, leaving the vehicle stranded.
Additionally when the vehicle drives on a bumpy
road, the driving wheel free of the ground will race
at a high speed and produce impulsive high
driving force when it touches the road surface
again. This may lead to the tail sway
phenomenon.

16 W563-0032E
 Function

4. No-spin differential
5. The raised wheel rotation is the same as the
1. The no-spin type differential compensates weak wheel on ground, and consequently, the tail sway
points of the ordinary. phenomenon does not occur easily.

2. The driving force from the engine is evenly divided

on the right and left wheels when going straight.

3. At the turning, the outside wheel is disconnected

from the power line, and the inside wheel is drived
by all engine torque with the no-spin type
differential function.

4. When the one side wheel loses surface resistance,

the wheel slips, the other side wheel is drived by
all engine torque, and the vehicle can propell
consequently.

4.1 Structure and configuration of No-spin type differential

Drive pinion

Ring gear
Center cam Spider

Retaining ring
Holdout ring No-spin differential ass'y
Driven clutch
Spring
Side gear

Axle shaft
No-spin differential ass'y
Differential case

IW563-0071010E

Spider

Retaining ring

Center cam

Holdout ring

Driven clutch

Spring

Side gear

IW563-0071011E

17 W563-0032E
 Function

4.2 Spider assy

3. The spider has a key, in the spider inner
1. Spider assy is composed of a spider, a center circumference, to limit the rotation of the center
cam, and retaining rings. cam and holdout ring.

Retaning ring Trunnion 4. The center cam is held with a retaining ring by the
spider. Therefor, the center cam is of structure
Driven cluch Spider
that allows the center cam to rotate in the
backlash between the spider key and center cam
flute.

5. The center cam has three flutes in outer, and

spider's key enters into the one flute and the
projections of the holdout ring enter into the other
flutes.

Left holdout ring Right holdout ring

Clutch teeth Trapezoid teeth Center cam
IW563-0071012E

The illustration shows the left driven clutch and

holdout ring are got out from the center cam
flute. Projections of
the holdout ring
When driving straight ahead, the left driven
Center cam flute
clutch and holdout ring are in the center cam
flute.

2. The spider has radial square teeth on both sides

as a clutch. The spider has four trunnions on outer
circumference as shown.

The rotation of the center cam is

limitted by the spider key.
The center cam is allowed to
rotate within this flute.
Key
(Only one position)
Square teeth
Center cam IW563-0071019E
The illustration shows the state of the left
holdout ring came out.
When driving straight ahead, the left holdout ring
is in the flute of the center cam, too.

6. The center cam has trapezoid teeth of the same

Trapezoid
number as the square teeth on both sides of the
teeth spider.

Center cam flute

Retaining ring
Center cam
IW563-0071014E

18 W563-0032E
 Function

4.3 Driven clutch assy 4.4 Spring

Square teeth
Springs are installed between the outside of the
Driven clutch Holdout ring driven clutch and the side gear flange. Springs
ensure the biting each other of the driven clutch
Projection of with the spider.
the holdout ring

4.5 Side gear

Square teeth
The outside spline bites each other to the internal
diameter spline of a driven clutch, and the internal
diameter spline bites each other to the axle shaft.

4.6 Operating explanation (propeller driving in a

straight-forward)
IW563-0071013E

Retaning ring Trunnion 1. The clutch teeth of the right and left driven clutch
bite each other to the spider's clutch teeth, and
Driven cluch Spider
the cam teeth bite each other to the cam teeth of
the center cam, too.

Backlash

Backlash

Clutch teeth Trapezoid teeth Center cam

IW563-0071012E

1. The driven clutch assy is composed of two driven

clutches and a holdout ring. The holdout ring is
Rotating at the same speed IW563-0071015E
inlaid into the flute of the driven clutch ,and it may
only rotate relatively. 2. Under this condition, the driving force is
transmitted to the right and left wheel by the
2. The driven clutch has square teeth of same
following route:
number as the spider, their teeth bite each other.
Drive pinion →Ring gear → Differential case →
Inside square teeth bite each other to trapezoid
spider → driven clutch → side gear → axle
teeth of the center cam.
shaft.
3. The internal diameter spline of the driven clutch
bite each other to the outside diameter spline of
the side gear.
Clutch teeth Cam teeth

Holdout ring

Driven clutch
IW563-0071022E

19 W563-0032E
 Function

Retaning ring Trunnion cam (the left side clutch is disengaged), and thus
the left wheel runs faster than the right and the
Driven cluch Spider
vehicle can consequntly turn the corner smoothly.

Left driben clutch Right driven clutch

Clutch teeth Trapezoid teeth Center cam

IW563-0071012E

4.7 Operating explanation (propeller driving in

forward turn) Center cam
IW563-0071016E

1. When turning, the rotating speed of the right and

left wheels should be different because the
mileage of the inside and outside wheel is
different.

2. When the spider is driving the driven clutch, it is

impossible the driven clutch turns later than the
spider, but the driven clutch can turn faster to the
backlash direction.
Rotating at a
faster speed

Rotating at the same speed IW563-0071017E

3. In propeller driving in forward-right turn, the spider

transmit the driven-right (inside) clutch the torque
of 100% with the spider engaging completlly with
the driven-right (inside) clutch.

4. Under this condition, the gear right (inside)

propellers vehicle forward, being recieved the
same rotation as the ring gear. However, in the
left(outer) side, the friction force from the ground
rises the drive clutch on the incline of the center

20 W563-0032E
 Function

Retaning ring Trunnion

Driven cluch Spider

Backlash

Backlash

Rotating at the same speed IW563-0071015E

Clutch teeth Trapezoid teeth Center cam
IW563-0071012E

5. When the clutch teeth are disengaged, the left

holdout ring contacts the spider key, the
protruding portions of the left holdout ring coming
out from the flutes of the center cam and being
held on the center cam.
The left holdout ring consequntly prevents the
driven clutch from engaging while the driven
clutch rotates faster than the spider.
Left holdout ring Right holdout ring

Projections of
the holdout ring

Center cam flute

Center cam IW563-0071019E

6. When turns completely, or it is not necessary to

differentiate, the no-spin differential returns to the
same condition as that of straightaway.

21 W563-0032E
 Axle Assembly

Axle Assembly 1.4 Axle shaft flange

1. Remove bolts A, and remove cover.

[NOTICE]
◆In some cases the illustrated images may differ 2. Remove snap ring from axle shaft.
from the actual parts, but the contents of the
operation are the same. 3. Remove bolts B, and remove flange.

1. Dismounting

1.1 Axle assembly Snap ring

[NOTICE] Cover
◆Disassemble both the right and left components in Bolt A
the same procedure. Be sure not to erroneously
mix the right and left parts when disassembling the Flange
right and left components at the same time.
Bolt B IW563-0031J18E

1.2 Draining gear oil

1. Remove drain plug, and drain gear oil from axle

3
housing. (approx. 14 lit. (854in )) Bolt B
Flange
Air breather
Bolt A
Snap ring
Axle housing
Cover
Level plug

IW563-0031J19E
Drain plug IW563-0031J16E

1.3 Disc brake assy 1.5 Wheel hub assy

1. Remove bearing nut with a nut wrench as shown

1. Remove bolts, and remove disc brake assy.
below.
Bolt
46
φ16
Disc brake
φ132

φ136
φ155

IW563-0031J17E 32
60 117

Bearing nut removal tool IW563-0031J21E

Unit : mm (1 mm = 0.039 in)

22 W563-0032E
 Axle Assembly

2. While being careful not to damage oil seal,
remove wheel hub assy by lifting it up with a
crane.
1.7 Spindle assy
[NOTICE]
◆To prevent axle shaft assy from accidentally
slipping off during spindle assy removal, be sure to
pull out spindle assy cautiously and slowly.

1. Remove bolts securing spindle, and remove

Bearing nut
spindle. Bushing and oil seal will come out with
Lock plate
spindle.

Wheel hub assy

Nut wrench IW563-0031J20E

1.6 Tie rod assy Spindle assy

Bolt to fix spindle
1. Remove nut securing ball joint on knuckle. IW563-0031J26E

2. Tap ball joint to remove tie rod assy from knuckle

arms. 1.8 Axle shaft assy

As axle shaft assy can bend at its center, be

careful not to allow one end to drop during
removal operation. Also be careful not to damage
Split pin oil seal.
Nut

Axle shaft

Ball joint
IW563-0031J24E

Split pin
Nut IW563-0031J28E

Knuckle

IW563-0031J25E

23 W563-0032E
 Axle Assembly

1.9 Knuckle assy 2. Disassembly

[NOTICE]
2.1 Wheel hub assy
◆To remove king pin, install two bolts into tapped
extractor holes and tighten bolts evenly. [NOTICE]
◆To remove upper king pin, first lightly tap and turn it
◆Do not remove outer races of taper roller bearings
until the matching holes of the upper king pin and
and disc plate unless the replacement of those
the knuckle do not meet each other. Then use
parts is necessary.
tapped extractor holes.
◆Keep removed shim with each king pin to have 1. Remove bolts, and remove disc brake.
them installed again in a correct combination.
2. Pull out taper roller bearing.
1. Remove bolts securing lower king pin, and
remove thrust bearing and lower king pin. 3. Remove outer race of taper roller bearing by
hitting a brass rod etc. put on it. Oil seal will
2. Remove bolts securing higher king pin. While come out at the same time.
pulling out upper king pin, remove knuckle at the
same time.

Bolt to fix upper king pin

Upper king pin
Shim Bolt
Knuckle
Brake disc
Oil seal
Taper roller bearing(inner)
Wheel hub
Taper roller bearing(outer) IW563-0031J22E

Thrust bearing
Brake disc
Lower king pin Bolt

Bolt to fix lower king pin Oil seal

IW563-0031J31E

1.10 Differential assy

Taper roller bearing(inner)
Remove bolts, and dismount differential assy. Taper roller bearing(outer) IW563-0031J23E

Differential assy

Bolt IW563-0031J34E

24 W563-0032E
 Axle Assembly

2.2 Spindle assy 2.4 Axle housing assy

1. Remove oil seal from spindle. [NOTICE]

◆Do not remove king pin bushings and housing
2. Remove bushing from spindle. bushings unless the replacement of those parts is
necessary.
Oil seal
◆Remove king pin bushings by striking them towards
Bushing the outside from the inside of axle housing.

King pin bushing

Plug

IW563-0031J27E

Housing

2.3 Axle shaft assy

1. Remove snap rings that retain bearings on spider.

Snap ring Housing

bushing
Oil seal IW563-0031J32E
Axle shaft assy

King pin bushing

Plug

Housing bushing
IW563-0031J29E
Oil seal

2. Carefully tap and remove bearing while being

careful not to allow needle rollers to scatter. IW563-0031J33E

Snap ring
Needle roller bearing 1. Strike and remove king pin bushing and plug at
the same time.
Valve
Dust cover 2. Remove oil seal.
Spider
Grease nipple 3. Strike and remove housing bushing.

Yoke

IW563-0031J30E

25 W563-0032E
 Axle Assembly

3. Cleaning •Flaw, crack, pitting corrosion, partial wear on the

raceway surface of inner race
[NOTICE] •Deformation and partial wear of cage
◆Do not use mineral oil. •Discoloration (a sign of seizure) on rollers, inner
race and outer race
3.1Metal parts
2. If no defect is found, apply a thin coat of grease.
Wash metal parts in clean kerosene, and allow
them to air dry. 4.6 Service brake

3.2 Rubber parts 1. Disc plate thickness

Standard value: 12.9 mm (0.51 in)
Clean rubber parts with alcohol or a clean wiper. Use limit: 10.9 mm (0.43 in)

2. Brake pad thickness (thickness of friction material)

4. Inspection
When brand-new: 14 mm (0.56 in)
Use limit: 4 mm (0.16 in)
4.1 Gear and spline

Check gears and splines for wear, pitting, etc.

Replace defective ones.
4.7 Parking brake
4.2 Oil seal 1. Drum inside diameter
Standard value: 254 mm (10 in)
Check sealing lip of oil seal for wear, cut, etc.
Use limit: 256 mm (10.1 in)
Replace ones having defects that can be felt by
fingertips. 2. Brake pad thickness (thickness of friction material)
Standard value: 5.75 mm (0.23 in)
4.3 Axle shaft
Use limit: 2.65 mm (0.105 in)
Replace ones if their straightness is over the
standard value. 4.8 Tie rod: straightness
Standard value: 1.0 mm (0.04 in) Standard value: 1.0 mm (0.04 in)
Use limit: 5.0 mm (0.2 in)
4.4 King pin bushing

Replace ones if the clearance between the king
pin OD and the king pin bushing ID is over the use
limit.
Standard value: 0.08 mm (0.003 in)
Use limit: 0.30 mm (0.012 in)
4.9 Housing bushing
Replace ones if the clearance between axle shaft
and housing bushing is over the use limit.
Standard value: 0.15 mm (0.006 in)
Use limit: 0.30 mm (0.012 in)

4.5 Bearing 4.10 Axle joint

1. Wash bearings in kerosene to thoroughly remove Replace ones if the play in the direction of rotation
oil and grease, and check them for the following is over the use limit.
items. If defects are found, replace a bearing as Standard value: 0.05 mm (0.002 in)
a set including inner and outer races. Use limit: 0.20 mm (0.008 in)
•Noisy, irregular rotation when turned by hand
•Flaw, crack, pitting corrosion, stepped wear on
outer race

26 W563-0032E
 Axle Assembly

5. Reassembly 2. Apply liquid gasket to the outer surface of oil seal

and press fit oil seal.
[NOTICE] After press fitting, apply grease to the lip and the
◆Replace all rubber parts such as O-rings and oil inside surface of bushing.
seals as well as packing with new ones. Never
reuse them.
◆Before press fitting oil seals, completely degrease
Special tool
the fitting surface and apply liquid gasket
(THREEBOND No. 1215 or equivalent) to it. King pin bushing
Plug
5.1 Differential assy

1. Apply THREEBOND No. 518 or equivalent to the

Housing
surface of axle housing where carrier case is to be
installed.

2. Install differential assy on axle housing, and

secure it with bolts and washers.
Tightening torque: 85 - 104 N•m {63 - 77 ft•lbf} Housing
bushing
Oil seal IW563-0031J36E

Differential assy

3. Apply THREEBOND No. 1215 to the outer surface

of plugs, and press fit them into the upper and
lower king pin holes.
Then press fit king pin bushings until their ends
comes flush with the housing surface.
Bolt IW563-0031J35E
4. After press fitting, apply lithium base grease to the
inside surface of bushings.

5.2 Axle housing assy King pin bushing

1. Press fit housing bushing into axle housing with

the grooves positioned as illustrated.

Plug IW563-0031J38E

Groove Bottom of carrier

IW563-0031J37E

27 W563-0032E
 Axle Assembly

5.3 Axle shaft assy Bolt to fix upper king pin

[NOTICE] Upper king pin

◆As axle shaft assy can bend at its center, be careful Shim
not to drop it. Knuckle

1. Insert axle shaft assy so that its end engages with

the internal spline of differential side gear.

Axle shaft assy

Thrust bearing

Lower king pin

Bolt to fix lower king pin
IW563-0031J31E
IW563-0031J40E

4. Measure the clearance (dimension X) between

2. Direct the tip of grease nipple toward housing. knuckle and king pin. Select a shim whose
thickness is t = X + 0.1 (mm).
Axle shaft assy
Grease nipple King pin

X
Knuckle
Housing this side

IW563-0031J41E

Drive joint
5.4 Knuckle assy
Thrust bearing IW563-0031J42E

1. When the king pin related parts are reused,

prepare upper king pin and shim as a set in a
condition when they were removed. Also prepare
lower king pin and thrust bearing in the same way.
2. Insert lower king pin in thrust bearing. Then insert
the set into knuckle.
3. Secure lower king pin to knuckle with bolts.
Tightening torque: 294 - 343 N•m {217 - 253ft•lbf}
5. After removing king pin, reinstall king pin with
selected shim. Secure king pin to knuckle with
bolts.
Tightening torque: 294 - 343 N･m {217 - 253 ft･lbf}
6. After securing king pin with bolts, make sure that
knuckle can be easily turned by hand.
King pin
Knuckle arm

IW563-0031J43E

28 W563-0032E
 Axle Assembly

5.5 Knuckle spindle 5.6 Wheel hub assy

1. Apply THREEBOND No. 1215 or equivalent to the [NOTICE]

oil seal fitting surface of spindle. ◆Before press fitting oil seal, place the inner race of
taper roller bearing on the hub seal side.
2. Press fit bushing and oil seal into knuckle spindle. ◆Apply grease to the rollers of taper roller bearing.
3. After press fitting, apply hub grease to bushing
1. Press fit the outer races of inner and outer taper
and oil seal.
roller bearings into wheel hub.
Oil seal 2. Apply liquid gasket (THREEBOND No. 1215 or
Bushing equivalent) to the outside surface of oil seal, and
press fit oil seal into wheel hub.
After press fitting, apply grease to the lip of oil
seal.

IW563-0031J27E 3. Install brake disc on hub with bolts.

Tightening torque: 294 - 343 N•m {217 - 253 ft•lbf}
[NOTICE]
◆When installing spindle to knuckle, be careful not to Brake disc
damage oil seal by the spline at the end of joint Bolt
assy.
Oil seal
4. Install knuckle spindle to knuckle with bolts.
Tightening torque: 294 - 343 N•m {217 - 253ft•lbf}

Taper roller bearing (inner)

Outer race of taper roller
bearing (outer) IW563-0031J45E

5.7 Wheel hub assy

1. While being careful not to damage oil seal, install

wheel hub assy to spindle.
Spindle assy 2. Install inner race of tape roller bearing, and secure
Bolt to fix spindle it with bearing nut. Tighten bearing nut in the
following procedure.

IW563-0031J44E

Wheel hub assy

Bearing nut

Inner race of taper roller bearing (outer)

IW563-0031J46E

29 W563-0032E
 Axle Assembly

3. Tighten bearing nut until hub cannot be turned by

hand. Then loosen bearing nut completely.

4. Tighten bearing nut again until the required force Snap ring
(starting force) to turn hub falls within the following
Cover
limits. Measure this force by hooking a spring
balance over one of wheel pins and pulling the Bolt A
spring balance in the tangential direction. Flange
Bearing (brand new): 59 - 118 N{13.2 - 26.5 ft•lbf } Bolt B IW563-0031J18E

Bearing (reused): 29 - 59 N {6.5 - 13.3 ft•lbf }

5. Place lock plate on bearing nut and secure it with
bolts whose threads are coated with LOCTITE No.
242 or equivalent.
Tightening torque: 5.8 - 10.7 N•m {4.3 - 7.9 ft•lbf }
Lock plate
Bolt
5.8 Brake assy
8. Put snap ring at the end of axle shaft.
9. Apply THREEBOND No. 1215 to the fitting
surface of cover, and install cover with bolts
whose threads are coated with LOCTITE No. 242
or equivalent.
Tightening torque: 7.8 - 17.6 N•m
{5.7 - 13 ft•lbf }

1. Install disc brake assy, and secure it with bolts.

IW563-0031J48E Tightening torque: 687 ± 30 N•m {507 ± 22 ft•lbf }

6. Pack lithium base grease (BESCO L2) in the 2. Install joint assy on the upper king pin with bolts.

space around two hub bearings. Tightening torque: 31.3-52.9 N•m {23.1-39 ft•lbf }
Apply lithium base grease evenly to the splines of 3. Install brake pipes.
yokes and axle shafts. Sleeve nut tightening torque: 15.7 - 23.5 N•m
{11.6 - 17.3 ft•lbf }
Pack lithium grease
Flared nut tightening torque: 22.5 - 29.5 N•m
{16.6 - 21.8 ft•lbf }

Bolt
Joint assy
Sleeve nut
Brake pipe

Disc brake Bolt

Flared nut
IW563-0031J49E
Elbow joint

7. Apply THREEBOND No. 1215 to the fitting

surface of flange, and install flange to hub with
bolts whose threads are coated with LOCTITE No. IW563-0031J50E

242 or equivalent.
Tightening torque: 294 - 343 N•m {217-253 ft•lbf } Elbow joint tightening torque: 22.5 ± 2.9 N•m
{16.6 ± 2.2 ft•lbf }

30 W563-0032E
 Axle Assembly

5.9 Tie rod 5.10 Lubrication

[NOTICE]
◆Tie rod has a right-handed screw and a left-handed
screw on the right end and left end respectively.
1. Turn tie rod in the tightening direction nearly to the
innermost thread ends of right and left tie rod end
assys.
[NOTICE]
◆Be sure to use Super Hypoid Gear Oil SH90
(GL-N05 or higher).
◆Change gear oil every 24,000 km (14,900 mi).
1. Tighten drain plug (with washer), and pour gear oil
into axle housing until oil rises to the oil level plug
3
opening. (approx. 14 lit.) (854 in )

Split pin Air breather

Nut
Tie rod Axle housing
Level plug :
11.7-15.6 N-m
(8.6-11.5 ft-lbf)
Rod end assy IW563-0031J51E

2. Insert the tapered portion of tie rod end into Drain plug : 83.3±14.7 N-m
knuckle arm, and secure it with nut. Then insert (61.4±10.8 ft-lbf) IW563-0032E08

split pin.
Tightening torque: 265 - 343 N•m {195 -253 ft•lbf }
2. Add grease through every grease nipple and
Split pin tapped hole for grease nipple.

Nut

Knuckle

IW563-0031J25E

3. Turn tie rod to make the difference between A and

B within 0 to 2 mm (0.08 in).
Tighten nut securely after adjustment.
Tightening torque: 60.8 - 91.2 N•m
{44.8 - 67.3 ft•lbf }

A
980 mm
(38.6 in)

(38.6 in)
980 mm

Left Shorten Right

B
IW563-0032E05

31 W563-0032E
 Differential Assembly

Differential Assembly 1.2 Drive pinion assy

1. Unstake nut, and loosen it while holding

[NOTICE]
companion flange to prevent it from turning with a
◆In some cases the illustrated images may differ
from the actual parts, but the contents of the proper tool.
operation are the same.
36 4

C
2
1. Dismounting

φ70
φ46

19.5
1.1 Differential carrier assy

1. Remove drain plug at the bottom of axle housing

42
and drain gear oil from axle housing. (approx. 14 19.5
3 50
lit.) (854 in ) 70
50
IW563-0031J62
Unit : mm (1 mm = 0.039 in)
Air breather

Axle housing
Nut removing tool
Level plug
Nut
O-ring

Companion flange

Drain plug IW563-0031J16E

2. Pull out right and left axle shaft shafts according to IW563-0031J63E

the "disassembly procedure of axle assy".

[NOTICE]
3. Remove bolts, and remove differential carrier assy
◆For easy adjustment at reassembly, store removed
from axle housing.
shims without bending them.

Differential carrier assy 2. Remove bolt, and remove drive pinion assy.

Bolt

Drive pinion assy

Shim

Bolt IW563-0031J80E

IW563-0031J64E

3. In case of the front axle, remove parking brake

assy and cover.

32 W563-0032E
 Differential Assembly

2. Disassembly Dial gauge Ring gear

2.1 Differential carrier assy

1. Mount differential carrier assy on a special stand.

Differential carrier assy

IW563-0031J54E

3. Put matchmarks on the right and left bearing caps

so that they can be used as an aid during
reassembly.

4. Remove bolt and lock plate from bearing cap.

Stand 5. To clearly distinguish the originally placed

IW563-0010J074E positions (right or left) during reassembly, put
appropriate marks on adjusting nuts and taper
roller bearing outer races.
2. Before disassembling differential carrier, measure
the backlash of ring gear, runout at its back, etc.
with a dial gauge, and check tooth contact pattern.
If they are within the required limits, try to restore
the same conditions during reassembly. Lock plate

Ring gear

Dial gauge
Matchmark IW563-0031J55E

Bearing cap
Bolt

IW563-0031J53E

Adjusting nut

IW563-0031J56E

33 W563-0032E
 Differential Assembly

6. Remove bolts, and remove bearing caps and 1. Put matchmarks on differential case B and C.
adjusting nuts.
2. Remove bolts, and separate differential case B
7. Put a bar or a pipe through differential case, and and C.
lift differential case assy with slings. Taper roller
bearing outer races will be removed along with the Differential
assembly. case B

Differential
case C

Matchmark IW563-0031J58E

3. Note where and in which direction thrust washer

are installed.

[NOTICE]
◆Do not remove taper roller bearings and ring gear
unless the replacement of those parts is necessary.
IW563-0031J57 ◆Do not reuse bolts and nuts as they were staked.

4. Take out differential pinions, side gears, spider

2.2 Standard differential case assy and thrust washers from differential case B and C.

Nut 5. Remove taper roller bearing inner races from

differential case with a pulley puller.
Differential case B
6. Remove bolts, and remove ring gear from
Thrust washer differential case.

Taper roller bearing

Side gear
Bolt
Thrust washer

Differential pinion Differential case

Spider
Differential pinion Ring gear
Thrust washer

Side gear

Thrust washer
IW563-0031J60E

Differential case C

Bolt IW563-0031J59E

34 W563-0032E
 Differential Assembly

2.3 No-spin differential case assy 2.4 Drive pinion assy

[NOTICE] [NOTICE]
◆Basically the disassembly procedure is the same as ◆Do not remove taper roller bearings unless the
that for the standard differential. But be sure to set replacement of those parts is necessary.
the special tool shown below to the no-spin
differential assy before starting the disassembly so 1. Remove drive pinion from pinion cage with a
that the differential case should not pop out by the press.
internal spring force.
Inner race of taper
Special tool roller bearing
M6×1.0
φ6.2 φ6.2 Spacer
M6×1.0 Shim
55 55
φ φ
Pinion cage
t=3.2 t=3.2
60 60
220
Unit: mm (1mm=0.039in) Drive pinion
No-spin differential

IW563-0031J65E

IW563-0032E06
2. Remove snap ring, and then remove roller bearing
inner race with a puller.

3. Remove taper roller bearing inner race with a

puller.

Inner race of taper

roller bearing

Drive pinion

Roller bearing
Snap ring IW563-0031J66E

4. Remove taper roller bearing outer races from

pinion cage.

Drive pinion Outer race of taper

roller bearing

IW563-0031J67E

35 W563-0032E
 Differential Assembly

3. Cleaning 4.5 Side gear and differential pinion

1. If the tooth surface of a gear is abnormally worn or

[NOTICE]
damaged, replace it with a new one. Check the
◆Do not use mineral oil.
inside of differential case, thrust washers, spider,
etc. If they are abnormally worn or damaged,
3.1 Metal parts
replace them.
Wash metal parts in clean kerosene, and allow
2. Replace side gears and differential pinions in a
them to air dry.
matched set, together with thrust washers.
3.2 Rubber parts Using different combination of side gears and
differential pinions that should be used only as a
Clean rubber parts with alcohol or a clean wiper.
matched set and using old thrust washers
together with new ones may cause a premature
4. Inspection failure of those parts.

4.1 Differential pinion and spider 4.6 Bearing

Check the clearance between differential pinion ID 1. Wash bearings in kerosene to thoroughly remove
and spider OD. oil and grease, and check them for the following
Standard value: 0.07 mm - 0.13 mm items. If defects are found, replace a bearing as a
(0.0028 in - 0.0052 in) set including inner and outer races.
Use limit: 0.23 mm (0.0092 in) •Noisy, irregular rotation when turned by hand
•Flaw, crack, pitting corrosion, stepped wear on
4.2 Side gear and axle shaft outer race
•Flaw, crack, pitting corrosion, partial wear on the
With axle shaft fixed, measure the spline play in
raceway surface of inner race
the direction of rotation at the outer end of side
•Deformation and partial wear of cage
gear with a dial gauge.
•Discoloration (a sign of seizure) on rollers, inner
Standard value: 0.06 mm - 0.26 mm
race and outer race
(0.0024 in - 0.0104 in)
Use limit: 0.46 mm (0.0184 in) 2. If no defect is found, apply a thin coat of grease.

4.3 Flange and drive pinion 4.7 Others

With drive pinion fixed, measure the spline play in Replace all parts that are found faulty.
the direction of rotation at the outer end of the
keyway in flange for propeller shaft installation
with a dial gauge.
Standard value: 0.03 mm - 0.33 mm
(0.0012 in - 0.0132 in)
Use limit: 0.53 mm (0.0212 in)

4.4 Drive pinion and ring gear

Check every gear tooth for contact pattern, wear

and pitting. Slight stepped wear can be repaired
with an oilstone or a fine file. If tooth surface is
damaged, replace drive pinion and ring gear in a
matched set.

36 W563-0032E
 Differential Assembly

5. Reassembly Inner race of taper

roller bearing
[NOTICE] Spacer
◆Replace all rubber parts such as O-rings and oil Shim
seals as well as packing with new ones. Never Pinion cage
reuse them.
◆Before press fitting oil seals, completely degrease
the fitting surface and apply liquid gasket
(THREEBOND No. 1215 or equivalent) to it. Drive pinion

5.1 Drive pinion assy

IW563-0031J65E
[NOTICE]
◆When reusing disassembled bearings, be sure not
to assemble them in wrong locations.
6. Install companion flange assy and O-ring on rear
1. Press fit taper roller bearing outer races into axle drive pinion, and secure them with lock nut.
pinion cage with a press. Tightening torque: 638 ± 49 N•m {471 ± 36 ft•lbf}

Drive pinion Outer race of taper Nut A

Companion flange
roller bearing
O-ring
Pinion cage assy

IW563-0031J67E

Drive pinion
2. Press fit taper roller bearing inner race on drive
IW563-0031J68E
pinion with a press.

Inner race of taper 7. Install pinion cage assy on front axle drive pinion,
roller bearing
and install cover assy on pinion cage assy with
bolts.
Drive pinion
8. Install parking brake assy on cover assy. Install
companion flange and O-ring on drive pinion, and
Roller bearing secure them with lock nut.
Snap ring IW563-0031J66E
Nut B

Companion flange
3. Press fit roller bearing on drive pinion with a Nut A
press. Parking brake assy
O-ring
Bolt
4. Install snap ring on drive pinion.
Cover
5. Install pinion cage, shim and spacer on drive Pinion cage assy
pinion. Then press fit taper roller bearing inner Drive pinion
race with a press.
IW563-0031J69E

37 W563-0032E
 Differential Assembly

Tightening torque
Bolt: 132 - 194 N•m {97 - 143 ft•lbf } 5.2 Standard differential case assy
Nut A: 638 ± 49 N•m {471 ± 36 ft•lbf }
1. Press fit taper roller bearing inner race on
Nut B: 155 ± 15 N•m {114 ± 11 ft•lbf }
differential case.
9. Adjust the clearance between the lining and drum
[NOTICE]
of the parking brake as follows:
◆Apply LOCTITE No. 270 - 271 or equivalent to bolt
Turn the adjuster wheel to the shoe expanding threads.
direction until the lining closely contacts the drum.
Then back off the adjuster wheel by 8 teeth to set 2. Install ring gear to differential case with bolts.
the clearance to approx. 0.2 mm (0.008 in). Tightening torque: 323 ± 20 N•m {239 ± 15 ft•lbf }
Standard value: 0.1 - 0.3 mm (0.004 - 0.012 in)
Taper roller bearing
10.Attach the hook of a spring balance in one of the Bolt
holes of pinion cage. Then slowly pull the
balance in the tangential direction and allow cage
Differential case
to rotate. Measure the force needed to turn cage
while it is turning (not the force when it starts to
turn). This measured force means the preload Ring gear
applied to the bearings.

Companion flange
Spring balance

Pinion cage
IW563-0031J60E

Drive pinion
3. Install spider, side gears, differential pinions and
IW563-0031J70E
thrust washers in differential case, and measure
the backlash between side gears and differential
Standard value: pinions.
Bearing (brand new): 29 - 36 N {6.5 - 8.1 lbf }
4. If the backlash is not within the standard value
Bearing (reused): 15 - 19 N {3.4 - 4.3 lbf }
range, replace all thrust washers.
If the readout is not within the limits, change the
Standard value: 0.15 - 0.20 mm (0.006 - 0.008 in)
shim thickness for correct preload.

11.After adjusting the preload within the limits,

tighten lock nut and lock it by staking at two points
with a punch. Dial gauge

IW563-0031J71E

38 W563-0032E
 Differential Assembly

5.4 Differential carrier assy

5. When the backlash is within the standard value
range, put together differential case halves after [NOTICE]
aligning the matchmarks, and fasten them with ◆When reusing disassembled parts, be sure not to
bolts and nuts. Stake nut at two or three places confuse the bearing outer races and bearing caps
originally located on the right side with those on the
with a punch. left side.
Tightening torque: 157 ± 15 N•m {116 ± 11 ft•lbf }
1. Put outer races on taper roller bearings at both
Differential sides of differential case assy. And place the
case B assembly in carrier cage.
Nut
2. Install right and left adjusting nuts, and place
Differential bearing caps according to the matchmarks put
case C during disassembly while mating the internal
threads of bearing cap with external threads of
Matchmark IW563-0031J58E adjusting nut.

Bearing cap
5.3 No-spin differential case assy Bolt

Basically the reassembly procedure is the same

as that for the standard differential.

[NOTICE]
◆Place no-spin differential assy, still having the
special tool on it, in differential cases. Then Adjusting nut
remove the special tool while no-spin differential
case is in differential cases.
◆If the special tool comes off before installing no-spin
differential assy in differential cases, be sure to
align the recess of the holdout ring with the spider
key before installing it.
IW563-0031J56E
Special tool
M6×1.0
φ6.2 φ6.2
M6×1.0
55 55
φ φ

t=3.2 t=3.2
60 60
220
Unit: mm (1mm=0.039in)
No-spin differential

IW563-0032E06

IW563-0031J57

39 W563-0032E
 Differential Assembly
3.Temporarily tighten cap bolts to secure bearing
caps to approx. 49 N {11 lbf }.
Hook a spring balance on the body of differential
case, and measure the preload.
Standard value:
Bearing (brand new): 29.4 - 36.3 N {6.6-8.2 lbf }
Bearing (reused): 14.7 - 18.6 N {3.3-4.2 lbf }
Spring balance
IW563-0031J72E
4. Measuring ring gear runout
[NOTICE]
◆If the runout is larger than the standard value,
possible causes may be: incorrect tightening of
adjusting nuts and bolts; dust particles between
assembled parts. In such a case, repeat
disassembling and reassembling.
◆If the runout is still larger than the use limit even
after repeated reassembling, replace the related
parts.
Set a dial gauge to make it perpendicular to the
back of ring gear as shown below. Then measure
the runout while turning it.
Standard value: 0.1 mm (0.004 in) or less
Use limit: 0.2 mm (0.008 in)
Dial gauge Ring gear
IW563-0031J54E
40
5.5 Drive pinion assy
1. Reuse shims that were removed during
disassembly. In case that differential carrier,
pinion cage, pinion gear and/or ring gear are
replaced, select the proper shim thickness from
the following.
Shim thickness
0.5, 0.2, 0.15 mm (0.02, 0.008, 0.006 in)
2. Apply THREEBOND No. 1215 to both sides of
shims, and put them on pinion cage by matching
their bolt holes and oil holes with those on pinion
cage.
3. Install drive pinion assy on differential carrier in
the same manner by matching their bolt holes and
oil holes with those on differential carrier.
4. Tighten pinion cage bolts to the specified torque
below.
Tightening torque: 155 N•m {114 ft•lbf }
5.6 Pinion gear backlash adjustment
1. The backlash between ring gear and pinion gear
can be adjusted by turning adjusting nuts at side
bearings, thus making ring gear move.
2. To keep the preload to side bearings, if one
adjusting nut is loosened, tighten the other
adjusting nut by the same amount.
Standard value: 0.25 mm - 0.33 mm
(0.01 in - 0.013 in)
Ring gear
Dial gauge
Adjusting nut
IW563-0031J73E
W563-0032E
 Differential Assembly

5.7 Inspection and adjustment of tooth contact 4. After adjustments, tighten cap bolts of side
pattern bearing.
1. Temper red lead with spindle oil. Apply it to both Tightening torque: 216 ± 20 N•m {159 ± 15 ft•lbf }
sides of about 7 to 8 teeth of ring gear. 5. Recheck the runout at the back of ring gear and
Ring gear the backlash.
If the results are satisfactory, place lock plate in a
Apply red lead groove of side bearing adjusting nut and tighten it
with bolt.
Tightening torque: 25.5 N•m {18.8 ft•lbf }

Cap bolt

Lock plate

IW563-0031J74E
Bolt

2. Turn ring gear by hand in both directions to press

its tooth flanks against those of pinion gear.
Matchmark IW563-0031J55E

3. Check the tooth contact pattern and correct it, if

necessary, according to the following table.
If unsatisfactory, repeat the whole assembly
procedure or replace parts.
Tooth contact pattern Adjustment method

5.8 Differential carrier assy

Good contact pattern No adjustment required

1. Apply THREEBOND No. 1215 or equivalent to the

1 surface of axle housing where carrier cage is
placed. Install differential carrier assy on axle
housing with bolts.
Tightening torque: 85 - 104 N•m
Wrong contact pattern {63 - 77 ft•lbf }
(High bearing) Use thinner shims to move
drive pinion close to ring
2. Refer to the axle assy assembly procedure and
gear, and adjust backlash
2 with adjusting nuts. install right and left axle shafts to complete axle
housing assy.

Wrong contact pattern

(Low bearing) Use thicker shims to move
drive pinion away from ring
gear, and adjust backlash
3
with adjusting nuts.

IW563-0010J106E

41 W563-0032E
 Differential Assembly

6. Lubrication
[NOTICE]
◆Be sure to use Super Hypoid Gear Oil SH90
(GL-N05 or higher).
◆Change gear oil every 24,000 km (14,900 mi).

1. Tighten drain plug (with washer), and pour gear oil

into axle housing until oil rises to the oil level plug
3
opening. (approx. 14 lit.) (854 in )

Air breather

Axle housing
Level plug :
11.7-15.6 N-m
(8.6-11.5 ft-lbf)

Drain plug : 83.3±14.7 N-m

(61.4±10.8 ft-lbf) IW563-0032E08

42 W563-0032E
 Parking Brake

Parking Brake

[NOTICE]
There is a case that the appearance and so on differ from the parts for this machine. Although there is not so
much difference in functions and disassembly procedures, make sure of the serial number of this machine and
the part sales unit described in the parts catalog before starting disassembling operations.

1. Structure
1. LEver is tilted right in this figure; it is
8 tilted left on certain models because of
1 the brake chamber position.

2. Apply grease to the sliding sections

(*1 and *2) when assembling the
1
7 4 brake.

9 A 11 12 13
10

Y Y
D D

C C
E 5
2
3
B B
Brake shoe expanding
E

direction
A 6 A-A
F
2 1 1

B-B C-C E-E View F

IW5 7 7 -0 1 2 0 E0 1

1. Support plate assy 5. Spring 9. Lever 13. Waved washer

2. Dust cover 6. Adjuster assy 10. Bolt
3. Shoe lining assy 7. Brace 11. Spring washer
4. Spring 8. Cam shaft 12. Nut

43 W563-0032E
 Parking Brake

2. Disassembly 2.2 Removing the cam shaft

1. Make sure that the alignment marks are present

2.1 Removing the brake shoes
at the connection between cam shaft and lever.
1. Jack up the crane, and compress the spring Put the marks if they are unclear.
chamber by air pressure to the end of its stroke.
2. Remove bolt to remove lever from cam shaft.
2. Disconnect the spring chamber and lever, so that
3. Remove waved washer from cam shaft and
the brake drum can be turned. Then remove the
remove the cam shaft from support plate assy.
brake drum.

3. Make marks on the parts of the shoe lining assy

and adjuster assy to ensure that they are replaced
in their original positions when reassembled.

4. Remove springs•A (2 springs), and remove the

brace.

NOTICE]
To remove the shoe lining assy, more the brake
shoe outward until the anchor end of the shoe
comes off the anchor pin.

5. Remove shoe lining assy and adjuster assy from

support plate assy.

44 W563-0032E
 Parking Brake

3. Check 4. Reassembly
[NOTICE] [NOTICE]
Before checking, remove worn lining powder, mud, When assembling, apply grease to the sliding parts
and any other dirt form all parts. Also wipe away (marked with *1 and *2 on page 1.)
deposited oils (lubricants).
1. Install adjuster assy on both shoe wave ends.
3.1 Checking shoe lining assy

1. Replace the lining if it is worn to a point where its

surface is less than 0.8mm (0.031in) from the rivet
head.

2. Replace the lining if the cam shaft contacting

surface of the shoe wave is excessively worn.

3. Replace the lining if it is contaminated with oil or

grease.

3.2 Checking adjuster assy

Repair or replace the adjuster assy if a damaged

or crushed threads are evident.

3.3 Checking cam shaft

A damaged or excessively worn cam shaft should

be replaced.

3.4 Checking springs

Replace springs if they are excessively worn or

have gaps between coils when they are free.
2. Move the brake shoes in such a way as to place
the anchor ends of the brake shoes one upon the
3.5 Checking support plate assy
other, and install spring•B in the holes of the shoe
An excessively worn, deformed or cracked waves.
support plate assy should be replaced.
3. Install shoe lining assy on support plate assy.
3.6 Checking brake drum
4. Move the anchor ends of the brake shoes outward
1. Check for wear and deformation. and install camshaft.

2. Inside diameter of brake drum
Assembly standard: Φ 254 - 254.3 mm
(10 - 10.01in)
Usable limit: Φ 256 mm(10.08in)
5. Fit wave washers on the ends of cam shaft, and
install lever, while lining up alignment marks.
Secure the lever by tightening nut.
6. Install brace on the anchor pins.

7. Fit one end of spring•A in the hole of the shoe

wave. While elongating the spring, hook the other
end on the head of the anchor pin.

45 W563-0032E
 Parking Brake

5. Adjustment 5.2 Connecting the spring chamber

1. Keep the parking brake lever at the 0 point (center

5.1 Adjusting the brake
of lever play).
[NOTICE]
2. Compress the spring chamber to the end of its
Perform the brake adjustments before the brake is
stroke (stroke end when extended by air pressure).
connected to the spring chamber.
At the stroke end, connect the chamber and brake
1. Jack up the crane, and rotate the brake drum and lever.
align the adjustment hole of the drum with the star
3. Now check that there is no friction between the
wheel of adjuster assy.
drum and lining, and lock in position with the nut.
2. Use a screwdriver inserted into the adjustment
hole to expand the brake shoes until resistance is
felt when the drum is rotated.

3. Under these conditions, back off the star wheel by

8 teeth. The clearance between the lining and
brake drum is now adjusted to 0.23 mm(0.009in).
Proper clearance: 0.1 - 0.25 mm
(0.004 - 0.01in)

46 W563-0032E
 Adjustment

Adjustment

1. Steering angle
1. Set the outriggers on a level surface so that the
clearance between the tires and the road surface
is equal on both side.

2. Bleed the steering cylinders of air by operating the

cylinders in the 4-wheel steer mode 2 or 3 times.

3. Using a steering angle measuring jig, adjust the

maximum steering angles in both A and B
directions by turning stopper bolts A and B
respectively.

Tie rod
Stopper bolt B Stopper bolt A
B A

θ θ

IW563-0010J113E

[NOTICE]
◆The adjustment angle varies with the crane model
and the tire size. See the service manual covering
your model.

[Reference]
•King pin angle: 0°
•Camber: 0°
•Caster: 0°
•Toe-in: 0 mm

4. After adjusting the maximum steering angles, lock

stopper bolts with lock nuts.
Tightening torque: 274 - 333 N•m {202 - 245 ft•lbf}

47 W563-0032E
 Troubleshooting

Troubleshooting

1. Noise

Fault area portion and cause Correction

Poor tooth contact between drive pinion and ring gear Adjust
Worn/damaged drive pinion and ring gear Replace
Loose/worn taper roller bearing on drive pinion Adjust preload. Or replace.
Differential

Loose/worn taper roller bearing on differential case Adjust tooth contact pattern,
preload and backlash, or
replace.
Worn side gears, pinions, thrust washers and spider on differential Replace
Damaged no-spin differential Replace
Worn spline teeth of drive pinion, side gears and no-spin differential Replace
Insufficient/dirty oil Replenish or replace oil.
Wheel

Worn/damaged bearing Replace

hub

Knuckle spindle and axle shaft Replace

2. Oil leak

Fault area portion and cause Correction

Damaged oil seal and packing Replace
Differential

Loose plug Re-tighten

Loose fixing bolt Re-tighten
Damaged shim Replace

3. Defective steering and turning operations

Fault area portion and cause Correction

Worn/damaged kingpin busing, kingpin thrust washer Replace
Housing

Incorrectly installed kingpin Adjust

Damaged universal joint (axle shaft) Replace
Damaged tie-rod bushing Replace

48 W563-0032E
 Troubleshooting

4. Insufficient braking

Fault area portion and cause Correction

Deterioration/deformation at pad surface Replace
Brake disk

Worn pad beyond use limit Replace

Oily material on pad surface Clean
Faulty piston operation Replace

5. Brake drag

Fault area portion and cause Correction

Brake disk

Faulty piston seal Replace

Deflected disk plate (too much run-out) Replace
Incorrectly installed pad Correct

49 W563-0032E
 Test for No-spin differential

Test for No-spin differential 5. After that, rotate both wheels until stopping
backward and hold the right wheel. Confirm the
The no-spin differential function can be checked with
left wheel free when rotae the left wheel forward.
the right and left wheel movement by the following
method.

1. Test with wheels jacked up

1. Raise the wheels completely from the floor by
jack-up.

2. Stop the engine, and lock the propeller shaft. Example: Right turn with the engine brake applying.
(Apply the parking brake under four-wheel drive
mode.)

[NOTICE]
Give measures necessary so that the third party
cannot start the engine.

3. Confirm the no-spin differential function with the

left wheel.
6. Confirm the no-spin differential function with the
Rotate both wheels until stopping forward.
right wheel.
In general, both wheels rotate by 5 to 6 cm and
Rotate both wheels until stopping forward.
stop.
In general, both wheels rotate by 5 to 6 cm and
stop.

4. Maintaine the right wheel with a torque forward

applied. Confirm the left wheel free when the
center-cam and the driven clutch are disengaed
by rotating the left wheel rearward.
Example: Left turn with the engine brake applying.
7. Maintaine the left wheel with a torque forward
applied. Confirm the left wheel free when the
center-cam and the driven clutch are disengaed
by rotating the left wheel rearward.

Example: Right turn with the engine brake applying.

50 W563-0032E
 Test for No-spin differential

8. After that, rotate both wheels until stopping 2. Test by traveling

backward and hold the right wheel. Confirm the
left wheel free when rotae the left wheel forward. [NOTICE]
Perform this test on a flat and dry paved road.

1. Before starting the test, make sure the tire radii of

the right and left tires are equal.

2. Select the four-wheel drive, front wheel steering

mode.

3. Drive the vehicle slowly in forward gear with the

steering wheel kept turned fully to the right.
Example: Left turn with the engine brake applying.
4. Do the same motion with the steering wheel
keptfully turned to the left.

5. Repeat the same test by driving the vehicle in

reverse gear.

Judgment
Normal:
The outer wheel rotates faster than the inner wheel
when turning a corner.
Abnormal:
Judgment
Large continuous noise is heard.
When the no-spin differential is assembled normally,
Tires are scuffling.
the enter-cam and the driven clutch, the rotated
wheel side, are disengaed manually and the wheel
becomes free.
After that, reverse the wheel rotation or loosen the 3. Abnormal conditions during traveling
holding wheel , the spider and the driven clutch
engage each other again. If the following conditions appear, disassemble
the differential for inspection.

1. Impulsive noises are frequently heard.

2. Only one wheel tends to spin.

3. Vehicle tends to be pulled to one side during

traveling straight.

4. Different feeling between the right turn and the

left turn.

5. Vehicle can not turn a corner or exposes

understeer.
(A large turning radius is needed)

363-816-50000 △
1

363-816-40000 △
1

363-816-30000 △
1

51 W563-0032E
Head Office Ko-34,Sinden-cho, Takamatsu, Japan

Overseas Service Group

Tadano Ryogoku Bldg.
4-12, Kamezawa 2-chome,
Sumida-ku,
Tokyo, Japan
Tel. 81 (3) 3621-7765
Tel fax 81 (3) 3621-7785

History of revision
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