DIFFERENTIAL

H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236];

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; H60-80C;
H110-150F; HR45-25, HR45-27, HR45-31, HR45-40S,
HR45-36L, HR45-40LS, HR45-45LSX [A227, B227, C227];
HR45-EC, HR48-EC [A228]; S/H6.00-7.00XL (S/H135-155XL,
S/H135-155XL 2) [B024, C024, F006, G006];
H8.00-12.00XL (H165-280XL) [E007]; H13.00-16.00XL (H300-
360XL) [D019]; H8.00-12.00XM (H170-280HD) [F007,
G007, H007]; H13.00-14.00XM (H300-330HD) [E019,
F019, G019]; H16.00XM-6 (H360HD) [E019, F019, G019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019, G019]H17.00CS-
32.00C (H370CS-700C) [C008]; H14.00-20.00XM (H400-450H) [A214];
H250-300A; H13.50-16.00B (H300-350B) [B019]; H360-620B [B008];
H16.00-32.00C (H360-650C, H370-700C) [C008]; H700-800A [A117];
H36.00-44.00B (H700-920B) [B117]; H36.00-48.00C (H800-
1050C) [C117]; H36.00-48.00E (H800-1050E) [D117]; H40.00-52.00XM-
16CH (H1050HD-CH,-1150HD-CH) [E117, F117]; S125-150A [A024];
P40-50A [A119]; P60-80A [A018]; P125-150A [B007];
P7.00-9.00B (P150-200B) [C007]; RS45-27CH, RS45-30CH,
RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH, RS46-33IH [A222];
H16.00-22.00XM-12EC (H400-500HD/HDS-EC) [B214]; RS45-27CH,
RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31,
HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222]

PART NO. 910072 1400 SRM 46

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Differential Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Differential Repair ............................................................................................................................................. 2
Remove ........................................................................................................................................................... 2
Differential Carrier From Axle Housing, Remove................................................................................... 2
Differential and Ring Gear From Differential Carrier, Remove............................................................. 4
Drive Pinion and Pinion Carrier From Differential Carrier, Remove.................................................... 6
Disassemble ................................................................................................................................................... 7
Differential and Ring Gear Assembly, Disassemble................................................................................ 7
Drive Pinion and Pinion Carrier, Disassemble........................................................................................ 9
Clean and Inspect .......................................................................................................................................... 12
Assemble ........................................................................................................................................................ 13
Pinion, Bearings, and Pinion Carrier, Assemble ..................................................................................... 13
Pinion Bearings, Adjust Preload .............................................................................................................. 13
Press Method......................................................................................................................................... 13
Yoke or Flange Method ......................................................................................................................... 14
Triple-Lip Seal, Install .............................................................................................................................. 15
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion) ............................................................... 16
Differential and Ring Gear, Assemble...................................................................................................... 18
Differential Gears Rotating Torque, Check ............................................................................................. 20
Differential and Ring Gear Assembly, Install.......................................................................................... 21
Differential Bearings, Preload Adjust...................................................................................................... 23
Ring Gear, Runout Check ......................................................................................................................... 24
Ring Gear Backlash, Adjust...................................................................................................................... 24
Gear Set, Tooth Contact Pattern Check................................................................................................... 26
Thrust Screw, Install and Adjust ............................................................................................................. 29
Install ............................................................................................................................................................. 29
Differential Assembly Into Axle Housing, Install ................................................................................... 29
Specifications...................................................................................................................................................... 31
Troubleshooting.................................................................................................................................................. 36

©2007 HYSTER COMPANY i

Table of Contents Differential

TABLE OF CONTENTS (Continued)

This section is for the following models:

H16.00-18.00XM/XMS-12 (H400-450HD/HDS) [A236];

H40.00-48.00XM-12 (H800-1050HD/HDS) [A917];
H60-80C; H110-150F; HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L,
HR45-40LS, HR45-45LSX [A227, B227, C227];
HR45-EC, HR48-EC [A228];
S/H6.00-7.00XL (S/H135-155XL, S/H135-155XL 2) [B024, C024, F006, G006];
H8.00-12.00XL (H165-280XL) [E007];
H13.00-16.00XL (H300-360XL) [D019];
H8.00-12.00XM (H170-280HD) [F007, G007, H007];
H13.00-14.00XM (H300-330HD) [E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019, G019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019, G019]
H17.00CS-32.00C (H370CS-700C) [C008];
H14.00-20.00XM (H400-450H) [A214];
H250-300A; H13.50-16.00B (H300-350B); [B019];
H360-620B; [B008];
H16.00-32.00C (H360-650C, H370-700C); [C008];
H700-800A; [A117];
H36.00-44.00B (H700-920B); [B117];
H36.00-48.00C (H800-1050C); [C117];
H36.00-48.00E (H800-1050E) [D117];
H40.00-52.00XM-16CH (H1050HD-CH,-1150HD-CH) [E117, F117];
S125-150A; [A024];
P40-50A; [A119];
P60-80A; [A018];
P125-150A; [B007];
P7.00-9.00B (P150-200B); [C007];
RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,
RS46-36CH, RS46-33IH [A222];
H16.00-22.00XM-12EC (H400-500HD/HDS-EC) [B214];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27, HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222]

ii
1400 SRM 46 Description

General
This section contains description and repair procedures for the differential. There is a Specifications section
and a Troubleshooting section at the end of this section.

Description
This differential is fastened to the drive axle hous- transfers power from the pinion through the differen-
ing of the lift truck. The differential provides a sin- tial assembly to the axles. The differential assembly
gle-speed reduction for an increase in torque to the permits the drive wheels to rotate at different speeds
drive wheels. There is a housing, a ring and pinion during a turn. See Figure 1.
gear set, and the differential assembly. The ring gear

Figure 1. Typical Differential Assembly

1
Differential Repair 1400 SRM 46

Legend for Figure 1

NOTE: *SOME AXLES DO NOT HAVE THE PARTS DESCRIBED.

1. PINION NUT 18. CAPSCREW OR RIVET* 34. SHIM
2. WASHER* 19. RING GEAR 35. PINION CARRIER
3. INPUT YOKE* 20. CASE HALF, FLANGE 36. COVER
4. DEFLECTOR 21. NUT* 37. BOLT
5. TRIPLE-LIP OIL SEAL 22. NUT 38. SHIFT FORK
6. DIFFERENTIAL CARRIER 23. WASHER 39. SPRING
7. FILL PLUG 24. THRUST BLOCK* 40. SHIFT SHAFT
8. ADJUSTMENT RING 25. BEARING CAP 41. PIN
9. LOCK PLATE 26. COTTER PIN (ADJUSTING 42. AIR CYLINDER TUBE
10. CAPSCREW RING)* 43. SCREW IN DIFFERENTIAL
11. SIDE GEAR 27. JAM NUT* LOCK CYLINDER
12. THRUST WASHER 28. THRUST SCREW* 44. CYLINDER COVER
13. CASE HALF 29. RETAINING RING 45. GASKET
14. BEARING CONE 30. WASHER 46. PLUG
15. BEARING CUP 31. SPIGOT BEARING 47. SHIFT COLLAR
16. PINION 32. PINION 48. PISTON
17. SPIDER 33. SPACER 49. O-RING

Differential Repair
REMOVE supported only by jacks. Jacks can slip and
fall over. Serious personal injury can result.
NOTE: The repair procedures cover all units unless
otherwise indicated. 3. Place jack stands under each spring seat of the
axle, to hold the lift truck in the raised position.
Differential Carrier From Axle Housing,
Remove
NOTE: The differential assembly can normally be
removed without removing the drive axle. On some
trucks, including the H7.00-12.50H (H150-275H),
the drive axle must be removed to remove the dif-
ferential assembly. If removal of the drive axle is
necessary, see the Drive Axle service manual for
your lift truck model.

1. Remove the mast. See the Mast section for your

lift truck model for the removal procedures.

2. Raise the end of the vehicle where the axle is

mounted. Use a jack or other lifting tool, and
place safety stands under each side of the axle.
See Figure 2.

WARNING
1. SAFETY STANDS
Block the wheels to prevent the lift truck
from moving. Support the lift truck with Figure 2. Lift Truck Support
safety stands. DO NOT work under a lift truck

2
1400 SRM 46
4. Remove plug from the bottom of the axle housing
and drain the oil from the axle assembly.
5. Disconnect the drive shaft at the differential. If
a speed reducer or gear box is installed, remove
the speed reducer or gear box.
6. Some units have a drum or disc brake attached to
the output yoke. Disconnect any brake linkage or
brake lines. See the Brake section for your unit.
7. Disconnect the driveline universal joint from the
pinion input yoke or flange on the differential
carrier. See Figure 3.
1. BEARING CUPS 4. WELD YOKE
2. END YOKE 5. BEARING STRAP
3. YOKE SADDLE 6. CAPSCREWS
Figure 3. Typical Driveline Universal Joint
Differential Repair
8. Remove the axle shafts from the axle housing.
See the Drive Axle section for your model of lift
truck for the procedures.
a. On Straddle Trucks™, disconnect the drive
axle universal joints at the differential
yokes. Remove the capscrews that fasten the
bearing retainers to the differential hous-
ing. Pull the yoke, stub shaft and bearing
retainer from the housing.
9. Place a transmission jack under the differential
carrier for support. See Figure 4.
7. U-JOINT CROSS
8. SLIP YOKE
9. TUBING
3
Differential Repair
1. WOOD BLOCK
2. TRANSMISSION JACK
3. CAPSCREWS
Figure 4. Differential Carrier Support
10. Remove all but the top two differential carrier
housing capscrews. See Figure 4.
11. Loosen the top two differential carrier housing
capscrews and leave them attached to the assem-
bly. The capscrews will hold the differential car-
rier in the housing.
12. Loosen the differential carrier in the axle hous-
ing. Use a leather mallet to hit the mounting
flange of the differential carrier at several points.
13. After the differential carrier is loosened, remove
the top two capscrews.
CAUTION
When using a pry bar, be careful not to dam-
age the differential carrier or housing flange.
Damage to these surfaces will cause oil leaks.
14. Remove the differential carrier from the axle
housing. Use a pry bar with a round end, to help
remove differential carrier from housing.
15. Remove the differential carrier assembly from
under the lift truck.
4
1400 SRM 46
16. Use a lifting device and lift the differential car-
rier by the input yoke or flange and place the as-
sembly on a repair stand. See Figure 5.
1. DIFFERENTIAL CARRIER
2. REPAIR STAND
Figure 5. Differential Carrier Stand
Differential and Ring Gear From
Differential Carrier, Remove
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
NOTE: Before working on the differential carrier, in-
spect the hypoid gear set for damage. If inspection
shows no damage, the same gear set can be used
again. Measure the backlash of the gear set and
make a record of the dimension. See the section Ring
Gear Backlash, Adjust. During differential reassem-
bly, adjust the backlash to the original recorded di-
mension when the gear set is installed into the dif-
ferential carrier.
1. Loosen the jam nuts on the thrust screw.
2. Remove the thrust screw and jam nut from the
differential carrier. See Figure 6.
1400 SRM 46 Differential Repair

5. Remove the cotter pins that hold the bearing ad-

justing rings in position. Some differential car-
rier models have dowel pins or lock plates hold-
ing the bearing adjusting rings in position. Each
lock plate is held in position by two capscrews.
See Figure 8.

6. Remove capscrews and washers holding the two

bearing caps on the differential carrier. See Fig-
ure 8.

Figure 6. Thrust Screw and Jam Nut Removal

3. Rotate the differential carrier until the ring gear

is at the top of the assembly.

4. Mark one differential carrier leg and bearing cap

to correctly match the parts during differential
carrier assembly. Mark the parts using a center
punch and hammer. See Figure 7.

1. COTTER PIN 2. LOCK PLATE

Figure 8. Bearing Adjusting Ring Removal

7. Remove the bearing caps and bearing adjusting

rings from the differential carrier. See Figure 9.
1. BEARING CAP
2. DIFFERENTIAL CARRIER LEG
3. MATCHMARKS

Figure 7. Mark Differential Carrier Leg and

Bearing Cap

5
Differential Repair 1400 SRM 46

1. Fasten a yoke or flange bar to the input yoke or

flange. When the nut is removed, the bar will
hold the drive pinion in position. See Figure 11.

2. Remove the nut and washer from the drive pin-

ion.

3. Remove the yoke or flange bar.

1. BEARING CAP
2. BEARING ADJUSTING RING

Figure 9. Bearing Cap Removal

8. Use a lifting device and lift the main differential

and ring gear assembly from the differential car-
rier. See Figure 10.

1. FLANGE BAR 2. YOKE BAR

Figure 11. Flange and Yoke Bar

CAUTION
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mal-
let can damage the parts and cause driveline
runout or driveline imbalance problems after
1. BEARING CUP carrier to driveline assembly.
2. DIFFERENTIAL CARRIER
3. BEARING BORE 4. Remove the yoke or flange from the drive pinion.
4. PUT ADHESIVE HERE (INSTALLATION ONLY)
If the yoke or flange is tight on the pinion, use a
Figure 10. Main Differential and Ring Gear puller for removal. See Figure 12.
Assembly Removal
5. Remove the capscrews and washers that hold the
pinion carrier in the differential carrier. See Fig-
Drive Pinion and Pinion Carrier From
ure 13.
Differential Carrier, Remove
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.

6
1400 SRM 46 Differential Repair

WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.

CAUTION
Do not use a pry bar to remove the pinion car-
rier from the carrier. A pry bar can damage the
bearing case, shims, and differential carrier.

6. Remove the drive pinion, pinion carrier, and

shims from the differential carrier. See Fig-
ure 13. If the pinion carrier is tight on the
differential carrier, hit the pinion carrier at sev-
eral points around the flange area with a leather,
plastic or rubber mallet.

7. Inspect the shims. If they are in good condition,

keep the shims together for use during differen-
tial carrier assembly.

8. If the shims are to be replaced, first measure the

total thickness of the pack. Make a note of the
A. YOKE PULLER B. FLANGE PULLER dimension. The dimension will be needed to cal-
culate the depth of the drive pinion in the differ-
Figure 12. Yoke and Flange Puller Tools ential carrier when the gear set is installed.

DISASSEMBLE
Differential and Ring Gear Assembly,
Disassemble
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.

NOTE: Make sure there are matching marks on the

case halves of the differential assembly. See Step 4
in the section Differential and Ring Gear From Dif-
ferential Carrier, Remove. See Figure 7.

1. DRIVE PINION AND PINION CARRIER
2. SHIMS
3. CAPSCREWS
Figure 13. Pinion Carrier Removal
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
1. Remove the capscrews and washers that hold
the case halves together and separate the case
halves. If necessary, use a brass, plastic, or
leather mallet to loosen the parts.

7
Differential Repair 1400 SRM 46

2. Remove the differential spider, four pinion gears, c. Press the rivets through holes in the ring
two side gears, and six thrust washers from in- gear and flange case half. Press from the
side the case halves. See Figure 14. drilled rivet head.

A. CORRECT DRILLING RIVETS FROM HEAD

B. WRONG CHISELING RIVETS FROM HEAD

Figure 15. Rivet Removal

1. THRUST WASHER
2. SIDE GEAR
3. SPIDER, PINIONS, AND THRUST WASHERS
Figure 14. Ring Gear Disassembly
3. If the ring gear needs to be replaced, remove
bolts, nuts, and washers holding the ring gear to
the flange case half.
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
5. Separate the case half and ring gear using a
press. Support the assembly under the ring gear
with metal or wood blocks and press the case
half through the gear. See Figure 16.

CAUTION
Do not remove the rivets or rivet heads with a
chisel and hammer. Using a flat edge tool can
cause damage to the flange case. See Figure 15.

4. If your differential model uses rivets to hold the

ring gear to the flange case half, remove the riv-
ets as follows:

a. Center punch each rivet head in the center,

on the ring gear side of the assembly.
1. CASE HALF 3. PLATE
b. Drill each rivet head on the ring gear side of 2. PRESS 4. SUPPORTS
the assembly to a depth equal to the thick-
ness of one rivet head. Use a drill bit that is Figure 16. Case Half and Ring Gear Separation
1/32 of an inch smaller than the body diame-
ter of the rivets. See Figure 15.

8
1400 SRM 46 Differential Repair

6. If the differential bearings need to be replaced,

remove the bearing cones from the case halves.
Use a bearing puller or press. See Figure 17.

1. PRESS 5. SUPPORT
2. DRIVE PINION 6. SPIGOT BEARING
3. OIL SEAL 7. FLANGE SUPPORT
4. PINION CARRIER

Figure 18. Drive Pinion Disassembly

A. PULLER B. PRESS
WARNING
Figure 17. Differential Bearings Replacement
Use a brass or leather mallet for assembly and
Drive Pinion and Pinion Carrier, disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
Disassemble
off and cause serious personal injury.

WARNING NOTE: The inner bearing cone and bearing spacer

Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Place drive pinion and pinion carrier in a press.
The pinion shaft must be toward the top of the
assembly. Add supports for the pinion carrier
under the flange area. See Figure 18.
2. Press the drive pinion through the pinion carrier.
See Figure 18.
will remain on the pinion shaft. See Figure 19.
3. If a press is not available, use a leather, plastic
or rubber mallet to drive the pinion through the
pinion carrier.
CAUTION
When removing the oil seal, Do not damage the
wall of the bore. Damage to the bore wall can
result in oil leaks.
NOTE: Always replace the oil seal with a new seal
during reassembly.
4. Remove the oil seal from the pinion carrier. See
Figure 19.

9
Differential Repair 1400 SRM 46

6. If the spigot bearing needs to be replaced, place

the drive pinion in a vise. Install a soft metal
cover over each vise jaw to protect the drive pin-
ion.

7. Remove the snap ring from the end of the drive

pinion. See Figure 22.

NOTE: Some spigot bearings are fastened to the drive

pinion with a special peening tool. See Figure 23.

NOTE: Some spigot bearings are a two-piece assem-

bly. Remove the inner race from the pinion with a
bearing puller. Remove the outer race/roller assem-
bly from the pinion carrier with a drift or a press. See
Figure 24.

8. Remove the spigot bearing from the drive pinion

with a bearing puller.

1. DRIVE PINION
2. OIL SEAL
3. OUTER BEARING (CUP AND CONE)
4. INNER BEARING (CUP AND CONE)
5. SPIGOT BEARING
6. SNAP RING
7. BEARING SPACER

Figure 19. Drive Pinion

5. Inspect the pinion bearings and replace if neces-

sary. If the pinion bearings need to be replaced,
perform the following:

a. Remove the inner and outer bearing cups

from the inside of the cage. Use either a press
and sleeve, bearing puller, or a small drift
pin. See Figure 17 and Figure 20. If a press
is used, provide support for the pinion car-
rier under the flange area with metal or wood
blocks.

CAUTION
The puller must fit under the inner race of
the cone to remove the cone correctly without
damage.

b. Remove the inner bearing cone from the

drive pinion with a press or bearing puller. A. BEARING DRIVER B. BEARING PULLER
See Figure 21.
Figure 20. Pinion Bearing Replacement

10
1400 SRM 46 Differential Repair

1. PEENING POINTS

Figure 23. Spigot Bearing Peening Points

1. PRESS 4. SUPPORTS
2. DRIVE PINION 5. INNER BEARING
3. BEARING PULLER CONE

Figure 21. Pinion Bearing Replacement

1. REMOVE OUTER RACE AND ROLLER

ASSEMBLY FROM CARRIER
2. REMOVE INNER RACE FROM PINION

Figure 24. Two-Piece Spigot Bearing

1. SPIGOT BEARING 2. SNAP RING

Figure 22. Snap Ring Removal

11
Differential Repair 1400 SRM 46

CLEAN AND INSPECT

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.

Clean and inspect the following parts of the differen-

tial:
• Yoke- Clean the surface of the yoke journal with a
cleaning solvent and inspect the original yoke seal
surface for any grooves.
• Drive axle- Clean the parts of the axle with sol-
vent and dry with compressed air. Inspect all ma-
chined surfaces and bearings for wear and damage.
• Tapered Roller Bearings- Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
assembly. If bearings show signs of wear, cracks, or
damage, replace with new bearing.
• Pinions and Gears- Inspect the pinions and gears
for wear or damage. Gears that are worn or dam-
aged must be replaced. A. DIFFERENTIAL CASE HALVES
• Axle shafts- Inspect the axle shafts for wear and B. DIFFERENTIAL GEAR NEST ASSEMBLY
cracks at the flange, shaft and splines. If axle
shafts show signs of wear or damage, replace the 1. INSPECT INSIDE SURFACES
2. PINION AND THRUST WASHER
axle shafts. 3. SIDE GEAR AND THRUST WASHER
• Main differential assembly- Inspect all parts of 4. SPIDER
the main differential assembly for wear or damage.
Parts that are damaged must be replaced. See Fig- Figure 25. Main Differential Assembly
ure 25 for parts to inspect. Inspection

12
1400 SRM 46
ASSEMBLE
Pinion, Bearings, and Pinion Carrier,
Assemble
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Put differential oil on the bearings and cups. In-
stall the cups in the pinion carrier. See Figure 1.
2. Install the inner bearing and spigot bearing
against the pinion shoulders. Use a sleeve and
press to push against the inner bearing race.
CAUTION
If a new pinion is installed, a new ring gear
must also be installed. The pinion and ring
gear are a set (see Figure 32) and must be in-
stalled together.
NOTE: During assembly at the factory, one spacer is
used. Two thinner spacers are used if the pinion or
bearings are replaced. These spacers are selected for
correct bearing preload.
NOTE: Some spigot bearings are fastened to the pin-
ion with a snap ring, and some are fastened with a
punch. Others can have a two-piece bearing. See Fig-
ure 24.
3. Install the spigot bearing washer and snap ring.
Put the pinion assembly in the pinion carrier. In-
stall the spacers on the pinion. See Figure 19.
4. Use a press to install the outer bearing against
the spacer. Rotate the carrier to make sure the
bearings are installed correctly.
5. Use either the Press Method or the Yoke or
Flange Method, and apply the correct preload.
See Specifications, Table 6. Check the bearing
preload as described in Pinion Bearings, Adjust
Preload of this section.
Differential Repair
Pinion Bearings, Adjust Preload
Press Method
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
NOTE: If a press is not available, or the press does
not have a pressure gauge, use the Yoke or Flange
Method to adjust pinion bearing preload.
1. Place the drive pinion and carrier assembly in a
press with the gear head (teeth) toward the bot-
tom.
2. Install a sleeve of the correct size against the in-
ner race of the outer bearing. See Figure 19.
3. Apply and hold the correct amount of pressure to
the pinion bearings. See Specifications, Table 6.
As pressure is applied, rotate the pinion carrier
several times so that the bearings make normal
contact.
4. While pressure is held against the assembly,
wrap a cord several times around the pinion
carrier. Fasten a Newton or pound scale to the
cord. See Figure 26.
1. PRESS 3. PINION BEARING
2. SLEEVE
Figure 26. Bearing Preload Check
13
Differential Repair 1400 SRM 46

5. Pull the scale to unwind the cord. Check
the reading on the scale as the cord unwinds
smoothly. Do not read starting torque. Read
only the torque value after the pinion carrier
starts to rotate. The starting torque will provide
a false reading.
NOTE: Use a press to install the yoke or flange.
1. Install the input yoke or flange, nut, and washer
on the drive pinion. The yoke or flange must
be seated against the outer bearing for proper
preload.

2. Temporarily install the drive pinion and pinion

CAUTION carrier assembly into the differential carrier. Do
On H7.00-12.50H (H150-275H) trucks, DO NOT not install shims under the pinion carrier. See
use the washer that is on the new pinion. Use Figure 34.
the thicker spacer (Hyster PN 125277). The
3. Install the pinion carrier to the differential car-
threads can be damaged or the nut can loosen
rier by installing the capscrews and tightening
if the washer is used.
them by hand. Do not install the washers, they
6. The scale reading must indicate 2.2 to 7.0 kg (5 are not required.
to 15 lb).
4. Fasten a yoke or flange bar to the input yoke or
A pinion carrier that has a 76.2 mm (3 in.) ra- flange. See Figure 11. The bar will hold the drive
dius and a 2.2 kg (5 lb) scale reading is equal pinion in position when the nut is tightened.
to 1.70 N•m (15 lbf in). Select a bearing spacer
5. Tighten the nut on the drive pinion to the correct
set for the correct preload. A thinner set will in-
torque value as shown in Specifications, Table 6.
crease the preload. A thicker bearing spacer set
Remove the yoke or flange bar.
will decrease preload.
6. Attach a torque wrench on the drive pinion nut.
7. Use the following procedure to calculate the bear-
Rotate the drive pinion and read the value indi-
ing preload (torque):
cated on the wrench. See Figure 27.
• Pounds pulled × radius (inches) = lb-in preload.
- Preload × 0.113 = N•m preload.
• Kilograms pulled × radius (cm) = kg-cm lb-in
preload
- Preload × 0.098 = N•m preload.
OR
EXAMPLES:
• Reading from spring scale = 3.4 kg (7.5 lb).
• Diameter of pinion carrier = 16.8 cm (6.62 in.).
• Radius of pinion carrier = 8.4 cm (3.31 in.).
7.5 lb × 3.31 in = 24.8 in-lb preload.
Preload × 0.113 = 2.8 N•m preload.
OR
3.4 kg × 8.4 cm = 28.6 kg-cm preload.
Preload × 0.098 = 2.8 N•m preload.

Yoke or Flange Method

WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury. Figure 27. Torque Value Reading

CAUTION 7. If the preload (torque) of pinion bearings is not

within specifications, remove the pinion and
Do not install tight fit yokes or flanges on shafts
pinion carrier from the differential carrier. Per-
using a hammer or mallet. A hammer or mallet
form Step a and Step b below, then repeat Step 1
will damage the yoke or flange.
through Step 6.

14
1400 SRM 46 Differential Repair

a. To increase preload, install a thinner bearing NOTE: If a press is not available, use a mallet and a
spacer. sleeve or driver to install the oil seal.

b. To decrease preload, install a thicker bearing 2. Place the drive pinion and carrier assembly in a
spacer. press, with seal bore toward the top.

Triple-Lip Seal, Install
Once the preload has been adjusted, remove the drive
pinion and pinion carrier from the differential carrier
as outlined in the first five steps in the section Drive
Pinion and Pinion Carrier From Differential Carrier,
Remove.
3. Press the seal into pinion carrier until flange of
seal is flat against the top of pinion carrier. Use
a sleeve or seal driver of the correct size that fits
against the metal flange of oil seal. The diameter
of the sleeve must be larger than the diameter of
the flange. See Figure 29.

CAUTION
Make sure that the seal lips are clean and free
from dirt and particles that will cause a leak
between the yoke and the seal.

Install a new triple-lip oil seal as described below:

1. Apply lubricant to the outer surface of the seal

and the seal bore in the pinion carrier. See Fig-
ure 28.

1. PRESS 4. OIL SEAL

2. SLEEVE 5. PINION CARRIER
3. SUPPORTS 6. DRIVE PINION

Figure 29. Triple-Lip Oil Seal Installation

1. APPLY GREASE
2. TRIPLE-LIP OIL SEAL
3. APPLY LUBRICANT TO SEAL BORE
4. PINION CARRIER
5. DRIVE PINION

Figure 28. Triple-Lip Oil Seal Lubrication

15
Differential Repair 1400 SRM 46

WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
4. Once the triple-lip oil seal has been installed,
check the gap between the flange and pinion car-
rier with a feeler gauge, at several points around
the seal. See Figure 30. The gap must be within
0.38 to 0.76 mm (0.015 to 0.030 in.). The differ-
ence between the largest and smallest gap mea-
surement must not exceed 0.0254 mm (0.010 in.).
CAUTION
Always use a minimum of three shims for the
shim set. Use the thinnest shims on the outside
of the set for a better seal.
1. The correct shim set thickness can be found by
using the old and new parts. Use the old shim set
thickness and the numbers on the old and new
pinion and ring gear sets. For the location and
identification of the numbers, see Figure 32.

NOTE: SHOWN WITHOUT BEARINGS AND PINION

1. SHIM SET (CONTROLS DEPTH OF PINION)
1. GAP MEASUREMENT = 0.38 to 0.76 mm 2. PINION CARRIER
(0.015 to 0.030 in.) 3. DIFFERENTIAL HOUSING
4. SPACER(S) (CONTROLS BEARING PRELOAD)
Figure 30. Oil Seal Gap Measurement
Figure 31. Shim Set Location
Pinion Carrier Shim Set, Adjust Thickness
(Depth of Pinion)
NOTE: Use this procedure if a new ring gear and pin-
ion set is installed, or if the depth of the pinion has
to be adjusted.

After the preload is correctly adjusted using the

spacer set, adjust the pinion. The pinion is adjusted
using shims on the pinion carrier assembly. If the
same ring gear and pinion are used, use the old shim
set. See Figure 31. If a new ring gear and pinion are 1. PART NUMBERS
used, adjust the pinion as described below. 2. GEAR TEETH NUMBERS
3. GEAR SET NUMBERS
4. PINION CONE NUMBERS

Figure 32. Pinion Set Numbers

16
1400 SRM 46
NOTE: Always check the gear set for the correct
marks to make sure the gears are a matched set.
2. The location of the pinion and ring gear marks
are shown in Figure 32. A description of the
marks is as follows:
Part Number. The part numbers are the part
number of the manufacturer. The part num-
ber for the ring gear is always an even number.
The part number for the pinion is the next odd
number. Check to make sure the pinion and
ring gear are in a sequence. Examples of gear
set part numbers: ring gear, 36786; drive pin-
ion, 36787. If a gear set number has a letter
that follows the number, the letters must be
the same for both the ring gear and pinion.
Gear Teeth Number. The gear teeth num-
bers are the numbers of the teeth on the pinion
and ring gear. The number of pinion teeth is
the first number. An example of this number
is 5-37. In the example, the drive pinion has 5
teeth and the ring gear has 37 teeth.
Gear Set Number. The gear set number is a
letter and number. Make sure the letter and
number are the same on the drive pinion and
ring gear. An example of a gear set number is
M29.
Pinion Cone Number. The pinion cone num-
ber is the variation from the design center.
The design center is the exact design distance
from the end of the pinion cone to the ring gear
centerline. See Figure 33.
1. PINION CONE NUMBER (VARIATION)
Figure 33. Pinion Cone Number Location
Differential Repair
NOTE: The pinion cone number is not used when the
gear set number is being checked. The pinion cone
number is used when you adjust the depth of the pin-
ion in the carrier.
Example: PC+3, PC 3, +3, or 3 equals 0.003
inch (variation). PC+0.03, PC 0.03, +0.03, or
0.03 equals 0.03 mm (variation).
Find the correct thickness of the shim set as fol-
lows:
3. Use a micrometer to measure the total thickness
of the old shim set that was removed from under
the pinion carrier. Make a note of the measure-
ment for later use.
4. Check the pinion cone number for the old pinion.
See Figure 33. If this number is a plus (+) value,
subtract the value from the value in Step 3. If
the pinion cone number is a minus ( ) value, add
the number to the value in Step 3. The number
shown is in 0.00 × inch (+2 = +0.002 inch). The
result is the standard thickness for a shim set.
NOTE: The value calculated in Step 4 is the thickness
of the standard shim set, without a variation.
5. Check the pinion cone number for the new pin-
ion. Add or subtract this number to the standard
thickness value of Step 4. Add the number if the
value is a plus (+) value. Subtract the number if
the value is a minus ( ) value. The result is the
correct thickness for the new shim set. See the
examples.
NOTE: The value calculated in Step 5 is the thickness
of the new shim set that will be installed. See the
examples shown in Specifications, Table 5.
CAUTION
Always use a minimum of three shims for the
shim set. Use the thinnest shims on the outside
of the set for a better seal.
6. Install the pinion carrier assembly using the cor-
rect shim set. See Figure 34. Tighten the cap-
screws to the correct value shown in Specifica-
tions, Table 7.
a. If there is a bracket for a disc brake caliper,
install the bracket and tighten the cap-
screws.
b. If there is a speed reducer or drop box, install
it on the pinion carrier assembly. Use John
17
Differential Repair 1400 SRM 46

Crane No. 2® as a sealant. Tighten the nuts 3. DIFFERENTIAL HOUSING

to the correct value shown in Specifications,
Table 7. Figure 34. Pinion Carrier Assembly
Installation

CAUTION
On H7.00-12.50H (H150-275H) trucks, DO NOT
use the washer that is on the new pinion.
Use the thicker spacer (Hyster Part Number
125277). The threads can be damaged or the
nut can loosen if the washer is used.

7. Install the universal joint yoke, flange for the

brake rotor or brake drum, or the gear for the
speed reducer. See Figure 35.

8. Install the spacer and pinion nut. Tighten the

1. PINION AND PINION CARRIER pinion nut to the correct torque as shown in Spec-
2. SHIMS ifications, Table 7.

1. BRAKE DISC 5. YOKE

2. BRAKE CALIPER 6. PINION CARRIER
3. AIR CHAMBER 7. SEAL
4. BRACKET

Figure 35. Units With Air-Operated Disc Brakes

Differential and Ring Gear, Assemble
CAUTION
Assembly of ring gear on the differential case
must be correct for correct gear adjustment
and maximum wear.
Make sure the ring gear is part of the set of the pinion
and ring gear. See Figure 32.
CAUTION
Do not install a cold ring gear on the flange
case half. A cold ring gear will damage the

18
1400 SRM 46 Differential Repair

case half because of the close tolerance. Metal
particles between the parts will cause gear
runout that will exceed the specification of
0.2 mm (0.008 in.).
1. Heat the ring gear in 71 to 82 C (160 to 180 F)
water for approximately ten minutes. Heating
the gear makes it fit easier on the differential
case.
WARNING
Wear protective clothing to prevent injury
when handling the hot ring gear.
CAUTION
Never use a press or hammer to install the ring
gear.
in pairs opposite each other (A-A, B-B), from the
case half side of the assembly. See Figure 37.
7. Use a thickness gauge that has a thickness of
0.08 mm (0.003 in.) to check for correct instal-
lation. Put the gauge between the ring gear and
the case at four points that are separated by 90
degrees. The gauge cannot go in more than half
the distance between the flange outer diameter
and the pilot diameter for the gear. If the gauge
goes more than half the distance, the ring gear
must be removed and installed again. See Fig-
ure 38.
8. Install the bearing cones on both of the case
halves. Use a press and a sleeve of the correct
size.

2. Lift the ring gear from the water using a lifting

tool.

3. Install the ring gear on the flange case half im-

mediately after the gear is heated. If the ring
gear does not fit easily on the case half, heat the
gear again.

4. Align fastener holes of the ring gear and flange

case half. Rotate the ring gear as needed.

5. If special capscrews are used to fasten the ring

gear to the flange case half, install the capscrews, 1. FLANGE CASE HALF
washers, and nuts as shown in Figure 36. The 2. RING GEAR
3. BOLT HEAD AGAINST GEAR
capscrew heads must be against the ring gear.
Use pairs of capscrews opposite each other to Figure 36. Installation With Capscrews
tighten the case and ring gear together. For cap-
screw torque specifications, see Specifications,
Table 7.

NOTE: On S/H6.00-7.00XL (S/H135-155XL, S/H135-

155XL 2) (B024, C024, F006, G006) lift truck models,
if rivets were use to hold the ring gear and flange
case half together, replace them with bolts, nuts, and
washers

6. If rivets are used to fasten the ring gear to the

flange case half, install the rivets cold. Do not
heat the rivets. For the correct pressure to press
the rivets, see Specifications, Table 4. The maxi-
mum pressure must be applied for approximately
one minute at the end of the press cycle. Do not
use more than the maximum pressure. Dam-
age to the holes can occur. A correctly installed 1. RING GEAR 2. CASE HALF
rivet will have a head at least 3.18 mm (0.125 in.)
Figure 37. Installation With Rivets
larger than the hole diameter. Install the rivets

19
Differential Repair 1400 SRM 46

9. Apply axle lubricant to the inside surfaces of both

case halves, spider (cross), thrust washers, side
gears, and differential pinions.

10. Put the flange case half on a bench with the ring
gear teeth toward the top.

1. THRUST WASHER 4. CASE HALF

2. SIDE GEAR 5. ALIGNMENT
3. SPIDER GEARS MARKS

Figure 39. Differential Pinion and Side Gears

1. CHECK FOR CLEARANCE IN FOUR PLACES

WITH 0.08 mm (0.003 in.) GAUGE

Figure 38. Gear and Case Half Installation

Check

11. Install one thrust washer and side gear into the
flange case half.

12. Install the spider (cross), differential pinions and

thrust washers into the flange case half. See Fig-
ure 14.
13. Install the second side gear and thrust washer
over spider and differential pinions.
14. Align the marks and assemble the two halves of
the differential case. See Figure 39.
15. Use Loctite No. 272® on the threads of the cap-
screws. Install four of the capscrews, washers
and nuts into the case halves in a cross pattern.
The distance between the fasteners must be
equal.
16. Tighten the fasteners to the correct torque value
in a pattern opposite each other. See Figure 40.
See Specifications, Table 7.
17. Install the other fasteners into the case halves.
Tighten the fasteners to the correct torque value.
Figure 40. Fasteners Tightening Sequence
18. Check that the differential gears can freely ro-
tate in the case.
Differential Gears Rotating Torque, Check
NOTE: Make a tool for checking the rotating torque
of the differential gears. The tool can be made from
an axle shaft that has the same spline size of the
differential side gear. See Figure 41.
1. Put the differential and ring gear assembly in a
vise. Install soft metal covers for the jaws of the
vise to protect the ring gear.
2. Install the tool into the differential until the
splines of the tool engage one side of the gear.

20
1400 SRM 46
1. APPROXIMATELY 305 mm (12 in.)
2. WELD NUT TO END OF SHAFT
Figure 41. Tool to Check Differential Gears
3. Attach a torque wrench to the nut on the tool
and rotate the differential gears. Read the value
indicated on the torque wrench as the differen-
tial gears rotate. See Figure 42. The maximum
torque applied to one side gear must not exceed
68 N•m (50 lbf ft). If the torque value exceeds
this specification, disassemble the differential
gears from the case halves. See the Differential
and Ring Gear Assembly, Disassemble section
for the procedure.
4. Check the case halves, spider, gears, and thrust
washers for cracks, wear, or damage that caused
the incorrect torque value. Repair or replace
parts as necessary. Assemble the parts after
repair and repeat Step 1 through Step 3.
1. TOOL
2. READ TORQUE VALUE
Figure 42. Rotating Torque Check
Differential Repair
Differential and Ring Gear Assembly,
Install
1. Clean the oil and dirt from the outer diameters
of the bearing cups and bearing bores in the dif-
ferential carrier and bearing caps.
2. Apply axle lubricant to the bearing cones and the
inner diameters of the bearing cups of the main
differential. Do not get oil on the outer diameter
of the bearing cup, and onto bearing bores.
NOTE: Adhesives normally become hard (dry) in ap-
proximately two hours. The assembly process must
be completed within this time period. If two hours
have passed since application of the adhesive, clean
the parts again and apply new adhesive.
3. Apply a continuous bead of adhesive to the bear-
ing bores in the carrier and bearing caps. Ap-
ply the adhesive completely around the smooth,
ground surfaces only. Do not put adhesive on
threaded areas. See Figure 43.
4. Install the bearing cups over the bearing cones
that are assembled on the case halves. See Fig-
ure 44.
1. ADHESIVE 3. CARRIER LEG
2. BEARING CAP
Figure 43. Adhesive Application
21
Differential Repair 1400 SRM 46

carrier damage after reassembly to axle and

during vehicle operation. Do not force the
bearing caps into unmatched bore locations in
the carrier.

8. Use a light leather, plastic, or rubber hammer

and seat each bearing cap to move it into posi-
tion. The caps must fit easily against the bear-
ings, adjustment rings, and carrier. Do not force
the bearing caps into position.

9. If the bearing caps do not correctly fit into po-

sition, check the alignment marks between the
caps and the differential carrier. Remove the
caps and repeat Step 5 through Step 9.

NOTE: Do not install the cotter keys, dowel pins, or

lock plates (as furnished on axle model) that hold the
1. BEARING CUP bearing adjusting rings in position. First, adjust the
2. CARRIER
3. BEARING BORE preload of the differential bearings, adjust the gear
4. PUT ADHESIVE HERE clearance, and check the tooth contact pattern.

Figure 44. Differential Assembly Installation 10. Install the capscrews and washers that hold
bearing caps to the differential carrier. Tighten
5. Use a lifting device that has the capacity to lift the capscrews by hand four to six turns, then
the weight of the differential assembly and in- tighten the capscrews to the correct torque value.
stall the assembly into the differential carrier. See Specifications, Table 7.
The bearing cups must be flat against the bores
between the differential carrier legs. See Fig-
ure 44. Make sure that the ring gear does not
touch the pinion.

6. Install both bearing adjusting rings into position

between the differential carrier legs. Turn each
adjusting ring until hand tight against the bear-
ing cups. See Figure 45.

7. Install the bearing caps over the bearings and ad-

justment rings in the correct location as marked
before removal.

WARNING
Wear eye protection. Do not hit steel parts with
a steel hammer. Parts can break and cause in-
jury.
1. BEARING CAP
2. BEARING BORE
CAUTION 3. ADJUSTMENT RING
If bearing caps are not installed in the correct 4. ALIGNMENT MARKS
original locations, the bores and threads in
caps will not match the carrier. Assembling Figure 45. Bearing Caps Installation
mismatched caps into the carrier can result in

22
1400 SRM 46 Differential Repair

Differential Bearings, Preload Adjust

1. Make sure the ring gear is not touching the pin-
ion. Install a dial indicator as shown in Fig-
ure 46. Adjust the dial indicator so that the
plunger or pointer is against the back surface of
the ring gear.

1. BARS MUST NOT TOUCH BEARINGS

1. DIAL INDICATOR
Figure 47. Gear Movement Check
Figure 46. Bearing Preload Adjustment

CAUTION
Always use a tool that engages two or more op-
posite notches in the adjustment ring. A T-bar
spanner type wrench can be used for this pur-
pose. Be sure the wrench fits correctly so that
the lugs will not be damaged.

2. Loosen the bearing adjustment ring that is on the

same side as the dial indicator so that a small
amount of end play shows on the dial indicator.

3. Push the differential assembly left and right with

pry bars while you read the dial indicator. Use
one of the methods described below:

a. Use two pry bars that fit between the bearing

adjustment rings and ends of the differential
1. BARS MUST NOT TOUCH BEARINGS
case. The pry bars must not touch the differ-
ential bearings. See Figure 47. Figure 48. Gear Movement Check
b. Use two pry bars between the differential 4. Tighten the bearing adjustment ring that was
case or ring gear and the carrier at locations just loosened so that there is no movement of the
other than described in Step a. The pry bars differential assembly.
must not touch the differential bearings. See
Figure 48.

23
Differential Repair 1400 SRM 46

5. Tighten each adjustment ring one notch to obtain
the preload. The maximum axial movement per-
mitted is 0.15 to 0.33 mm (0.006 to 0.013 in.).
See NOTE that follows. The maximum torque
required to turn the differential bearings is 1.7
to 3.9 N•m (15 to 35 lbf in).
NOTE: Use 0.05 to 0.23 mm (0.002 to 0.009 in.) on
Rockwell RS-140 and RS-145 axles.
6. Continue assembly and check the runout of the
ring gear.
Ring Gear, Runout Check
Check the tooth contact pattern first. See Gear Set,
Tooth Contact Pattern Check. Once the gear contact
pattern has been checked, backlash can be adjusted
within specifications, if needed.
To change the location of the pattern, follow the steps
outlined below:
1. Install a dial indicator on the mounting flange of
the differential carrier as shown in Figure 50.
2. Adjust the dial indicator so that the plunger or
pointer is against the tooth surface. See Fig-
ure 50.

1. Attach a dial indicator to the mounting flange of 3. Adjust the indicator to zero.
the differential carrier as shown in Figure 46.
4. Hold the drive pinion in position.
2. Adjust the dial indicator so that the plunger or
5. After reading the dial indicator, rotate the differ-
pointer is against the back surface of the ring
ential and ring gear a small amount in both di-
gear.
rections, against the drive pinion teeth.
3. Set the indicator to zero.
6. If the backlash reading is within specifications,
4. Rotate the ring gear and check the dial indicator (see Table 1), continue checking tooth contact
for the maximum needle movement. The maxi- patterns.
mum movement permitted is 0.20 mm (0.008 in.).
7. If the backlash reading is not within specifica-
5. If the movement exceeds the maximum limit, tions, (see Table 1), adjust backlash as needed.
remove the differential and ring gear assembly Continue onto Step 8 and Step 9.
from the differential carrier and find the reason
for the movement. See Step 5 and Step 6 in
the section Differential and Ring Gear From
Differential Carrier, Remove for the removal
procedures.

6. Install the differential and ring gear into the dif-

ferential carrier after the parts are repaired or
replaced. Use the procedure in the section Differ-
ential and Ring Gear Assembly, Install. Repeat
the preload adjustment of the differential bear-
ings.

Ring Gear Backlash, Adjust

NOTE: Measure the outer diameter of ring gear for
approximate pitch diameter. See Figure 49.

If the old gear set is installed, adjust the backlash to

the setting that was measured before the differential 1. MEASURE OUTER DIAMETER FOR
APPROXIMATE PITCH DIAMETER
carrier was disassembled.
Figure 49. Pitch Diameter Measurement
If a new gear set will be installed, adjust the backlash
to the correct specifications for new gear sets. See
Table 1.

24
1400 SRM 46 Differential Repair

1. TIGHTEN ADJUSTING RING THIS SIDE

2. INCREASE BACKLASH
3. LOOSEN ADJUSTING RING THIS SIDE

Figure 51. Backlash Increase

Figure 50. Gear Clearance Check

NOTE: To increase backlash, move ring gear away

from drive pinion. To decrease backlash, move ring
gear toward drive pinion.

NOTE: When adjusting backlash, move the ring gear

only. Do not move the drive pinion.

8. Loosen one bearing adjusting ring one notch,

then tighten the opposite ring the same amount.
See Figure 51 and Figure 52.

9. Repeat Step 2 through Step 8 until backlash is

within specifications. See Table 1.

1. LOOSEN ADJUSTING RING THIS SIDE

2. DECREASE BACKLASH
3. TIGHTEN ADJUSTING RING THIS SIDE

Figure 52. Backlash Decrease

25
Differential Repair
Table 1. Ring Gear Backlash Adjustment Specifications
Specification
Ring gears with pitch diameter of less than 431.8 mm
(17 in.). See Figure 49.
Ring gears with pitch diameter greater than
431.8 mm (17 in.). See Figure 49.
Gear Set, Tooth Contact Pattern Check
NOTE: The gear clearance can be changed within the
limits of 0.13 to 0.38 mm (0.005 to 0.015 in.) for better
tooth contact.
26
1400 SRM 46
Backlash Measurement
Range of backlash setting:
0.20 to 0.46 mm (0.008 to 0.018 in.)
Backlash setting for new gears:
0.30 mm (0.012 in.)
Range of backlash setting:
0.25 to 0.51 mm (0.010 to 0.020 in.)
Backlash setting for new gears:
0.38 mm (0.015 in.)
NOTE: If the original gear set is installed, adjust the
clearance to the original value recorded in Differen-
tial and Ring Gear Assembly, Disassemble. If a new
gear set is installed, adjust the adjustment rings for
0.25 mm (0.010 in.). Refer to Ring and Pinion Tooth
Contact Adjustment.
1400 SRM 46 Differential Repair

Table 2. Ring and Pinion Tooth Contact Adjustment

1. Apply a colored dye or grease to approximately 12

of the ring gear teeth.
2. Rotate ring gear forward and backward so that
the 12 gear teeth go past the drive six times to
get to the contact patterns. Repeat if needed to
get a clearer pattern.
3. Check the tooth contact pattern on the ring gear.
Make sure that the pattern is checked on the side
of the tooth where the pinion applies the force.

Correct Tooth Contact

The contact area is the center between the top and
bottom of the tooth. The contact area is toward the NOTE: Normal pattern during adjustment shown.
inner circumference of the ring gear.

The contact area is the center between the top and

the bottom of the tooth. The contact area will be NOTE: Wear pattern from operation shown.
almost the full length of the tooth.

27
Differential Repair 1400 SRM 46

Table 2. Ring and Pinion Tooth Contact Adjustment (Continued)

Incorrect Tooth Contact

The pinion is too far away from the center of the
gear. Add shims to move pinion toward ring gear.
Check that the clearance is correct. Some movement
of ring gear away from pinion may be necessary.

The pinion is too close to the center of the ring gear.

Remove shims to move pinion away from the ring
gear. Check that the clearance is correct. Some
movement of the ring gear toward the pinion may
be necessary.

28
1400 SRM 46 Differential Repair

Thrust Screw, Install and Adjust

NOTE: Not all differential carrier models will have a
thrust screw. Some may have a thrust block instead.
Before installing and adjusting either the thrust
screw or thrust block, install the adjusting ring
locking device as described in Step 1.

CAUTION
If the differential carrier has cotter pins, lock
the adjusting rings only with cotter pins. If the
differential carrier has dowel pins, reuse the
dowel pins or lock the adjusting rings with cot-
ter pins. Do not force a dowel pin into a cotter
pin hole.

1. Use the following procedures to install the ad-

justing ring locking device:

a. Cotter Pins - Install cotter pins between 1. COTTER PIN

lugs of the adjusting ring and through the
boss of the bearing cap. Bend two ends of the
cotter pin around the boss. See Figure 53.
b. Dowel Pins - Install dowel pins through the
boss of the bearing cap until dowel pin is be-
tween lugs of the adjusting ring. Use a drift
and hammer to install dowel pin. See Fig-
ure 53.
c. Lock Plate - Install lock plate on bearing
cap so that the tab is between lugs of the ad-
justing ring. Install two capscrews that hold
the lock plate to the bearing cap. Tighten
capscrews to 28 to 35 N•m (21 to 26 lbf ft).
See Figure 53.
2. DOWEL PIN
3. LOCK PLATE
4. THREADED HOLES FOR LOCK PLATE
Figure 53. Adjusting Ring Installation
4. For early model H6.00-7.00XL (H135-155XL)
(F006) units, the correct clearance between
the thrust screw and the ring gear is 0.635 to
0.889 mm (0.025 to 0.035 in.). For later model
H6.00-7.00XL (H135-155XL, H135-155XL 2)
(F006, G006) units, the correct clearance be-
tween the thrust screw and the ring gear is 0.65
to 1.14 mm (0.025 to 0.045 in.).
INSTALL

2. If the unit has a thrust block, tighten the ad-

justment screw. The thrust block must be tight
against the ring gear. Turn the adjustment
screw 90 degrees counterclockwise and tighten
the jam nut. The clearance between the thrust
block and ring gear will be 0.25 to 0.38 mm
(0.010 to 0.015 in.).
3. On H6.00-7.00XL (H135-155XL, H135-155XL 2)
units, install thrust screw until it seats against
ring gear. Set the clearance by turning thrust
screw counterclockwise 180 degrees. Tighten the
jam nut to the specification shown in Specifica-
tions, Table 7.
Differential Assembly Into Axle Housing,
Install
NOTE: For correct torque values for the fasteners
used in this installation, see Specifications, Table 7.
For general location of the fasteners, see Figure 55.
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Use Loctite Sealant No. 504 or silicone RTV
sealant on the flange of the differential assem-
bly housing.
2. Install the differential assembly in the axle hous-
ing. Tighten the nuts or capscrews. See Specifi-
cations, Table 7 for torque values.

29
Differential Repair
3. Do the following as required:
a. On units with air-operated disc brakes,
install mounting brackets for slack ad-
justers. Install the air chamber rod pins and
the cotter pin in the splined coupling.
b. On units with hydraulic disc brakes, in-
stall the parts of the brake as described in
the Brake section for your unit. Connect the
drive shaft and tighten the capscrews at the
yoke to 120 N•m (90 lbf ft).
c. On H7.00-12.50H (H150-257H) units, as-
semble the axle. Install the axle in the lift
truck if it was removed. Connect the drive
shaft. Use a 11 mm (0.4375 in.) spacer be-
tween the speed reducer gear and the pinion
nut. Use a new nut and tighten the nut to
1342 to 1790 N•m (990 to 1320 lbf ft) with-
out lubricant.
d. On Straddle Trucks™, install the bearing
and seal in the bearing retainer. Install the
universal joint yoke in the bearing retainer.
Install the snap ring to hold the yoke. Install
the stub shaft in the differential. Use a new
gasket and install the yoke and bearing re-
tainer. Install the capscrews for the bearing
retainer. Install the yoke capscrew. Tighten
the capscrews.
4. For H26.00-32.00C (H550-700C) and H36.00-
48.00C (H800-1050C) units with a drum
brake installed on the differential, do the
following
NOTE: Special tools (a pilot shaft, a collar, and an
installation nut) are required to install the yoke cor-
rectly. See Figure 54.
a. Apply axle lubricant on the yoke seal.
b. Check all surfaces of the yoke hub for dam-
age. If necessary, polish the yoke hub with
emery cloth or crocus cloth.
30
1400 SRM 46
c. Install the pilot shaft on the input shaft of
the differential. See Figure 54.
CAUTION
Do not use a hammer or mallet to install the
yoke onto the shaft. A hammer or mallet can
damage the yoke.
d. Slide the yoke over the pilot shaft. Align the
yoke splines with the shaft splines. Slide the
collar onto the pilot shaft and against the
yoke. See Figure 54.
CAUTION
Do not use the yoke assembly nut for the instal-
lation procedure. Use a similar nut for the pro-
cedure described in Figure 54.
e. Install the nut on the pilot shaft. Tighten the
nut against the collar until the yoke is in the
correct position on the input shaft. The nut
can require torque up to 271 N•m (200 lbf ft)
to install the yoke correctly.
CAUTION
Make sure the seal is not damaged as the yoke
passes through the seal.
f. Remove the nut, collar, and pilot shaft. In-
stall the assembly nut for the yoke on the end
of the input shaft. Tighten the assembly nut
to 1627 N•m (1200 lbf ft).
g. Install the brake drum and fasten with the
eight capscrews.
h. Attach the linkage to the brake adjuster arm.
Connect the drive shaft from the yoke flange
on the brake drum.
1400 SRM 46 Specifications

Legend for Figure 54

1. INPUT SHAFT 5. COLLAR*
2. YOKE 6. PILOT SHAFT*
3. BRAKE DRUM 7. DIFFERENTIAL
4. INSTALLATION HOUSING
NUT*

*SPECIAL TOOL

Figure 54. Yoke Installation

Specifications
Table 3. General Specifications Table 4. Rivet Installation Pressure

Item Specification Pressure for Correct Installation

Pinion Rotating Torque 0.11 to 1.70 N•m Kg/Metric mm (in.) Pounds/Tons
(0.08 to 1.3 lbf ft) Tons
Ring Gear Movement 0.20 mm (0.008 in.) 19958/20 11.11 (7/16) 44,000/22
(Clearance)
27216/27.2 12.7 (1/2) 60,000/30
Ring Gear Clearance 0.13 to 0.38 mm
32659/32.7 14.3 (9/16) 72,000/36
(0.005 to 0.015 in.)
40824/40.8 15.88 (5/8) 90,000/45

31
Specifications 1400 SRM 46

Table 5. Pinion Adjustment Table 5. Pinion Adjustment (Continued)

mm in.
mm in.
Example 1
Thickness of old shim set 0.76 0.030
Thickness of old shim set 0.76 0.030 Old pinion cone number (PC+2) 0.05 0.002
Oil pinion cone number (PC+2) 0.05 0.002
Standard thickness of shim set 0.71 0.028
Standard thickness of shim set 0.71 0.028 New pinion cone number 0.13 0.005
New pinion cone number +0.13 +0.005 (PC 5)
(PC+5)
Correct thickness for new shim 0.58 0.023
Correct thickness for new shim 0.84 0.033 set
set
Example 4
Example 2
Thickness of old shim set 0.76 0.030
Thickness of old shim set 0.76 0.030 Old pinion cone number (PC 2) +0.05 +0.002
Old pinion cone number (PC+2) 0.05 +0.002
Standard thickness of shim set 0.81 0.032
Standard thickness of shim set 0.81 0.032 New pinion cone number 0.13 0.005
New pinion cone number +0.13 +0.005 (PC 5)
(PC+5)
Correct thickness for new shim 0.68 0.027
Correct thickness for new shim 0.94 0.037 set
set
Example 3

Table 6. Pinion Preload Pressure

Pressure for Correct Preload Torque Value for Correct

Bearing Preload
Pinion Nut Kg/Metric Tons Pounds/Tons N•m lbf-ft
Thread Size
7/8" - 20 9979/10 22,000/11 271 to 373 200 to 275
1" - 20 13608/13.6 30,000/15 407 to 542 300 to 400
1-1/4" - 12 24494/24.5 54,000/27 949 to 1220 700 to 900
1-1/4" - 18 24494/24.5 54,000/27 949 to 1220 700 to 900
1-1/2" - 12 24494/24.5 54,000/27 1085 to 1491 800 to 1100
1-1/2" - 18 24494/24.5 54,000/27 1085 to 1491 800 to 1100
1-3/4" - 12 22680/22.7 50,000/25 1220 to 1627 900 to 1200
2" - 12 22680/22.7 50,000/25 1627 to 2034 1200 to 1500

NOTE: Numbered callouts in Figure 55 correspond to

item numbers in Table 7.

32
1400 SRM 46 Specifications

NOTE: SEE TABLE 7 FOR TORQUE VALUES.

Figure 55. Fasteners Location (Typical Differential Assembly)

Table 7. Torque Specifications

Item Location Size N•m* lbf ft*

No.
1 Bearing Cap Capscrews 9/16" - 12 156 to 190 115 to 140
5/8" - 11 217 to 258 160 to 190
3/4" - 10 393 to 475 290 to 350
7/8" - 14 504 to 590 372 to 435
7/8" - 9 637 to 746 470 to 550
2 Differential Case Capscrews** 3/8" - 16 41 to 68 30 to 50
7/16" - 14 81 to 102 60 to 75
1/2" - 13 122 to 163 90 to 120
1/2" - 20 142 to 183 105 to 135
5/8" - 11 251 to 319 185 to 235
5/8" - 18 285 to 366 210 to 270
3 Ring Gear to Case Capscrews 1/2" - 13 122 to 163 90 to 120
5/8" - 11 203 to 258 150 to 190
5/8" - 18 258 to 285 190 to 210
See Figure 55 for Item Nos.
*Torque values are for threads lubricated with machine oil unless Loctite is used.
**Use Loctite No. 272 on the capscrews.

33
Specifications 1400 SRM 46

Table 7. Torque Specifications (Continued)

Item Location Size N•m* lbf ft*

No.
4 Thrust Screw Jam Nut 3/4" - 16 197 to 258 145 to 190
7/8" - 14 197 to 258 145 to 190
5 Pinion Carrier to Housing Capscrews 3/8" - 16 41 to 54 30 to 40
7/16" - 14 68 to 88 50 to 65
1/2" - 13 108 to 142 80 to 105
5/8" - 11 176 to 230 130 to 170
6 Pinion Nut 7/8" - 20 271 to 373 200 to 275
1" - 20 407 to 542 300 to 400
1-1/4" - 12 949 to 1220 700 to 900
1-1/4" - 18 949 to 1220 700 to 900
1-1/2" - 12 1085 to 1492 800 to 1100
1-1/2" - 18 1085 to 1492 800 to 1100
1-3/4" - 12 1220 to 1627 900 to 1200
2" - 12 1627 to 2034 1200 to 1500
See Figure 55 for Item Nos.
*Torque values are for threads lubricated with machine oil unless Loctite is used.
**Use Loctite No. 272 on the capscrews.

Table 8. Torque Specifications for Metric Hardware

Metric Standard Threads

10.9 Capscrews/10.0 12.9 Capscrews/12.0
Thread Size 8.8 Capscrews/8.0 Nuts
Nuts Nuts
M4 3.0 N•m (2.2 lbf ft) 4.4 N•m (3.3 lbf ft) 5.1 N•m (3.8 lbf ft)
M5 5.9 N•m (4.5 lbf ft) 8.7 N•m (6.5 lbf ft) 10 N•m (7.4 lbf ft)
M6 10 N•m (7 lbf ft) 15 N•m (11 lbf ft) 18 N•m (13 lbf ft)
M8 25 N•m (18 lbf ft) 36 N•m (27 lbf ft) 43 N•m (32 lbf ft)
M10 49 N•m (35 lbf ft) 72 N•m (53 lbf ft) 84 N•m (62 lbf ft)
M12 85 N•m (65 lbf ft) 125 N•m (92 lbf ft) 145 N•m (107 lbf ft)
M14 135 N•m (100 lbf ft) 200 N•m (148 lbf ft) 235 N•m (173 lbf ft)
M16 210 N•m (155 lbf ft) 310 N•m (229 lbf ft) 365 N•m (270 lbf ft)
M18 300 N•m (221 lbf ft) 430 N•m (317 lbf ft) 500 N•m (369 lbf ft)
M20 425 N•m (314 lbf ft) 610 N•m (450 lbf ft) 710 N•m (524 lbf ft)
*Torque values are for parts lubricated with light weight oil

34
1400 SRM 46 Specifications

Table 8. Torque Specifications for Metric Hardware (Continued)

Metric Standard Threads

10.9 Capscrews/10.0 12.9 Capscrews/12.0
Thread Size 8.8 Capscrews/8.0 Nuts
Nuts Nuts
M22 580 N•m (430 lbf ft) 830 N•m (613 lbf ft) 970 N•m (716 lbf ft)
M24 730 N•m (540 lbf ft) 1050 N•m (750 lbf ft) 1220 N•m (900 lbf ft)
M27 1100 N•m (812 lbf ft) 1550 N•m (1144 lbf ft) 1800 N•m (1328 lbf ft)
M30 1450 N•m (1070 lbf ft) 2100 N•m (1550 lbf ft) 2450 N•m (1808 lbf ft)
*Torque values are for parts lubricated with light weight oil

Table 9. Torque Specifications for Metric (Fine) Hardware

Metric Fine Pitch Threads

10.9 Capscrews/10.0 12.9 Capscrews/12.0
Thread Size 8.8 Capscrews/8.0 Nuts
Nuts Nuts
M8 × 1 27 N•m (20 lbf ft) 39 N•m (29 lbf ft) 46 N•m (34 lbf ft)
M10 × 1 55 N•m (41 lbf ft) 81 N•m (60 lbf ft) 95 N•m (70 lbf ft)
M10 × 1.25 52 N•m (38 lbf ft) 76 N•m (56 lbf ft) 90 N•m (66 lbf ft)
M12 × 1.25 93 N•m (69 lbf ft) 135 N•m (100 lbf ft) 160 N•m (118 lbf ft)
M12 × 1.5 89 N•m (66 lbf ft) 130 N•m (96 lbf ft) 155 N•m (114 lbf ft)
M14 × 1.5 145 N•m (107 lbf ft) 215 N•m (159 lbf ft) 255 N•m (188 lbf ft)
M16 × 1.5 225 N•m (166 lbf ft) 330 N•m (244 lbf ft) 390 N•m (288 lbf ft)
M18 × 1.5 340 N•m (251 lbf ft) 485 N•m (358 lbf ft) 570 N•m (421 lbf ft)
M20 × 1.5 475 N•m (351 lbf ft) 680 N•m (502 lbf ft) 790 N•m (583 lbf ft)
M22 × 1.5 650 N•m (480 lbf ft) 920 N•m (679 lbf ft) 1050 N•m (775 lbf ft)
* Torque values are for parts lubricated with light weight oil

35
Troubleshooting 1400 SRM 46

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

The lift truck will not move. Ring and pinion gears are damaged. Repair the damaged gears.

Axle shaft(s) is damaged. Replace axle shaft(s).

The differential makes noise. The gears or shafts in the differential Repair the damaged gears.
are damaged.

There is no oil in the axle housing. Fill the axle with the correct oil.

Parts of the brake assembly are dam- Repair the parts of the brakes.
aged.

The mounting bolts for the differen- Tighten the capscrews.

tial housing are loose.

The ring and pinion are not adjusted Check and adjust the gears.
correctly.

The nut for the input yoke is loose. Tighten the nut.

The thrust screw is not adjusted cor- Adjust and tighten the screw and jam
rectly. nut.

The differential has leaks. There is no sealant between the dif- Assemble the parts with the correct
ferential and drive axle housing. sealant.

There are capscrews missing from Install the missing capscrews.

the differential assembly.

There are plug(s) missing from the Install the missing plug(s).
differential housing.

The seal for the yoke is damaged. Install a new seal.

36
 TECHNICAL PUBLICATIONS

1400 SRM 46 7/07 (3/07)(12/06)(7/06)(5/06)(8/05)(3/05)(8/04)(4/04)(11/03)(10/03)(2/01) Printed in U.S.A.