YALE GDP40VX Drive Axle Dry Brake

Maintenance
DRIVE AXLE AND

DIFFERENTIAL
ASSEMBLY REPAIR
(DRY BRAKE)
GLC40, 45, 55VX; GLC55SVX (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) [E818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) [F813, G813, H813]
PART NO. 524262277 1400 YRM 1245

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 Maintenance 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 YALE 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 hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Drive Axle and Differential Assembly Repair Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Drive Axle Repair................................................................................................................................................. 1
Remove and Disassemble .............................................................................................................................. 1
Clean and Inspect ........................................................................................................................................... 4
Assemble and Install ....................................................................................................................................... 4
Differential Repair................................................................................................................................................ 6
Remove ........................................................................................................................................................... 6
Support Differential Assembly From Differential Housing Assembly .......................................................... 6
Differential Assembly From Differential Assembly Support......................................................................... 8
Differential Assembly Support from Drop Box ............................................................................................ 11
Drive Pinion and Pinion Gear, From Differential Assembly Support ........................................................... 13
Disassemble.................................................................................................................................................... 14
Differential Assembly .................................................................................................................................. 14
Drop Box Housing....................................................................................................................................... 16
Differential Assembly Support..................................................................................................................... 17
Differential Housing..................................................................................................................................... 18
Clean and Inspect ........................................................................................................................................... 19
Assemble ........................................................................................................................................................ 19
Differential Housing..................................................................................................................................... 19
Differential Assembly Support..................................................................................................................... 20
Drop Box Housing....................................................................................................................................... 21
Differential Assembly .................................................................................................................................. 22
Install............................................................................................................................................................... 26
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) ........................................................................ 26
Drive Pinion and Pinion Gear Into Differential Assembly Support .............................................................. 28
Differential Assembly Into Differential Assembly Support ........................................................................... 30
Ring Gear Backlash, Adjust ........................................................................................................................ 33
Gear Set, Tooth Contact Pattern Check...................................................................................................... 34
Differential Assembly Support Into Differential Housing ............................................................................. 37
Torque Specifications .......................................................................................................................................... 38
This section is for the following models:
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,

100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813]
©2012 Yale Materials Handling Corp. i

1400 YRM 1245 Drive Axle Repair
General
This section has the repair procedures for the drive axle and differential assembly.
Drive Axle Repair

REMOVE AND DISASSEMBLE 15. Place blocks under the differential assembly.
16. Remove the axle shafts, hub/brake drum assembly,

WARNING and back plates. Refer to the section Brake Sys-
When putting the lift truck on blocks, make sure the tem 1800 YRM 1247.
surface is solid, even, and level. Any blocks used to
support the lift truck must be solid, one-piece units. 17. Remove the capscrews and washers retaining the
hanger assembly to the internal gear and differen-
1. Put blocks on each side (front and back) of the tial housing.
steering tires to prevent movement of the lift truck.
18. Remove the planetary gear assembly from the dif-
2. Raise the lift truck and put blocks under the frame ferential housing.
so that the drive wheels do not touch the floor. Put
blocks under the counterweight for stability. 19. Remove the internal gear from the differential hous-
ing.
3. Remove the mast assembly as described in the
section Mast Repairs, 2- and 3-Stage Masts 4000 20. Remove the sun gear from the differential housing.
YRM 1250.
21. Remove the outer snap ring retaining the ball bear-
4. Remove the fill plug and O-ring. Discard O-ring. ing. See Figure 3.
5. Remove the drain plug and O-ring to drain the oil

from the drive axle into a suitable container. Dis-
card O-ring. See Figure 1.
6. Remove the wheels.
7. Disconnect the brake line connecting the master

cylinder to the brake manifold located on top of the
differential housing assembly.
8. Remove the parking brake cable. Refer to the sec-

tion Brake System 1800 YRM 1247.
9. Place blocks under the axle assembly and connect

slings and lifting device.
10. Place blocks under the transmission to support the

transmission while removing the drive axle.
11. Remove the capscrews retaining the drive shaft and

remove the drive shaft.
12. Remove the transmission isolator mounting bolt lo-

cated on top of the assembly. See Figure 7. 1. DIFFERENTIAL HOUSING ASSEMBLY
2. O-RING
3. OIL FILL PLUG
13. Remove the four mounting capscrews from the 4. OIL DRAIN PLUG
drive axle. See Figure 2. 5. O-RING
14. Remove blocks and lower the drive axle assembly. Figure 1. Drain Plug
Pull axle forward and away from frame.
1
Drive Axle Repair 1400 YRM 1245
Figure 2. Drive Axle
2
Legend for Figure 2

1. BRAKE MANIFOLD 14. CAPSCREW
2. INPUT SHAFT (YOKE) 15. CAPSCREW
3. OUTER SEAL 16. BRAKE ASSEMBLY
4. BEARING CONE 17. BRAKE LINE
5. BEARING CUP 18. CAPSCREW
6. INNER SEAL 19. WASHER
7. HUB/BRAKE DRUM ASSEMBLY 20. CAPSCREW
8. BEARING CUP 21. WASHER
9. BEARING CONE 22. HANGER ASSEMBLY
10. WHEEL BEARING WASHER 23. INTERNAL GEAR
11. LOCK PLATE 24. PLANETARY GEAR ASSEMBLY
12. LOCK NUT 25. SUN GEAR
13. AXLE SHAFT 26. DIFFERENTIAL HOUSING ASSEMBLY
1. PLANETARY GEAR ASSEMBLY

2. INNER SNAP RING
3. BALL BEARING
4. OUTER SNAP RING
1. PLANETARY GEAR ASSEMBLY
Figure 3. Planetary Gear Disassembly/Assembly 2. PIN
3. THRUST WASHER
22. Remove ball bearing. 4. SPACER
5. NEEDLE BEARINGS (QTY 48)
23. Remove inner snap ring. 6. PLANETARY GEAR
Figure 4. Planetary Gear and Needle Bearings

CAUTION
When removing the planetary gear, ensure that the 26. Remove the 48 needle bearings (24 on each side
needle bearings are not lost. Losing any needle of spacer) and spacer from the planetary gear. Re-
bearing could result in damage to the equipment. peat this step on the remainder planetary gears.
24. Remove pin retaining the thrust washer, planetary 27. Remove the thrust washer from the inside of plan-
gear, spacer, and needle bearings. See Figure 4. etary gear assembly. Repeat Step 19 through
Step 27 for the opposite side. See Figure 5.
25. Remove planetary gear, thrust washers, and nee-
dle bearings from housing.
3
Drive Axle Repair 1400 YRM 1245
ASSEMBLE AND INSTALL

1. Install thrust washer inside the planetary gear as-
sembly.
2. Apply a light coat of grease on the inside of the plan-

etary gear and slowly install 24 needle bearings on
each side of the spacer into planetary gear to be
flush with the gear face.
NOTE: Spacer should split the needle bearings into two

separate sections for one planetary gear assembly.
3. Apply a light coat of grease on thrust washer and

install the thrust washer on the ends of the plane-
tary gear.
4. Install the thrust washers, planetary gear, and nee-

1. PLANETARY GEAR ASSEMBLY dle bearings as an assembly into the planetary gear
2. THRUST WASHER assembly.
Figure 5. Planetary Gear Assembly and Thrust 5. Ensure flat surface of the pin is toward the center
Washer of the carrier and install pin in alignment with the
planetary gear. Repeat Step 2 through Step 5 for
CLEAN AND INSPECT remainder planetary gears.
WARNING 6. Install inner snap ring to retain pins.

Cleaning solvents can be flammable and toxic and
7. Install ball bearing.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s 8. Install outer snap ring to retain the ball bearing.
recommended safety precautions.
9. Install the sun gear in the differential housing. Re-
1. Clean all the parts of the drive axle with solvent. peat steps Step 1 through Step 9 for the opposite
side.
2. Inspect the planetary gears, spacers, needle bear-
ings, and thrust washers for damage. If planetary 10. Apply RTV High Performance sealant, Yale Part No.
gears, spacers, needle bearings, or thrust washers 580057351 or equivalent, to the mating surface of
show signs of wear or damage, replace the compo- the internal gear. Install the internal gear on the
nents as needed. differential housing.
3. Inspect the internal gears for wear and damage. 11. Install planetary gear assembly into the differential
Replace as needed. Clean silicone from mating housing assembly.
surfaces.
12. Place the hanger assembly in position on the dif-
4. Inspect the sun gear for wear or damage. If the sun ferential housing assembly. Apply Loctite® 242 to
gears show signs of wear or damage, replace the the capscrews and install capscrews and lockwash-
sun gear. The splines of the sun gears must not be ers to retain differential housing assembly. Tighten
damaged. capscrews in sequence shown in Figure 6 to 225 to
248 N•m (166 to 183 lbf ft). Repeat steps Step 10
5. Inspect the axle shafts for wear and cracks at the
through Step 12 for the opposite side.
flange, shaft, and splines. If axle shafts show signs
of wear or damage, replace the axle shafts. The
splines for the axle shafts must not be damaged.
4
Figure 6. Hanger Assembly Tightening Sequence
NOTE: Apply Loctite® 515 or High Performance RTV

Silicone Gasket Maker on the axle shaft flange when 1. TRANSMISSION
installing. 2. DIFFERENTIAL HOUSING ASSEMBLY
3. ISOLATOR, TRANSMISSION
13. Install the back plates, hub/brake drum assemblies, 4. WASHER
and axle shafts. Refer to the section Brake System 5. LOCKWASHER
1800 YRM 1247. 6. CAPSCREW
14. Connect slings and lifting device to drive axle. Figure 7. Transmission to Differential Housing
Assembly Mounting Bolts
NOTE: When installing the drive axle, ensure the drive
axle is held with the upper surface of the drive axle 19. Remove blocks from under the transmission.
against the frame. This will prevent any gap between
20. Install parking brake cable. Make sure the brake ca-
the frame and the drive axle mount, and will ensure
ble is routed properly and has no interference. Ver-
even weight distribution.
ify that the parking brake operates properly. Refer
15. Position the drive axle in the lift truck. to the section Brake System 1800 YRM 1247.
NOTE: It is recommended to use a torque multiplier to 21. Connect the brake line connecting the master cylin-
achieve the torque specification in Step 16. der to the brake manifold located on top of the dif-
ferential housing assembly.
16. Install the four mounting capscrews and washers.
Tighten the capscrews to 820 to 902 N•m (605 to NOTE: When tightening the wheel nuts, DO NOT use
665 lbf ft). any lubricant on the studs or nuts.
17. Place the drive shaft in position and install the re- 22. Install the wheel and nuts and tighten the nuts to
taining capscrews. Tighten the drive shaft cap- 610 to 680 N•m (450 to 502 lbf ft).
screws to 50 to 66 N•m (37 to 49 lbf ft).
23. Apply multipurpose grease to new O-ring and install
18. Install the transmission isolator mounting bolt lo- O-ring on the drain plug.
cated on top of the assembly. Tighten the bolt to
24. Install the O-ring and drain plug, and tighten to 14
225 to 250 N•m (166 to 184 lbf ft). See Figure 7.
to 27 N•m (10 to 20 lbf ft).
5
Differential Repair 1400 YRM 1245
25. Fill the drive axle to the proper level with 7.5 to
8.0 liter (7.9 to 8.4 qt) of SAE 80W-90 gear oil
through the fill hole as shown in Figure 8.
26. Apply multipurpose grease to new O-ring and install

O-ring on the fill plug.
27. Install the O-ring, fill plug, and tighten to 14 to

27 N•m (10 to 27 lbf ft).
28. Remove the air from the brake system as described

in the section Brake System 1800 YRM 1247.
29. Install the mast assembly as described in the sec-

tion Mast Repairs, 2- and 3-Stage Masts 4000
YRM 1250.
1. OIL FILL PLUG
30. Raise the lift truck and remove blocks from under 2. OIL DRAIN PLUG
frame and from under the counterweight. Lower the 3. OIL FILL LEVEL
lift truck.
Figure 8. Oil Fill Level
31. Remove the blocks on each side (front and back) of
the steering tires.
32. Operate the lift truck and check for proper operation
and leaks.
Differential Repair
REMOVE 5. Remove brake manifold bracket.
For the following repair procedures, the drive axle must 6. Remove capscrews and lockwashers retaining
be removed and disassembled. Refer to the section the differential assembly support to the differential
Drive Axle Repair. housing.
Support Differential Assembly From Using two of the M8 × 1.25 × 40 capscrews re-
Differential Housing Assembly moved from the differential assembly support, push
the differential assembly support from the differen-
1. Remove input shaft (yoke). tial housing. If the capscrews do not have enough
threaded length, use a pry bar to finish removing
2. Remove the dust cover. the differential assembly support.
3. Remove the oil seal. See Figure 9. 7. Remove differential assembly support from the dif-
ferential housing assembly. See Figure 10.
4. Remove capscrew and lockwasher retaining brake
manifold bracket to the differential assembly sup-
port. See Figure 10.
6
1400 YRM 1245 Differential Repair
1. DIFFERENTIAL HOUSING ASSEMBLY

2. OIL SEAL 1. DIFFERENTIAL HOUSING
3. DUST COVER 2. DIFFERENTIAL ASSEMBLY SUPPORT
4. INPUT SHAFT (YOKE) 3. BRAKE MANIFOLD BRACKET
4. LOCKWASHERS
Figure 9. Drive Axle Yoke 5. CAPSCREWS
6. CAPSCREW
7. LOCKWASHER
Figure 10. Differential Housing Assembly Section

Disassembly
7
Differential Assembly From Differential Assembly Support

NOTE: Before working on the differential assembly, inspect the hypoid gear set for damage. If inspection shows no
damage, the same gear set can be used again. Using a dial indicator, measure the backlash of the gear set and
make a record of the dimension.
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced, go
to STEP 1. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced in a lift
truck manufactured prior to October 2006, go to STEP 2.
STEP 1.
Remove differential assembly retainer ring cotter pins.
Using a retainer ring special tool, Yale P/N 580055253,
loosen the retainer rings. If necessary, loosen the
bearing cap capscrews to allow the retainer rings to
turn freely.
1. COTTER PIN
2. RETAINER RING
1. RETAINER RING SPECIAL TOOL
8
STEP 2.
Remove differential assembly retainer ring cotter pins.
loosen the retainer rings. If necessary, loosen the
bearing cap capscrews to allow the retainer rings to
turn freely.
1. COTTER PIN
2. RETAINER RING
9
STEP 3.
Remove the retainer rings.
1. DIFFERENTIAL ASSEMBLY SUPPORT

2. RETAINER RINGS
STEP 4.
Mark one differential carrier leg and bearing cap to cor-
rectly match the parts when assembling differential as-
sembly support. Mark the part using a center punch
and hammer. Remove the capscrews and washers re-
taining the bearing caps. Remove the bearing caps.

2. BEARINGS
3. BEARING CAPS
4. WASHERS
5. CAPSCREWS
10
STEP 5.
Remove the differential assembly from the differential
assembly support.

2. TAPERED ROLLER BEARING AND CUP
3. DIFFERENTIAL ASSEMBLY
Differential Assembly Support from Drop Box

STEP 1.
Remove the capscrews and lockwashers retaining the
pinion cover plate.
Remove pinion cover plate.

2. PINION COVER PLATE
3. CAPSCREWS
4. LOCKWASHERS
5. DROP BOX ASSEMBLY
11
CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The staked
areas can cause damage to the pinion threads, making the pinion unserviceable.
NOTE: When removing the pinion, be sure to retain the shims.
STEP 2.
Use a small, flat chisel to unstake the pinion nut.
Remove the pinion nut, washer, bearing cone, and

shims.

2. SHIMS
3. BEARING CONE
4. WASHER
5. PINION NUT
STEP 3.
Remove the capscrews, washers, and clamp retaining
the drop box housing.
Using two of the M8 × 1.25 × 50 capscrews removed

from the drop box housing, push the drop box housing
from the differential assembly support. If the capscrews
do not have enough threaded length, use a pry bar to
finish removing the drop box housing.

2. DROP BOX HOUSING
3. CLAMP
4. LOCKWASHERS
5. CAPSCREWS
12
Drive Pinion and Pinion Gear, From Differential Assembly Support

NOTE: When removing the pinion, be sure to retain the shims.
STEP 1.
Carefully remove pinion assembly from the differential
assembly support. Using a press and a bearing puller,
remove the shims and inner bearing from the pinion.

2. INNER BEARING
3. SHIMS
4. PINION
STEP 2.
Remove drive gear and driven gear.

2. DRIVE GEAR
3. DRIVEN GEAR
13
DISASSEMBLE
Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable bearing
puller, remove the bearings from the differential assem-
bly.
1. BEARING CUP
2. TAPERED ROLLER BEARING
STEP 2.
Remove the capscrews retaining the ring gear to the dif-
ferential assembly. Remove the ring gear.
1. RING GEAR
3. CAPSCREW
14
NOTE: Mark each side of the case halves before separating to ensure alignment at reassembly.
STEP 3.
Remove the capscrews retaining the case halves to-
gether and separate the case halves.
Inspect the case halves for wear or damage. If wear

or damage is present, the entire differential assembly
must be replaced.
1. CAPSCREWS
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF
STEP 4.
Remove the side gears and thrust washers from the
case halves.
1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF
15
STEP 5.
Remove the spherical washers and spider gears from
the cross.
Inspect the spider gears for wear or damage. Replace

as needed.
1. SPHERICAL WASHER
2. SPIDER GEAR
3. CROSS
Drop Box Housing

STEP 1.
Using a bearing puller, remove outer bearing from the
drop box housing.
1. OUTER BEARING
2. DROP BOX HOUSING
16
STEP 2.
Using a suitable soft drift, remove the bearing cup.
1. DROP BOX HOUSING

2. BEARING CUP
Differential Assembly Support

STEP 1.
Using a suitable soft drift, remove the bearing cup from
the differential assembly support.

2. BEARING CUP
17
STEP 2.
Using a bearing puller, remove inner bearing from the
differential assembly support.

2. INNER BEARING
Differential Housing
NOTE: Only remove the breather cap if damaged.
STEP 1.
Remove breather cap from differential housing.
1. DIFFERENTIAL HOUSING
2. BREATHER CAP
18
CLEAN AND INSPECT • Tapered roller bearings- Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
WARNING assembly. If bearings show signs of wear, cracks, or
damage, replace with new bearing.
Cleaning solvents can be flammable and toxic and
• Pinion and gears- Inspect the pinion and gears for
can cause skin irritation. When using cleaning sol-
wear or damage. Gears that are worn or damaged
vents, always follow the recommendations of the
must be replaced.
manufacturer.
• Main differential assembly- Inspect all parts of the
main differential assembly for corrosion, wear, or
WARNING damage. Parts that are damaged must be replaced.
Compressed air can move particles so that they • Differential Assembly Support- Inspect all parts of
cause injury to the user or to other personnel. the differential assembly support for corrosion, wear,
Make sure that the path of the compressed air is or damage. Parts that are damaged must be re-
away from all personnel. Wear protective goggles placed.
or a face shield to prevent injury to the eyes. • Drop box housing- Inspect all parts of the drop box
housing for corrosion, wear, or damage. Parts that
Clean and inspect the following parts of the differential: are damaged must be replaced.
• Drive axle- Clean the parts of the axle with solvent • Alignment pins- Inspect all alignment pins for corro-
and dry with compressed air. Inspect all machined sion, wear, or damage. Parts that are damaged must
surfaces and bearings for wear and damage. be replaced.
ASSEMBLE
Differential Housing
STEP 1.
Wrap the breather cap threads with approximately 1.5
turns of Teflon tape. Install the breather cap.
2. BREATHER CAP
19
Differential Assembly Support

STEP 1.
Using a press, press the outer race of the inner bearing
into the differential assembly support until it is contact-
ing the bottom of the bore.

2. INNER BEARING
STEP 2.
Using a press, press the pinion inner bearing cup into

2. BEARING CUP
20
Drop Box Housing

STEP 1.
Using a press, press the outer race of the outer bearing
into the drop box housing until it is contacting the bot-
tom of the bore.
1. OUTER BEARING
2. DROP BOX HOUSING
STEP 2.
Using a press, press the inner cup until it seats on the
bottom of the bore.
1. DROP BOX HOUSING

2. INNER CUP
21
Differential Assembly
STEP 1.
Lubricate both sides of the spherical washers with 80W
- 90 gear lube. Install the spider gears and spherical
washers onto the cross.
1. SPHERICAL WASHER
2. SPIDER GEAR
3. CROSS
STEP 2.
Lubricate both sides of the thrust washers with 80W -
90 gear lube. Install the side gears and thrust washers
into the differential halves.
1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF
22
STEP 3.
Place spider assembly into the case halves and assem-
ble the case halves. Apply Loctite® 242 to the threads
of the capscrews and install the capscrews. Tighten the
capscrews in the sequence shown to 125 to 145 N•m
(92 to 107 lbf ft).
1. CAPSCREWS
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF
23
STEP 4.
Place the ring gear in position on the differential assem-
bly and install the capscrews. Tighten the capscrews
in the sequence shown to 152 to 167 N•m (112 to
123 lbf ft).
1. RING GEAR
3. CAPSCREW
24
CAUTION
Do not damage the bearing rollers or cage when pressing the bearing cones onto the differential assembly.
Press on the inner raceway of the cone.
STEP 5.
Press the bearing cones onto the differential assembly.
Install the bearing cups onto the bearing cones.
1. BEARING CUP
2. TAPERED ROLLER BEARING
25
INSTALL The correct shim set thickness can be found by using

the original and new parts. Use the original shim set
Pinion Inner Shim Set, Adjust Thickness thickness and the pinion variation number on the orig-
(Depth of Pinion) inal and new pinion. For the location and identification
of the number, see Figure 12.
NOTE: Use this procedure if a new ring gear and pinion
set is installed, or if the depth of the pinion has to be
adjusted.
NOTE: If replacing the center section, use a new

standard shim set with nominal thickness of 1 mm for
adjusting the depth of the pinion and a new standard
shim set with nominal thickness of 1 mm for adjusting
the preload. Perform the following procedure until
the correct backlash and gear tooth contact pattern is
achieved. 1. PINION VARIATION NUMBER
The pinion is adjusted using shims. If the same bear- Figure 12. Pinion Variation Number
ings, ring gear, and pinion are used, use the original
shim set. See Figure 11. If a new bearings, ring gear, Find the correct thickness of the mounting distance (in-
and pinion are used, adjust the pinion as described be- ner) shim set as follows:
low.
1. Use a micrometer to measure the thickness of each
individual shim of the original shim set that was re-
moved from under the pinion carrier. Add the indi-
vidual thickness together for total thickness. Make
a note of the measurement for later use.
2. Check the pinion variation number for the original

pinion. See Figure 12. If this number is a plus
(+) value, subtract the value from the value in step
Step 1. If the pinion variation number is a minus ( )
value, add the number to the value in Step 1. The
number shown is in 0.00 × inch (+2 = +0.002 in.).
The result is the standard thickness for a shim set.
NOTE: The value calculated in Step 2 is the thickness

of the standard shim set, without a variation.
3. Check the pinion variation number for the new pin-

ion. Add or subtract this number to the standard
thickness value of Step 2. 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
1. PINION NUT in Table 1.
2. WASHER
3. BEARING, TAIL NOTE: The value calculated in Step 3 is the thickness
4. OUTER SHIM SET (CONTROLS BEARING
PRELOAD) of the new shim set that will be installed. See the ex-
5. GEAR amples shown in Table 1.
6. BEARING, HEAD
7. INNER SHIM SET (CONTROLS DEPTH OF
PINION)
Figure 11. Shim Set Location
26
Table 1. Pinion Variation Numbers Examples
Examples in. mm
NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 12.
1. Original Shim Set Thickness 0.030 0.76
Original Pinion Variation Number = +2 in. (+0.05 mm) 0.002 0.05
Standard Shim Set Thickness 0.028 0.71
New Pinion Variation Number = +5 in. (+0.13 mm) +0.005 +0.13
New Shim Set Thickness = 0.033 0.84
Original Pinion Variation Number = 2 in. ( 0.05 mm) +0.002 +0.05
New Pinion Variation Number = +5 in. (+0.13 mm) +0.005 +0.13
Original Pinion Variation Number = +2 in. (+0.05 mm) 0.002 0.05
New Pinion Variation Number = 5 in. ( 0.13 mm) 0.005 0.13
Original Pinion Variation Number = 2 in. ( 0.05 mm) +0.002 +0.05
New Pinion Variation Number = 5 in. ( 0.13 mm) 0.005 0.13
27
Drive Pinion and Pinion Gear Into Differential Assembly Support

STEP 1.
Install the drive gear and driven gear.

2. DRIVE GEAR
3. DRIVEN GEAR
STEP 2.
Install mounting distance (inner) shims, determined in
Pinion Inner Shim Set, Adjust Thickness (Depth of Pin-
ion), onto the pinion.
NOTE: Ensure the bearing being installed is lubricated

with SAE 80W-90 gear oil.
Using a press, press the inner bearing onto the pinion

and carefully install the pinion assembly into the differ-
ential assembly support.

2. INNER BEARING
3. SHIMS
4. PINION
28
STEP 3.
Apply Loctite 515 sealant to the mating surface of the
drop box housing.
Place the drop box housing in position on the differen-

tial assembly support. Install the clamp, washers, and
capscrews. Tighten capscrews to 19 to 23 N•m (14 to
17 lbf ft).

2. DROP BOX
3. CLAMP
4. WASHERS
5. CAPSCREWS
NOTE: Ensure the bearing being installed is lubricated with SAE 80W-90 gear oil.
STEP 4.
Install the preload (outer) shims and outer bearing. In-
stall the washer and new pinion nut.
Tighten the pinion nut to 530 to 645 N•m (391 to

476 lbf ft) to seat the bearings. Rotate the pinion two
revolutions in both directions. Loosen the pinion nut
and retighten to 370 to 410 N•m (273 to 302 lbf ft) for
the pre-load. Rotate the pinion ten revolutions in both
directions. Verify pinion shaft rotating torque is 4.0 to
6.0 N•m (44.2 to 53.1 lbf in). Add or remove preload
(outer) shims as necessary to obtain the correct rotat-
ing torque.

2. SHIMS
3. BEARING
4. WASHER
5. PINION NUT
29
Differential Assembly Into Differential Assembly Support

STEP 1.
Place the differential assembly into the differential as-
sembly support.

2. TAPERED ROLLER BEARING AND CUP
STEP 2.
Place the retainer rings in position in the differential as-
sembly support. Carefully place the bearing caps in the
same location as removed.
Install the capscrews and washers. Tighten capscrews

finger tight. Verify the retainer rings rotate easily and
are not cross threaded.
Tighten the bearing cap capscrews to 225 to 270 N•m

(166 to 199 lbf ft).

2. RETAINER RING
3. BEARING
4. BEARING CAP
5. WASHER
6. CAPSCREWS
30
NOTE: If the lift truck was manufactured prior to October 2006 and the retaining rings have not been replaced, go
to STEP 3. If the lift truck was manufactured after October 2006 or the retaining rings have been replaced in a lift
truck manufactured prior to October 2006, go to STEP 4.
STEP 3.
adjust the retainer rings in equal rotations so the back-
lash of the ring gear is 0.15 to 0.20 mm (0.006 to
0.008 in.). See Ring Gear Backlash, Adjust.
Tighten each retainer ring one to two notches past the

point where the retainer makes contact with the bearing
cup.
Recheck the backlash.
Verify that the rotating torque at the pinion shaft has in-
creased 0.5 to 0.7 N•m (4.4 to 6.2 lbf in). Check the
pinion and ring gear tooth contact pattern. See Gear
Set, Tooth Contact Pattern Check.
Install differential assembly retainer ring cotter pins and

bend tabs over.
1. COTTER PIN
2. RETAINER RING
31
STEP 4.
adjust the retainer rings in equal rotations so the back-
lash of the ring gear is 0.20 to 0.28 mm (0.008 to
0.011 in.). See Ring Gear Backlash, Adjust.
Tighten each retainer ring one to two notches past the

point where the retainer makes contact with the bearing
cup.
Tighten the bearing cap capscrews to 225 to 270 N•m

(166 to 199 lbf ft). Recheck the backlash.
Verify that the rotating torque at the pinion shaft has in-
creased 0.5 to 0.7 N•m (4.4 to 6.2 lbf in). check the
pinion and ring gear tooth contact pattern. See Gear
Set, Tooth Contact Pattern Check.
Install differential assembly retainer ring cotter pins.
1. COTTER PIN
2. RETAINER RING
STEP 5.
Stake the pinion nut with 8 mm spherical punch until a 1 to 2 mm (0.039 to 0.079 in.) gap is between the nut and
pinion shaft at two places. Retighten the drop box capscrews to 19 to 23 N•m (14 to 17 lbf ft).
32
STEP 6.
Apply RTV High Performance sealant, Yale P/N
580057351 or equivalent, to the mating surface of
the pinion cover plate.
Place the pinion cover plate in position on the drop box

and install the washers and capscrews. Tighten the
capscrews to 19 to 23 N•m (14 to 17 lbf ft).

2. PINION COVER PLATE
3. CAPSCREWS
4. WASHERS
5. DROP BOX
Ring Gear Backlash, Adjust 7. If the backlash reading is not within specifications,
adjust backlash using retainer rings. Continue onto
If the old gear set is installed, adjust the backlash to Step 8 through Step 11.
the setting that was measured before the differential as-
sembly was disassembled. 8. Verify that the bearing cap capscrews are only fin-
ger tight.
If a new gear set will be installed, adjust the backlash
to 0.15 to 0.20 mm (0.006 to 0.008 in.).
To adjust/check the backlash, follow the steps outlined

below:
1. Install a dial indicator on the mounting flange of the

differential as shown in Figure 13.
2. Adjust the dial indicator so that the plunger or

pointer is against the tooth surface. See Figure 13.
3. Adjust the indicator to zero.
4. Hold the drive pinion in position.
5. After reading the dial indicator, rotate the ring gear

in both directions, against the drive pinion teeth until
it contacts the pinion.
Measure 3 to 5 places for correct specification.
6. If the backlash reading is within specifications, 0.15

to 0.20 mm (0.006 to 0.008 in.), continue checking
tooth contact patterns. Figure 13. Gear Clearance Check
33
NOTE: To increase backlash, move ring gear away from

drive pinion. To decrease backlash, move ring gear to-
ward drive pinion.
NOTE: When adjusting backlash, move the ring gear

only. Do not move the drive pinion.
9. Loosen one bearing adjusting ring one notch, then

tighten the opposite ring the same amount. See
Figure 14 and Figure 15.
10. Tighten the bearing cap capscrews to 225 to

270 N•m (166 to 199 lbf ft). Recheck the backlash.
11. Repeat Step 2 through Step 10 until backlash is

within 0.15 to 0.20 mm (0.006 to 0.008 in.).
1. LOOSEN RETAINER RING THIS SIDE

2. DECREASE BACKLASH
3. TIGHTEN RETAINER RING THIS SIDE
Figure 15. Backlash Decrease
12. Check the tooth contact pattern. See Gear Set,

Tooth Contact Pattern Check.
Gear Set, Tooth Contact Pattern Check

NOTE: The gear clearance can be changed within the
limits of 0.15 to 0.20 mm (0.006 to 0.008 in.).
NOTE: If the original gear set is installed, adjust the

clearance to the original value recorded in Differential
Assembly From Differential Assembly Support. If a new
1. TIGHTEN RETAINER RING THIS SIDE gear set is installed, adjust the retainer rings for 0.15 to
2. INCREASE BACKLASH 0.20 mm (0.006 to 0.008 in.) clearance. Refer to Ring
3. LOOSEN RETAINER RING THIS SIDE and Pinion Tooth Contact Adjustment.
Figure 14. Backlash Increase
34
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.
See Table 3 and Table 4. Make sure that the pattern
is checked on the side of the tooth where the pinion
applies the force in the forward direction.
Table 3. Correct Tooth Contact
The contact area is the center between the top and NOTE: Normal pattern during adjustment shown.
bottom of the tooth. The contact area is toward the
inner circumference of the ring gear.
The contact area is the center between the top and the NOTE: Wear pattern from operation shown.
bottom of the tooth. The contact area will be almost
the full length of the tooth.
35
Table 4. 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.
36
Differential Assembly Support Into Differential Housing

STEP 1.
Apply RTV High Performance sealant, Yale P/N
580057351 or equivalent, to the mating surface of
Place the differential assembly support in position on

the differential housing. Install the capscrews, wash-
ers, and brake manifold bracket. Tighten capscrews to
66 to 79 N•m (49 to 58 lbf ft).
3. BRAKE MANIFOLD BRACKET
4. WASHERS
5. CAPSCREWS
6. CAPSCREWS
7. WASHERS
STEP 2.
Using a press on the outer diameter of the input shaft
oil seal, press the input shaft oil seal into the drop box
until the seal is flush with the housing. After installing
the oil seal, apply grease to the lip of the oil seal.
Install the input shaft (yoke).
1. DIFFERENTIAL HOUSING ASSEMBLY

2. OIL SEAL
3. DUST COVER
4. INPUT SHAFT (YOKE)
Assemble and install the drive axle. Refer to the section

Drive Axle Repair.
37
Torque Specifications 1400 YRM 1245
Torque Specifications
Axle Shaft Capscrews Drop Box Housing Capscrews
90 to 99 N•m (66 to 73 lbf ft) 19 to 23 N•m (14 to 17 lbf ft)
Bearing Cap Capscrews Hanger Assembly to Differential Housing

Brake Assembly to Axle Mount Capscrews Hanger Assembly to Frame

Brake Manifold to Differential Housing Capscrews Pinion Cover Capscrews

Differential Assembly Support to Differ- Pinion Gear Capscrews

ential Housing 152 to 167 N•m (112 to 123 lbf ft)
66 to 79 N•m (49 to 58 lbf ft)
Pinion Nut, for Pre-Load
Differential Carrier Halves Capscrews 370 to 410 N•m (273 to 302 lbf ft)
125 to 145 N•m (92 to 107 lbf ft)
Pinion Nut, to Seat Bearings
Differential Drain Plug 530 to 645 N•m (391 to 476 lbf ft)
50 to 55 N•m (37 to 41 lbf ft)
Transmission Mount Bolt to Differential Housing
Differential Fill Plug 225 to 250 N•m (166 to 184 lbf ft)
151 to 166 N•m (111 to 122 lbf ft)
Wheel Nuts
Drive Shaft Capscrews 610 to 680 N•m (450 to 502 lbf ft)
50 to 66 N•m (37 to 49 lbf ft)
38
Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom
1400 YRM 1245 1/12 (11/08)(7/08)(3/07)(6/06)(3/06) Printed in the United Kingdom

YALE GDP40VX Drive Axle Dry Brake

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Maintenance

DRIVE AXLE AND

PART NO. 524262277 1400 YRM 1245

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

This section is for the following models:

GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,

©2012 Yale Materials Handling Corp. i

Drive Axle Repair

16. Remove the axle shafts, hub/brake drum assembly,

5. Remove the drain plug and O-ring to drain the oil

6. Remove the wheels.

7. Disconnect the brake line connecting the master

8. Remove the parking brake cable. Refer to the sec-

9. Place blocks under the axle assembly and connect

10. Place blocks under the transmission to support the

11. Remove the capscrews retaining the drive shaft and

12. Remove the transmission isolator mounting bolt lo-

Figure 2. Drive Axle

Legend for Figure 2

1. PLANETARY GEAR ASSEMBLY

Figure 4. Planetary Gear and Needle Bearings

ASSEMBLE AND INSTALL

2. Apply a light coat of grease on the inside of the plan-

NOTE: Spacer should split the needle bearings into two

3. Apply a light coat of grease on thrust washer and

4. Install the thrust washers, planetary gear, and nee-

WARNING 6. Install inner snap ring to retain pins.

Figure 6. Hanger Assembly Tightening Sequence

NOTE: Apply Loctite® 515 or High Performance RTV

26. Apply multipurpose grease to new O-ring and install

27. Install the O-ring, fill plug, and tighten to 14 to

28. Remove the air from the brake system as described

29. Install the mast assembly as described in the sec-

1. DIFFERENTIAL HOUSING ASSEMBLY

Figure 10. Differential Housing Assembly Section

Differential Assembly From Differential Assembly Support

1. RETAINER RING SPECIAL TOOL

1. RETAINER RING SPECIAL TOOL

1. DIFFERENTIAL ASSEMBLY SUPPORT

1. DIFFERENTIAL ASSEMBLY SUPPORT

1. DIFFERENTIAL ASSEMBLY SUPPORT

Differential Assembly Support from Drop Box

Remove pinion cover plate.

1. DIFFERENTIAL ASSEMBLY SUPPORT

NOTE: When removing the pinion, be sure to retain the shims.

Remove the pinion nut, washer, bearing cone, and

1. DIFFERENTIAL ASSEMBLY SUPPORT

Using two of the M8 × 1.25 × 50 capscrews removed

1. DIFFERENTIAL ASSEMBLY SUPPORT

Drive Pinion and Pinion Gear, From Differential Assembly Support

1. DIFFERENTIAL ASSEMBLY SUPPORT

1. DIFFERENTIAL ASSEMBLY SUPPORT

Inspect the case halves for wear or damage. If wear

Inspect the spider gears for wear or damage. Replace

Drop Box Housing

1. DROP BOX HOUSING

Differential Assembly Support

1. DIFFERENTIAL ASSEMBLY SUPPORT

1. DIFFERENTIAL ASSEMBLY SUPPORT