DIFFERENTIAL CARRIER SECTION D F CONTENTS SERVICE DATA AND SPECIFICATIONS 2 Construction ‘TROUBLE DIAGNOSES AND CORREC 3 Removal... PRECAUTIONS AND PREPARATION. 4 Disassembly... Precautions... 2 4 Inspection. Special Service Tools 4 Assembly... DIFFERENTIAL CARRIER 6 InstallationSERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS Adjusting parts Roped model Poreenes | Piasones » Tictness | seecton artname mm in) e — = iter cartier Cepnion ype) | tenon ype) a5 0058) cocaceen Bearing preload ajvsing | 018 0.0071) |Sotect and com- Reduction gar Sa Shim (eect aust arve | 0200.00) bine ima ee nee are Since rotston sarang” | 025,0.008) fachiowe proper Resucton gear rato ‘000 a8 tore) 020 00116) |tcaness, umber et reducton paar 0 (017) femme of input pion | S718 ean ve pion nigh aan ea eel inet washer (aed together wih adating | 29,0119 |seectone Fina gear rato S057 See shims to ast dre pi | 38(0.138) [pce Number of ng gear tat ‘ontoving gar toch con- Nomber et arve pion gear | 7 wn tac paler) teeth Drive pinion height agin | %5 8050 iainmem eae saan naaciat | SC [et antcom Recuctongeerveto rinat | 17573 19200 iranian uses vote: | 525 00078) |ine shine oar ‘it astrting waster te | Goan) |acave proper = ; : it de pirionso-ing | 32p qari) | widmess Theat bot % % Gear etn comact pao | O30 00138 clmsication and capacity | _ SAEBOW-90. Aporox. 2.8 ¢ ide gear Oras water Ot catcntin an cons | “uae a Sexo ra ame | 5 006 teoion mate gear ect- | 180°008%0) [select one et {es fones) INSPECTION AND ADJUSTMENT lash) (One st 2 peces) ; Adjustment specifications TIGHTENING TORQUE en eee Unit Nn em ‘ve pon rotaon sarong train Wen boemimb)| 127 US(- 1610-19) adilon GO CORE ag da 10-19 Ring gear-io-arve pinion beckiasn| rom (in) ‘Side geario-pinion mate gear Dacklash amin) ‘Left side bearing cap-to-right side bearing cap distance (Gide bearing prelons) 0-02 (0- 0.008) 0.15 - 020 (0.0059 - 0.0078) 262.88 - 262.88 (10.350 - 10.352) am (in) Side bearing cap bolt Ring gear securing bolt Ditoremtia! case securing bolt (pinion type only), Drive pinion nut ‘Sie boating adjusting nut lock plate securing bolt “Traction motor securing bot Drain plug Ditlrental carrer securing ott “Thrust bolt épinion type onty) 8-10 s8-72 195-228 20-23 145-166 49-60 50-61 35-46 25-9 28-35 703-259 9-2 099-12 67- 7 105-205 19-24 197-174 m-39 90-40 2-29 0 19-25 14-18 18 72-108 DF-2TROUBLE DIAGNOSES AND CORRECTIONS CAUTION: The following table lists only typical exampl To pertorm an accurate diagnosis, carefully listen to the user's complaints and check the actual vehicle to fully understand under what conditions the symptoms occur. Condition Probable cause Corrective action (ir leakage of oll seepage (Cocate the part experiencing oll loss and ‘etermine whether the prodiem is wit ot [e Deterirated oF imaroper type ot gasket andlor O-ing loose dierentialcarrier-o-axle housing Replace. + Tighten or replace gasket ‘seepage or oll leakage) ‘case securing belts 3 Tighten. jo Loose dain plug Failure of iterental cairo rotate ‘Seized or damaged bearing [+ Replace Excessive bearing prelose ‘mautficint gear backlash Insuticient or improper grade/type of gear [Disassemble and acjut. Je Disassemble and acjst. Je Rofl or repiace with proper grade/type of gear oi, ‘Abnormal noise during vehicle starts (Positively determine noise source isin cit- ferential earier) > Improper adjusted ring goarto-drve pine ion backiash + improperly adjusted eilerentia! gear back- leh Inuticient drive pinion bearing preload Worn or camagad gear teeth faces Loose pinion nut or other belts Insuticient or improper grade/type of gear crs Adjust Je Aajust, Je Replace /¢ Tighten. /¢ Refi or replace with proper grade/type of ear oi “Abnormal noise during turns (Postvely determine noise source isin dite forentit carrier} [e Excessively worn or damaged diferentat gear + Seizes, damaged or excessively worn Je Worn or damaged pinion mate shaft Jo Seized or damages sige bearing = Insufficient or improper grade/type of gear ol [> Replace Je Replace. |e Replace js Replace Je Refill or replace with proper gradeltype of 90 oi ‘Gear squeaks {To check for gear squeaks, proceed as fol lows: Raise trort wheels using a jack and run the traction motor. Determine when af ‘squeaking eccurs—during acceleration, ‘deceleration or constant-speed griving.) [> improper adjusted dfterental gear con- tact J+ Abnormal diferentiat gear contact patern J Crackes or damaged aiferentia! gear teeth faces '= improperly adjusted crve pinion preload J Seized or damaged drive pinion bearing Seized oF damaged side bearing 1 Excessive ring gear runout [Loose nuts and bolts DF-3 [> Adjust or replace goars as a set Je Adjust or replace gears as a set. J* Replace goars as a set dust Replace. Replace. Replace. Je Tighten.PRECAUTIONS AND PREPARATION Precautions CAUTION: © Be extremely careful when hoisting and moving heavy objects. These can be extremely dangerous operations. © Always clean working area to prevent foreign matter from getting into parts being assembled or serviced. @ Use a paper rag rather than a cloth when wiping clean parts. Use of a cloth rag may leave lint or other foreign matter on parts being wiped. NOTE: ‘® Its good practice to remove or install differential carrier together with front axle assembly. This procedure makes it easier to work on the differential carrier. ‘© Before removing differential carrier, it is advisable to clean front axle assembly and differential carrier. @ Removal and installation of some differential carrier parts requires use of special service tools as indicated in the table below. Special Service Tools Too! number Mates Description "5732590000 installing or removing diferential case ‘Side bearing nut wrench adjusting put orto v1 7100500 Driving pinion mate shaft lock pin out of ai Pin {erential case (2-inion type only) ‘sTovs60002 Press-fiting let and right side bearing inner '$702371000 races into ditterential case Bearing replacer v38103300 Presectiting front and rear drive pinion Bearing replacer bearing outer races into differential carrier 'ST30817000 Presscfiing front bearing inner race onto Bearing replacer ‘drive pinion DF-4PRECAUTIONS AND PREPARATION Special Service Tools (Contd) ‘Too! number Tool name 'S733200000 Bearing replacer Description Press-fting bearing onto input pinionDIFFERENTIAL CARRIER Construction (Cont'd) COMPONENT PARTS gDIFFERENTIAL CARRIER For additional information, not covered In this DF section, refer to the applicable section, as required, to familiarize yourself with work being performed. 1. Raise front of vehicle using a jack. Place wooden blocks under left and right frames to support vehicle. Refer to Gi section for details. 2. Remove mast assembly from vehicle. Refer to LM section. ‘© Before removing lift hose, release pressure in hydrauli line. © A-small amount of hydraulic line oil will escape when lift hose is removed. Immediately plug the opening following removal. Placing a cloth on the upper surface of differential carrier enables easier cleaning. 3. Support traction motor by placing a wooden block under traction motor. 4, Remove left and right front wheels, then remove drive axle shaft. Refer to FA section for details. 5. Disconnect speed sensor harness connector. CAUTION: ‘Two speed sensors, A and B, are used. Do not mix them up when re-connecting. 6. Remove differential carrier drain plug to drain gear oil. Refer to MA section. 7. Remove flare nuts from left and right wheel cylinders, then remove brake tubes. Refer to BR section. CAUTION: Plug the opening of brake tube to prevent brake fluid trom flowing out. 8. Remove brake pedal bracket assembly. Refer to BR section. 8. Remove parking brake cable from parking brake lever. 10. Attach a lifting wire/nylon sling to front axle assembly. Then ‘support front axle assembly using a hoist, keeping the wire/ nylon sling stretched tight. 11. Support differential carrier by placing a jack under it. 42, Remove axle mounting bracket securing bolts. DF-8DIFFERENTIAL CARRIER Removal (Cont'd) 18. Remove the four bolts securing traction motor to differential carrier. CAUTION: Place a wooden block under traction motor to prevent it from dropping. 14. Draw front axle assembly together with differential carrier ‘out from the front of vehicle. 15. Remove differential carrier from axle housing. CAUTION: Before removing differential carrier, make sure drive axle shafts have been removed in advance. 16. Place differential carrier on worktable. Disassembly Before disassembiing differential carrier assembly, clean its entire surface using a cloth and white kerosene. 1. Before disassembling differential carrier, check and/or measure the following items to approximate trouble areas and ascertain disassembly and/or maintenance work to be performed. © Check for ring gear-to-drive pinion backlash and tooth con- tact. patterns. For inspection procedures, refer to “Assembly”. CAUTION: Be sure to perform this inspection and note the results, which will be used as standard during assembly. © Check ring gear and differential gear for improper rotation. 2, Remove side bearing adjusting nut lock plate securing bolt, then remove lock plate. DF-9DIFFERENTIAL CARRIER Disassembly (Cont'd) 3. Loosen side bearing cap bolt until possible to turn by hand. Using special service tool (ST32530000), remove side bear- ing adjusting nut. [4 Remove lft and right side bearing aps. Yy CAUTION: Scribe an alignment mark on side bearing caps and differential carrier as a guide for re-installation. Alignment, mark 5. Remove differential case assembly and left and right side bearings as a unit. Remove bearing outer races trom difter- ential case. CAUTION: Scribe an Identification mark on left and right bearing outer Faces so as not to mix them up. 6. Remove cover. CAUTION: © When removing reduction gear cover, be careful not to dam- age gasket. © When removing end bearing cover, be careful not to drop key plate. © When removing end bearing cover, be careful not to dam- age O-ring. NOTE: End bearing cover must be pried up at the groove. pinion end bearing cover and reduction gear 7. Using snap ring pliers, remove snap ring. Remove input pinion and bearing as a unit. if necessary, remove bearing remaining in differential carrier. 8 Using a puller, remove drive pinion end bearing. DF-10DIFFERENTIAL CARRIER Extension bar ‘Reduction gear aS Disassembly (Cont'd) 9. Unlock drive pinion lock nut at the groove of drive pinion. Also straighten lock washer under nut [width across flats: 50 mm (1.7 in)}, then remove nut and lock washer. CAUTION: Insert an extension bar through hole in differential carrier to hole in reduction gear to prevent gears from rotating, then remove nut. 40. Withdraw drive pinion towards tront of differential carrier by driving with a copper hammer. Then remove reduction gear and rear bearing inner race. 11, Remove adjusting shim and distance piece from drive pin- ion 12. Using a pressing tool, press front bearing inner race out of drive pinion. Remove adjusting shim and adjusting washer. 48. Using a brass or aluminum drift, drive front and rear bear- ing outer races out of differential carrier. CAUTION: Attach an identification tag to removed front and rear bearing outer races, and place them in order for easier and proper reassembly. 44. Using a puller, remove left and right side bearing inner races from differential case. CAUTION: Side bearing inner races need not be removed unless nec- essary. © Attach an identification tag to removed side bearing inner nd place them in order for easier and proper reas- DF-11DIFFERENTIAL CARRIER Disassembly (Cont'd) 15. If ring gear needs to be removed, remove ring gear bolts, then drive ring gear out using a plastic hammer. 16. Remove differential case securing bolts and remove difter- ential case. Then remove pinion mate shaft, pinion mate gear, side gears and thrust washers. (4-pinion type only) 17. Using special service tool (KV31100300), remove pinion mate shaft lock pin from ring gear side. (2-pinion type only) 18. Remove pinion mate shaft, pinion mate gear, side gears and thrust washers. (2-pinion type only) CAUTION: Before removing gears and thrust washers, scribe an alignment mark on them as a guide for re-installation. Inspection Clean all removed parts in cleaning solvent. Carefully check for cracks or damage. If necessary, repair or replace faulty parts with new ones. DRIVE PINION AND RING GEAR (Hypoid gear set) © Check gears for wear or improper tooth contact. Adjust tooth contact when reassembling as necessary. If gears are excessively worn or adjusting tooth contact is impossible, replace with new ones. © Check for cracks, seizing or damage on teeth faces. If nec- essary replace with new ones. CAUTION: When replacing drive pinion or ring ges gears as a set. , always replace both INPUT PINION AND REDUCTION GEAR Check for cracks or damage on teeth faces. If necessary, replace with new ones. DF-12DIFFERENTIAL CARRIER Inspection (Cont'd) PINION MATE GEAR © Check for cracks or damage on teeth faces. If necessary, replace with a new one. © Check for seizing or excessive wear on contacting surface to thrust washer. If necessary, replace with a new one. SIDE GEARS © Check for cracks or damage on teeth faces. If necessary, replace with new ones. © Check for seizing or excessive wear on contacting surfaces to thrust washers. If necessary, replace with new ones. SIDE GEAR THRUST WASHERS AND PINION MATE GEAR THRUST WASHER Check for seizing, damage or excessive wear. If necessary, replace with new ones. BEARINGS Check for seizing, flaking, wear, rust formation, improper spin- ning or noise. If necessary, replace with new ones. O-RINGS AND GASKETS Always replace after every disassembly. DIFFERENTIAL CASE AND DIFFERENTIAL CARRIER © Check bearing-ixed areas for wear or damage. If necessary, replace with a new differential case and differ- ential carrier. © Check sliding surfaces for wear or damage. If necessary, replace with new ones. Assembly CAUTION: ¢ Adjust various parts while reassembling differential case and differential carrier assemblies. ‘¢ Apply a coat of gear oil before installing gears, bearings, O-rings, ete. 1. Install side gear, pinion mate shaft and pinion mate gear into each of differential cases together with their corre sponding thrust washers. (4-pinion type only) 2. Install side gear and thrust washer into differential case, stall pinion mate gear and thrust washer, then insert pin- ion mate shaft into differential case. (2-pinion type only) CAUTION: Pay attention to direction and location of pinion mate shaft lock pins during installation. DF-13,DIFFERENTIAL CARRIER ‘Assembly (Cont'd) 3. Using a dial gauge, measure side gear-to-pinion mate gear backlash. Standard backlash: 0 - 0.2 mm (0 - 0.008 In) CAUTION: © Hold pinion mate shaft in place when measuring backlash. (4-pinion type only) © 4-pinion type is shown at left. 4, If backlash is outside specifications, remove side gear thrust washer. Then select and install a new one of proper thickness. Unit: mm (in) “Thickness 1.55 (0.0610) ‘Available side gear thrust washers 1.60 (0.0690) 1.85 (0.0650) 5. Use the same procedures as outlined in steps 3 and 4 above, to measure and adjust side gear-to-pinion mate gear backlash in the other differential case. (4-pinion type only) Install left and right differential cases, then tighten with securing bolts in a criss-cross fashion. (4-pinion type only) [Ey: 49 - 60 Nem (5.0 - 6.1 kg-m, 36 - 44 feb) 7. Drive pinion mate shaft lock pin into place using a punch and hammer. (2-pinion type only) DF-14DIFFERENTIAL CARRIER & fe 5702377000 orroaz| sTo1sso0a2 Ditlerential case ‘Assembly (Cont'd) 8. Install ring gear (it previously removed) to differential case. ightly tighten ring gear securing bolts in a criss-cross fash- ion. Tap bolt heads with a copper hammer to properly seat. Then tighten bolts to specified torque. (Dy: 196 - 226 Nem (20 - 23 kg-m, 145 - 166 ft-lb) CAUTION: Before tightening ring gear securing bolts, apply a coat of screw lock agent (Three Bond # 1303 or equivalent) to bolt threads. 9. Using special service tools (ST01550002, ST02371000), press-fit left and right side bearing inner races into their 1g bores in differential case. 10. Using special service tool (KV38103300), press-fit front and rear bearing outer races into their corresponding bores in differential carrier. CAUTION: Do not confuse the front bearing outer race with the rear one. 11. Install pinion height adjusting washer and shim(s) to drive pinion in that order. Select suitable washer and shim(s) to provide proper ring gear-drive pinion tooth contact pattern. For adjusting washer and shim selection procedures, refer to step 25, page DF-20. [Adjusting pant peoes Number of parts to select ‘Avaliable pinion height 29078 z ‘jucting washers 35 (0138) ce (0.15 00089) 0.18 007%) ‘Avaliable pinion height 0.20 (0.0079) opening on shim thick adjusting shims 0.35 (0.0008) ess caleuation 030 (00118) 050 (00387) CAUTION: After installing adjusting washer and shim(s) to drive pinion, check ring gear-to-drive pinion tooth contact pattern. if necessary, select sultable washer and shim(s) again to adjust drive pinion height. DF-15DIFFERENTIAL CARRIER 'g131241000 (Dummy sna) To02s Front bearing id Adjusting washer and shim Fron] Assembly (Cont'd) NOTE: ‘© When installing adjusting washer and shim(s), first use pre- viously removed washer and shim(s), then check tooth con- tact pattern. If adjustment is necessary, replace them with cones of proper thickness. Shim(s) can be selected using the following procedure: ¢ Press-fit front bearing inner race onto special service tool (dummy shaft), then install dummy shaft assembly onto dif- ferential carrier. © Install setting gauge (special service tool) to differential carrier, then measure setting gauge end-to-dummy shaft ‘end face clearance "'N” using a feeler gauge. Make sure the arc area of the setting gauge contacts differential carrier during clearance measurements. ‘© Use the following formula to calculate suitable shim thick- ness. T = N-(Hx 0.01) + (Dx 0.01) + (Sx 0.01) - 0.35 where T: Shim thickness required, mm N: Clearance measured using feeler gauge, mm H: Numeric mark stamped on drive pinion head D: Numeral (Dummy shaft machining accuracy) stamped on dummy shaft S: Numeral (Gauge machining accuracy) stamped on setting gauge © Calculation exampie (When N = 0.80 mm, H = -2,D = +3.and S = -2): Required shim thickness can be calculated as follows: 0.80 — (-2 x 0.01) + (3x 0.01) + (-2 x 0.01) - 0.35 0.80 — (-0.02) + 0.03 + (0.02) - 0.35 0.80 + 0.02 + 0.03 - 0.02 - 0.35 = 0.48 (mm) .... Required shim thickness Select one 0.18 mm thick shim and one 0.90 thick shim. Total shim thickness will then be 0.48 mm. 7 12. After installing required pinion height adjusting washer and shim(s) to drive pinion, drive front bearing inner race onto drive pinion using special service tool (ST30911000) DF-16DIFFERENTIAL CARRIER Distance piece ‘Adjusting shin Assembly (Cont'd) 18, install drive pinion to differential carrier. Install distance piece and bearing preload adjusting shim to. drive pinion assembly. © Make sure front and rear bearing outer races are pressed into differential carrier. While inserting drive pinion assem- bly into differential carrier, install rear bearing inner race and reduction gear to differential carrier. © Install drive pinion lock nut [width across flats: 50 mm (1.97 in)] with a lock washer. While measuring and/or adjusting drive pinion preload (Refer to ), tighten the lock nut. (D275 - 343 Nem (28 - 35 kg-m, 203 - 253 ft-lb) NOTE: Tighten drive pinion lock nut while preventing reduction gear from rotating with an extension bar inserted through the hole in differential carrier to hole in reduction gear as shown at lett. © Drive pinion preload is determined by the rotation starting torque of drive pinion. © Using a torque wrench, measure drive pinion rotation start- ing torque. Reduction gear must be free to rotate. © Ifrotation starting torque is within specifications when drive pinion nut is tightened to specified torque, it indicates that bearing preload is properly adjusted. Rotation starting torque: 1.18 ~ 1.47 Nem (0.12 - 0.15 kg-m, 0.9 - 1.1 ft-Ib) © If rotation starting torque is outside specifications, once again disassemble and replace bearing preload adjusting shim(s) with ones of proper thickness. © Select required shim(s) to obtain proper bearing preload. ‘Unit: mm (in) Thiekness 10.15 (0.0059), (0.18 20071), (0.20 0.0079), 10.25 (0.0098), (030 00118), 050 (0.0197) ‘Available bearing preload adjusting ‘hime CAUTION: © While tightening drive pinion nut, measure rotation starting torque. Be careful not to exceed specified bearing preload while tightening drive pinion nut. © Measure the bearing preload after rotating the drive pinion 2 to 5 turns to properly seat bearing. During bearing preload adjustments, always observe the rule of replacing a thicker shim with a thinner one (not a thinner shim with a thicker one) until the actual bearing preload Is close to specifications. DF-17DIFFERENTIAL CARRIER Inout pinion ‘Frog ‘Assembly (Cont'd) NOTE: Keep in mind that the greater the total adjusting shim thickness, the smaller the bearing preload or vice versa. 14, After making sure that correct bearing preload is obtained, align drive pinion nuts (2 places) with the grooves in pinion, then clinch the nuts and washers. 15. Press-fit end bearing onto the rear end of drive pinion. While aligning end bearing cover with end bearing, insert drive pinion into differential carrier. Install a woodruff key into the groove in end bearing cover. CAUTION: Be careful not to twist or damage bearing cover O-ring while inserting drive pinion into differential carrier. 16. Using special service tool (ST33200000), press-fit bearings conto input pinion and into differential carrier. Install input pinion to differential carrier. Using snap ring pliers, secure snap ring to the groove. 17. Install reduction gear cover with a gasket to differential carrier, then tighten with bolts. 14 - 18 Nem (1.4 = 1.8 kg-m, 10 - 13 ft-lb) a CAUTION: Make sure that reduction gear cover Is installed with “TOP” mark side facing upward. 18. Install differential case assembly together with left and right side bearing outer races to differential carrier. CAUTION: Do not confuse the left and right side bearing outer races. 19, Install left and right side bearing caps to differential carrier, then tighten cap bolts equally. Make sure there is no clear- ance between bearing caps and differential carrier. CAUTION: Do not confuse the left and right side bearing caps. DF-18DIFFERENTIAL CARRIER ‘Assembly (Cont'd) 20. While aligning side bearing adjusting nuts with differential carrier and cap threads, lightly turn adjusting nuts by hand. After making sure that two adjusting nuts are equally started, alternately tighten the nuts using special service too! (ST32530000) until they contact bearings. 21. Measure ring gear-to-drive pinion backlash at the outer perimeter of ring gear. If necessary, adjust by tightening and loosening side bearing adjusting nuts. Ring gear-to-drive pinion backlash: (0.15 - 0.20 mm (0.0059 - 0.0079 in) © If backiash is excessive, loosen the nut located on the oppo- site side (A) of ring gear and then tighten the nut located on the rear (B) of ring gear by the same amount. © Ifbacklash is insufficient, loosen the nut on the rear side (B) of ring gear and tighten the nut on the opposite side (A) of ring gear by the same amount. CAUTIOF © Measure ring gear-to-drive pinion backlash at several points while rotating ring gear. ‘© If the measured backlash values vary greatly at different points, check differential case for improper installation and ring gear for evidence of runout. tring gear runout exceeds specification, replace ring gear and drive pinion as a unit. Ring gear runout timit: 0.06 mm (0.0024 in) 22. Tighten side bearing caps bolts to specified torque. 1D): 78 - 98 Nem (8 - 10 kg-m, 58 - 72 f-Ib) DF-19DIFFERENTIAL CARRIER Assembly (Cont'd) .23. Apply preload to left and right side bearings. ‘© Equally tighten left and right side bearing adjusting nuts until the diameter across flanges between left and right side bearing cap end faces is within specifications. Standard diameter across flangé 262.88 - 262.93 mm (10.350 - 10.352 in) © If diameter exceeds specifications, equally loosen left and right side bearing adjusting nuts until correct adjustment is achieved. © After applying preload to side bearings, measure ring gear- to-drive pinion backlash again. CAUTION: Always tighten or loosen left and right side bearing adjusting nuts by an equal amount to obtain correct adjustments. NOTE: It is recommended to fabricate a diameter measuring gauge beforehand. 24. Install lock plates securing side bearing adjusting nuts, then tighten bolts. Oy: 9.1 - 11.8 Nem (0.93 - 1.2 kg-m, 6.7 - 8.7 ft-lb) 2. Check ring gear-to-drive pinion tooth contact. If necessary, adjust. ‘© Apply rouge (red) or iron yellow (yellow) to 3 or 4 ring gear teeth faces as shown at left. Manually rotate ring gear sev- eral turns back and forth to check tooth contact pattern. © Using the following table as a guide, adjust the gear tooth contact pattern as required. DF-20Ring gear tooth contact con- dition DIFFERENTIAL CARRIER Asseml Cause of problem (Cont'd) ‘Adjustment procedure Typical correct tooth contact | [Adjustment not required Face contact, (ing gear face under load) LOE Drive pinion too far trom ring gear (Low pinion height) [Reduce pinion height adjust- ing washer/shim thickness. Flank contact Drive pinion t00 close to ring Increase pinion height adjust- (Ring gear flank under load) | gear ing washer/shim thickness. (High pinion height) G ¢ . rraoes oFroxs| Toe contact (Ring gear toe under load) ——— Insutficient backlash Increase backlash, Heel contact Excessive backlash Reduce backlash, (Ring gear heel under load) HA Hee! side DF-21DIFFERENTIAL CARRIER Assembly (Cont'd) ‘26. Install thrust bolt, then adjust clearance. (4-pinion type only) ‘@ Loosen thrust bolt lock nut, then tighten thrust bolt until it contacts the rear surface of ring gear. CAUTION: Apply a coat of sealing agent (Three Bond 1104 or equivalent) to thrust bolt threads before installation. © After thrust bolt contacts ring gear, loosen the bolt 1/4 to 1/3 rotation (80 to 120 degrees) to obtain specified clearance ie Clearance “H”: 0.2 - 0.6 mm (0.008 - 0.024 In) © While holding thrust bolt, tighten lock nut to specified torque. (0): 98 - 147 N-m (10 - 15 kg-m, 72 - 108 ft-lb) CAUTION: © Adjust thrust bolt clearance every total operation time of 2,400 hours, or one year, whichever comes first. ¢ Do not loosen the thrust bolt more than 1/3 rotation during clearance re-adjustments. Lock mut Thrust bot Ring gear 9 oe LA DF-22DIFFERENTIAL CARRIER Installation 41. Install drain plug on differential carrier, then tighten to spec- ified torque. (0): 29 - 39 Nem (3.0 - 4.0 kg-m, 22 - 29 f-tb) CAUTION: Before installing drain plug, apply a coat of liquid packing to plug threads. 2. Completely remove traces of gasket from differential carrier and axle housing flanged surfaces, then degrease and wipe clean. Make sure differential carrier and axle housing flanges are completely clean and free from dust, dirt, oil, water, etc, CAUTION: Always use a scraper or suitable tool to remove traces of gas- ket from the flanged surfaces. 3. Install differential carrier to axle housing with new gasket in place, then tighten securing bolts to specified torque. [Dy 19 - 25 Nem (1.9 - 2.5 kg-m, 14 - 18 ft-lb) 4, While supporting differential carrier using a jack, lft front axle assembly and differential carrier as a unit using a lift ing wire/nylon sling and hoist. While aligning traction motor shaft with input pinion of differential carrier, insert the motor shaft into the input pinion. CAUTION: Do not apply an undue force to traction motor shaft during installation. © Apply a coat of chassis grease to traction motor shaft beforehand. © Apply @ coat of gear oil to O-ring beforehand. © Be careful not to damage O-ring. 5. Tighten differential carrier-to-traction motor secu and bolts to specified torque. (Dy: 186 - 235 Nem (19 - 24 kg-m, 137 - 174 f1-tb) DF-23DIFFERENTIAL CARRIER jon (Cont'd) 6. Install axle mounting bracket to frame. © Tighten securing nuts and bolts to specified torque. (Oy: 186 - 235 Nom (19 - 24 kg-m, 137 - 174 ft-1b) NOTE: To facilitate installation of axle mounting bracket, insert a bar rod into the hole at frame (A), then pry as required to align the frame with the bolt holes in drive mounting bracket. 7. Connect parking brake cable to parking brake lever. 8. Install brake pedal bracket assembly. Refer to BR section for details. 9. Connect brake tube to brake cylinder, then bleed air from brake line. Refer to MA section for det 10. Connect speed sensor harness connectors. CAUTION: © Do not contuse the A speed sensor with the B speed sen- sor. © Ifthe sensors are mistakenly connected, the vehicle cannot be driven normally (the regenerative braking contactor chatters). 11. Install front wheels and axle shaft. Refer to FA section. 42. Refill specified amount of gear oil. Refer to MA section. 18. Remove wooden block from under traction motor. 14. Install mast assembly to vehicle. Refer to LM section. 15. Remove wooden blocks used to support vehicle, then lower the vehicle to the floor. Refer to GI section for details. DF-24