550013975-Drive Axle and Differential Assembly Repair-Us

Maintenance
DRIVE AXLE AND

DIFFERENTIAL
ASSEMBLY REPAIR
GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]
PART NO. 550013975 1400 YRM 1426

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
Identification Plate........................................................................................................................................... 1
Drive Axle Repair................................................................................................................................................. 2
Remove and Disassemble .............................................................................................................................. 2
Clean and Inspect ........................................................................................................................................... 5
Assemble and Install ....................................................................................................................................... 5
Differential Repair................................................................................................................................................ 8
Remove ........................................................................................................................................................... 8
Differential Assembly From Drive Axle Center Section Assembly .............................................................. 8
Drive Pinion, Pinion Gear, and Bearings From Drive Axle Center Section ................................................. 10
Disassemble.................................................................................................................................................... 15
Differential Assembly .................................................................................................................................. 15
Drop Box Housing....................................................................................................................................... 19
Differential Assembly Cover........................................................................................................................ 20
Drive Axle Center Section........................................................................................................................... 21
Clean and Inspect ........................................................................................................................................... 22
Assemble ........................................................................................................................................................ 23
Drive Axle Center Section........................................................................................................................... 23
Differential Assembly Cover........................................................................................................................ 25
Drop Box Housing....................................................................................................................................... 26
Differential Assembly .................................................................................................................................. 27
Install............................................................................................................................................................... 31
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) ........................................................................ 31
Drive Pinion, Pinion Gear, and Bearings Into Drive Axle Center Section ................................................... 33
Differential Assembly Into Drive Axle Center Section ................................................................................. 37
Hypoid Gear Backlash, Adjust .................................................................................................................... 40
Hypoid Gear, Runout Check ....................................................................................................................... 41
Gear Set, Tooth Contact Pattern Check...................................................................................................... 41
Torque Specifications .......................................................................................................................................... 44
This section is for the following models:
GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]
©2011 Yale Materials Handling Corp. i

1400 YRM 1426 General
General
This manual covers the repair procedures for the drive IDENTIFICATION PLATE
axle and differential assembly.
There is an identification plate located on the differential
assembly cover. See Figure 1.
A. FRONT OF TRUCK B. REAR OF TRUCK

1. SERIAL NUMBER 3. IDENTIFICATION PLATE
2. DATE 4. DIFFERENTIAL ASSEMBLY COVER
Figure 1. Drive Axle Identification Plate
1
Drive Axle Repair 1400 YRM 1426
Drive Axle Repair

REMOVE AND DISASSEMBLE 4. Remove oil drain plug and drain oil from drive axle
into a suitable container. See Figure 2. Discard oil
WARNING drain plug O-ring.
When putting the lift truck on blocks, make sure the
surface is solid, even, and level. Any blocks used to WARNING
support the lift truck must be solid, one-piece units. On lift trucks with pneumatic tires, completely re-
move air from tires before removing them from lift
1. Put blocks on each side (front and back) of the truck. Air pressure in tires can cause tire and rim
steering tires to prevent movement of the lift truck. parts to explode, which can cause serious injury or
2. Raise lift truck and put blocks under frame so that death. Never loosen nuts that hold together inner
drive wheels do not touch floor. Put blocks under and outer wheel halves when there is air pressure
counterweight for stability. in tire.
3. Remove mast assembly as described in section 5. Remove wheels.

Mast Repair 4000 YRM 1431. 6. Disconnect brake line connecting master cylinder to
brake manifold located on top of drive axle assem-
CAUTION bly. See Figure 4.
Disposal of lubricants and fluids must meet local
environmental regulations.
NOTE: BOTTOM VIEW OF DRIVE AXLE SHOWN.

1. OIL DRAIN PLUG 3. LEFT HUB
2. DRIVE AXLE CENTER SECTION
Figure 2. Oil Drain Plug
2
1400 YRM 1426 Drive Axle Repair
7. Remove parking brake cable. Refer to section 13. Remove blocks, lower drive axle assembly, and dis-
Brake System 1800 YRM 1135 for procedures. engage the drive axle assembly from transmission.
8. Place blocks under drive axle assembly and con- 14. Place blocks under the drive axle center section
nect slings and lifting device to drive axle. assembly.
9. Place blocks under transmission to support the 15. Remove the drive axle shafts, hub/brake drum as-
transmission while removing drive axle. semblies, and back plates. Refer to the section
Brake System 1800 YRM 1135.
10. Remove two bolts and remove universal joint from
transmission. See Figure 3. 16. Remove hanger assembly capscrews and hanger
assembly. Repeat this step on the opposite side.
11. Remove transmission isolator mounting bolt from See Figure 4.
transmission mounting bracket, located on top of
drive axle assembly. See Figure 7.
12. Remove four drive axle mounting capscrews from

hanger assembly. See Figure 4.
1. BOLTS 3. DRIVE AXLE CENTER SECTION

2. UNIVERSAL JOINT 4. TRANSMISSION MOUNTING BRACKET
Figure 3. Universal Joint Removal
3
1. CAPSCREW 14. BRAKE ASSEMBLY

2. DRIVE AXLE SHAFT 15. LEFT BRAKE LINE
3. LOCKNUT 16. DRIVE AXLE MOUNTING CAPSCREW
4. BEARING LOCKWASHER 17. DRIVE AXLE MOUNTING NUT
5. WASHER 18. DIFFERENTIAL COVER
6. TAPER ROLLER BEARING 19. RIGHT BRAKE LINE
7. HUB/BRAKE ASSEMBLY 20. DRIVE AXLE CENTER SECTION
8. HUB BOLT 21. UNIVERSAL JOINT
9. ROLLER BEARING 22. DUST COVER
10. INNER SEAL 23. INPUT SHAFT (YOKE)
11. INNER BEARING 24. BRAKE MANIFOLD
12. OUTER SEAL 25. HANGER ASSEMBLY
13. WEAR SLEEVE
Figure 4. Drive Axle
4
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety precautions.
1. Clean all the parts of the drive axle assembly with

solvent.
2. Inspect the bearings and seals for damage.
3. Inspect the drive axle shafts for wear and cracks

at the flange, shaft, and damaged splines. If axle
shafts show signs of wear or damage, replace the
axle shafts.
ASSEMBLE AND INSTALL Figure 6. Hanger Assembly Tightening Sequence
1. Apply grease to new O-rings and install O-rings on NOTE: Apply Loctite® 515 or High Performance RTV
the hanger assemblies. See Figure 4 and Figure 5. Silicone Gasket Maker on the drive axle shaft flange
when installing.
2. Place hanger assembly in position on differential
cover. Apply Loctite® 242 to capscrews and install 3. Install the back plates, hub/brake drum assemblies,
capscrews. Tighten capscrews in sequence shown and drive axle shafts. Refer to the section Brake
in Figure 6 to 90 to 99 N•m (66 to 73 lbf ft). Repeat System 1800 YRM 1135.
step for opposite side.
4. Connect slings and lifting device to drive axle.
NOTE: When installing the drive axle, ensure the drive

axle is held with the upper surface of the drive axle
against the frame. This will prevent any gap between
the frame and the drive axle mount, and will ensure
even weight bearing distribution.
5. Position the drive axle in the lift truck.
NOTE: It is recommended to use a torque multiplier to

achieve the torque specification in Step 6.
6. Install four drive axle mounting capscrews and

nuts. Tighten capscrews to 245 to 270 N•m (181
to 199 lbf ft).
7. Install universal joint to transmission using two

bolts. Tighten bolts to 30 to 37 N•m (22 to 27 lbf ft).
See Figure 3.
8. Install the isolators as shown in Figure 7.
9. Apply adhesive sealant, Loctite® 271, to transmis-

1. O-RING
2. HANGER ASSEMBLY sion isolator mounting bolt. Install transmission iso-
3. DRIVE AXLE SPINDLE lator mounting bolt and snubbing washer into trans-
mission mounting bracket, located on top of drive
Figure 5. Hanger Assembly axle assembly. Tighten the bolt to 225 to 250 N•m
(166 to 184 lbf ft). See Figure 7.
5
1. TRANSMISSION MOUNTING BRACKET 5. ISOLATOR

2. TRANSMISSION ISOLATOR MOUNTING BOLT 6. TRANSMISSION
3. WASHER 7. DRIVE AXLE CENTER SECTION
4. SNUBBING WASHER
Figure 7. Transmission to Center Section Housing Mounting Bolt
10. Remove blocks from under transmission. O-ring on drain plug. Install the drain plug and
tighten to 50 to 55 N•m (37 to 41 lbf ft). See Fig-
11. Install parking brake cable. Make sure brake cable ure 2.
is routed properly and has no interference. Verify
that parking brake operates properly. Refer to sec- 15. Remove the fill plug and fill the drive axle to the
tion Brake System 1800 YRM 1135. proper level as shown in Figure 8. See section Peri-
odic Maintenance 8000 YRM 1424 for oil quantity
12. Connect the brake line connecting the master cylin- and oil type to use. Install the fill plug.
der to the brake manifold located on top of the drive
axle assembly. See Figure 4. 16. Remove air from brake system as described in sec-
tion Brake System 1800 YRM 1135.
WARNING 17. Install mast assembly as described in section Mast
Add air to the tires only in a safety cage. Inspect Repair 4000 YRM 1431.
safety cage for damage before use. When adding
air, use a clip-on chuck with enough hose to let the 18. Raise lift truck and remove blocks from under frame
operator stand clear of the cage. and counterweight. Lower lift truck.
NOTE: When tightening the wheel nuts, DO NOT use 19. Remove blocks on each side (front and back) of
any lubricant on the studs or nuts. steering tires.
13. Inflate the tires using a safety cage. Install the 20. Operate lift truck and check for proper operation
wheels and nuts and tighten the nuts to 155 to and leaks.
175 N•m (114 to 129 lbf ft).
14. Apply multipurpose grease with 2 to 4% molybde-

num disulfide to new drain plug O-ring and install
6
Legend for Figure 8

A. LEFT SIDE VIEW B. FRONT VIEW
1. OIL FILL PLUG 3. DRIVE AXLE
2. OIL FILL LEVEL CENTER SECTION
Figure 8. Oil Fill Level
7
Differential Repair 1400 YRM 1426
Differential Repair
REMOVE
For the following repair procedures, the drive axle must
be removed and disassembled. Refer to section Drive
Axle Repair for removal and dissemble procedures.
Differential Assembly From Drive Axle Center Section Assembly

STEP 1.
Using a retainer ring special tool, Yale Part No.
580083667, loosen the differential retainer rings. If
necessary, loosen retainer ring capscrews to allow the
retainer rings to turn freely. Remove differential retainer
rings and retainer ring capscrews from center section.
1. RETAINER RING CAPSCREW

2. DIFFERENTIAL RETAINER RING
3. DIFFERENTIAL ASSEMBLY COVER
1. RETAINER RING SPECIAL TOOL
8
1400 YRM 1426 Differential Repair
STEP 2.
Remove differential assembly cover capscrews and re-
move differential assembly cover.

CAPSCREWS
3. DIFFERENTIAL ASSEMBLY
STEP 3.
Remove differential assembly from drive axle center
section.
2. HYPOID GEAR
9
Drive Pinion, Pinion Gear, and Bearings From Drive Axle Center Section
STEP 1.
Remove capscrews, washers, and pinion cover.
1. CAPSCREW
2. WASHER
3. PINION COVER
4. PINION NUT
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.
STEP 2.
Using a small, flat chisel, unstake the pinion nut.
Remove pinion nut and washer.
1. PINION NUT
2. WASHER
3. PINION SHAFT
10
STEP 3.
Remove input shaft (yoke), oil seal, and dust cover from
drop box housing.
1. INPUT SHAFT (YOKE)

2. DUST COVER
3. OIL SEAL
STEP 4.
Remove capscrews and washers from the drop box
housing.
1. CAPSCREW
2. WASHER
3. DROP BOX HOUSING
11
STEP 5.
Install two capscrews removed in STEP 4 in location shown. Tighten each capscrew alternately, until drop box
housing can be removed. If the capscrews do not have enough threaded length, use a pry bar to finish removing
the housing.
STEP 6.
Remove outer tapered bearing from drop box housing.
1. INSERT TWO CAPSCREWS
1. OUTER TAPERED ROLLER BEARING

2. DROP BOX HOUSING
3. PINION SHAFT
12
NOTE: When removing pinion shaft, be sure to retain the shims.
STEP 7.
Carefully remove pinion shaft assembly from drive axle
center section. Using a press and bearing puller, re-
move inner shims and inner tapered roller bearing from
pinion shaft assembly.
1. INNER TAPERED ROLLER BEARING

2. INNER SHIMS
3. PINION SHAFT
5. DRIVEN GEAR
STEP 8.
Remove driven gear and pinion crush sleeve
1. DRIVEN GEAR
2. PINION CRUSH SLEEVE
13
STEP 9.
Using a press or suitable soft drift, remove the outer ta-
pered roller bearing cup from drop box housing.
1. OUTER TAPERED ROLLER BEARING CUP

2. DROP BOX HOUSING
STEP 10.
Using a suitable soft drift, remove the pinion inner ta-
pered roller bearing cup.
1. PINION INNER TAPERED ROLLER BEARING

CUP
14
DISASSEMBLE
Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable bearing
puller, remove the tapered roller bearings from the
differential assembly.
1. BEARING CUP
2. TAPERED ROLLER BEARING
STEP 2.
Remove the capscrews and hypoid gear from differen-
tial assembly case.
1. HYPOID GEAR
2. DIFFERENTIAL ASSEMBLY CASE
3. CAPSCREW
15
STEP 3.
Remove pin from differential assembly case and pin-
ion shaft. Remove pinion shaft. Inspect pinion shaft
for wear. Replace as needed.
1. PIN
3. PINION SHAFT
16
STEP 4.
Rotate side gears until pinion gears can be removed
from the differential assembly case. Remove pinion
gears. Inspect pinion gears spherical washers for wear.
Replace as needed.

2. PINION GEARS
17
STEP 5.
Remove side gears and thrust washers from the differ-
ential assembly case.
Inspect the differential assembly case and side gears

for wear or damage. Replace as needed.

2. THRUST WASHER
3. SIDE GEAR
18
Drop Box Housing

STEP 1.
Remove the input shaft outer bearing.
1. INPUT SHAFT OUTER BEARING

2. DROP BOX HOUSING
19
Differential Assembly Cover

NOTE: Remove the breather assembly only if it is damaged.
STEP 1.
Remove breather assembly from differential assembly
cover.
1. BREATHER CAP
2. PLUG
3. SPRING
4. BALL
6. BREATHER ASSEMBLY
20
Drive Axle Center Section

STEP 1.
Remove the drive gear.
1. DRIVE GEAR
STEP 2.
Remove the drive gear inner bearing.
1. DRIVE GEAR INNER BEARING

21
NOTE: Remove the brake manifold and bracket only if damaged.
STEP 3.
Remove capscrew and washer retaining the brake man-
ifold and bracket. Remove brake manifold and bracket.
1. CAPSCREW
2. WASHER
3. BRACKET
4. BRAKE MANIFOLD
CLEAN AND INSPECT assembly. If bearings show signs of wear, cracks, or

damage, replace with new bearing.
WARNING • Pinions and gears - Inspect the pinions and gears
for wear or damage. Gears that are worn or damaged
Cleaning solvents can be flammable and toxic and
must be replaced.
can cause skin irritation. When using cleaning sol-
• Main differential assembly - Inspect the hypoid gear
vents, always follow the recommendations of the
set and pinion shaft for damage. If either is damaged,
manufacturer.
both must be replaced as a set.
If inspection shows no damage, the same hypoid gear
WARNING set and pinion shaft can be used again. Using a dial
Compressed air can move particles so that they indicator, measure the backlash of the hypoid gear
cause injury to the user or to other personnel. set and make a record of the dimension. See the
Make sure that the path of the compressed air is procedure Gear Set, Tooth Contact Pattern Check.
away from all personnel. Wear protective goggles During differential reassembly, adjust the backlash to
or a face shield to prevent injury to the eyes. the original recorded dimension when the hypoid gear
set is installed into the drive axle center section. In-
Clean and inspect the following parts of the differential spect all other parts of the main differential assembly
and drive axle assemblies: for wear or damage. Parts that are damaged must be
• Drive axle - Clean the parts of the axle with solvent replaced.
and dry with compressed air. Inspect all machined
surfaces and bearings for wear and damage.
• Tapered roller bearings - Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
22
ASSEMBLE
Drive Axle Center Section

STEP 1.
If brake manifold and bracket were removed, place
brake manifold and bracket in position on drive axle
center section. Install capscrew and washer. Tighten
capscrew to 19 to 21 N•m (168 to 186 lbf in)
1. CAPSCREW
2. WASHER
3. BRACKET
4. BRAKE MANIFOLD
STEP 2.
Using a press on the outer race of the drive gear inner
bearing, press the drive gear inner bearing into drive
axle center section until it is contacting the bottom of
the bore.
1. DRIVE GEAR INNER BEARING

23
STEP 3.
Install drive gear. Check orientation to make sure yoke
will slip into the drive gear.
1. DRIVE GEAR
A. TOWARD YOKE
B. TOWARD DRIVE AXLE CENTER SECTION
24
Differential Assembly Cover

STEP 1.
If breather assembly was removed, install breather as-
sembly into differential cover assembly.
1. BREATHER CAP
2. PLUG
3. SPRING
4. BALL
6. BREATHER ASSEMBLY
25
Drop Box Housing

STEP 1.
Using a press on the outer bearing cup, press drive gear
outer bearing into drop box housing until it is contacting
the bottom of the bore.
1. OUTER BEARING
2. DROP BOX HOUSING
26
Differential Assembly
STEP 1.
Lubricate both sides of thrust washers with 80W-90W
gear lube. Install side gears and thrust washers into
differential assembly case.

2. THRUST WASHER
3. SIDE GEAR
27
STEP 2.
Lubricate pinion gears with 80W-90W gear lube. Install
pinion gears by rotating the side gears until the pinion
gears are in position.

2. PINION GEARS
28
STEP 3.
Install the pinion shaft into the differential assembly
case, through the pinion gears. Install the pin into the
differential assembly case and pinion shaft.
1. PIN
3. PINION SHAFT
29
STEP 4.
Place hypoid gear in position on the differential as-
sembly and install capscrews. Tighten capscrews in
sequence as shown below to 152 to 167 N•m (112 to
123 lbf ft).
1. HYPOID GEAR
3. CAPSCREW
30
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 bearing cones onto the differential assembly
case. Install the bearing cups onto bearing cones.
1. BEARING CUP
2. TAPERED ROLLER BEARING
INSTALL Find the correct thickness of the mounting distance (in-

ner) shim set as follows:
Pinion Inner Shim Set, Adjust Thickness
(Depth of Pinion) 1. Use a micrometer to measure the total thickness of
the original shim set that was removed from under
NOTE: Use this procedure if a new hypoid gear and the pinion carrier. Make a note of the measurement
pinion set is installed, or if the depth of the pinion has for later use.
to be adjusted.
2. Check the pinion variation number for the original
NOTE: If replacing the drive axle center section, use pinion. See Figure 10. If this number is a plus (+)
a new standard shim set with nominal thickness of value, subtract the value from the value in Step 1.
1.0 mm (0.040 in.) for adjusting the depth of the pin- If the pinion variation number is a minus ( ) value,
ion. Perform the following procedure until the correct add the number to the value in Step 1. The number
backlash and gear tooth contact pattern is achieved. shown is in 0.00 × inch (+2 = +0.002 in.). The result
is the standard thickness for a shim set.
The pinion is adjusted using shims. If the same bear-
ings, hypoid gear, and pinion are used, use the original NOTE: The value calculated in Step 2 is the thickness
shim set. See Figure 9. If a new bearings, hypoid gear, of the standard shim set, without a variation.
and pinion are used, adjust the pinion as described be-
low. 3. Check the pinion variation number for the new pin-
ion. Add or subtract this number to the standard
The correct shim set thickness can be found by using thickness value of Step 2. Add the number if the
the original and new parts. Use the original shim set value is a plus (+) value. Subtract the number if the
thickness and the pinion variation number on the orig- value is a minus ( ) value. The result is the correct
inal and new pinion. For the location and identification thickness for the new shim set. See the examples
of the number, see Figure 10. in Table 1.
31
Table 1. Pinion Variation Numbers Examples
Examples in. mm
NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 10.
1. Original Shim Set Thickness 0.030 0.76
Original Pinion Variation Number = +0.05 mm (+2 in.) 0.002 0.05
Standard Shim Set Thickness 0.028 0.71
New Pinion Variation Number = +0.13 mm (+5 in.) +0.005 +0.13
New Shim Set Thickness = 0.033 0.84
Original Pinion Variation Number = 0.05 mm ( 2 in.) +0.002 +0.05
New Pinion Variation Number = +0.13 mm (+5 in.) +0.005 +0.13
Original Pinion Variation Number = +0.05 mm (+2 in.) 0.002 0.05
New Pinion Variation Number = 0.13 mm ( 5 in.) 0.005 0.13
Original Pinion Variation Number = 0.05 mm ( 2 in.) +0.002 +0.05
New Pinion Variation Number = 0.13 mm ( 5 in.) 0.005 0.13
Legend for Figure 9

1. INNER SHIM SET (CONTROLS DEPTH OF
PINION)
2. INNER TAPER ROLLER BEARING
3. PINION SHAFT
4. DROP BOX HOUSING
5. DRIVE GEAR OUTER BEARING
1. PINION VARIATION NUMBER
Figure 10. Pinion Variation Number
NOTE: The value calculated in Step 3 is the thickness

Figure 9. Shim Set Location of the new shim set that will be installed. See the ex-
amples shown in Table 1.
32
Drive Pinion, Pinion Gear, and Bearings Into Drive Axle Center Section
STEP 1.
Press pinion inner taper roller bearing cup into drive axle
center section.
1. PINION INNER TAPERED ROLLER BEARING

CUP
STEP 2.
Press outer tapered roller bearing cup into drop box
housing.
1. OUTER TAPERED ROLLER BEARING CUP

2. DROP BOX HOUSING
33
STEP 3.
Install inner shims, as determined in section Pinion In-
ner Shim Set, Adjust Thickness (Depth of Pinion), and
inner tapered roller bearing on pinion shaft.
Install pinion shaft assembly into drive axle center sec-

tion.
1. INNER TAPERED ROLLER BEARING

2. INNER SHIMS
3. PINION SHAFT
5. DRIVEN GEAR
STEP 4.
Install the pinion crush sleeve and driven gear onto pin-
ion shaft assembly.
1. DRIVEN GEAR
2. PINION CRUSH SLEEVE
34
STEP 5.
Apply sealant, Yale Part No. 520042831 or equivalent,
to mating surface of drop box housing.
Place drop box housing in position on drive axle center

section. Install washers and capscrews. Tighten cap-
screws to 19 to 23 N•m (168 to 204 lbf in).

2. DROP BOX HOUSING
3. CAPSCREWS
STEP 6.
Using a press on the outer diameter of the input shaft oil
seal, press the input shaft oil seal into drop box housing
until input shaft oil seal is flush with the drop box hous-
ing.
After installing input shaft oil seal, apply grease to lip of

input shaft oil seal.
1. DROP BOX HOUSING

2. INPUT SHAFT OIL SEAL
35
STEP 7.
Attach an angle bracket to input shaft (yoke). Angle
bracket will lock pinion shaft in place while adjusting
pinion nut in STEP 8. Install input shaft and dust cover
into drop box housing.
A. 152 mm (6 in.)
B. 127 mm (5 in.)
C. 102 mm (4 in.)
1. INPUT SHAFT
2. DUST COVER
3. CAPSCREWS
4. ANGLE BRACKET
NOTE: If a manual torque wrench will be used, be sure drive axle center section is secured and will not move when
torquing pinion nut.
STEP 8.
Lock pinion shaft in place by attaching angle bracket to
input shaft (yoke). See STEP 7. Once pinion shaft is
locked in place:
• Tighten pinion nut to 530 to 645 N•m (391 to 476 lbf ft)
to seat bearings. Loosen and retighten nut to 60 to
80 N•m (44 to 59 lbf ft).
• Remove angle bracket from input shaft.
• Using ¼ inch dial torque wrench, rotate pinion nut two
rotations in both directions and check rotating torque.
If less than 2 N•m (18 lbf in), reinstall angle bracket
to input shaft and increase torque on pinion nut by an
additional 60 to 80 N•m (44 to 59 lbf ft).
• Remove angle bracket and recheck rotating torque.
Continue adding torque to pinion nut in 60 to 80 N•m
(44 to 59 lbf ft) increments until rotating torque of 2 to
3 N•m (18 to 27 lbf in) is achieved.
• Stake pinion nut with 8 mm (0.30 in.) spherical end
punch, until contacting bottom of groove in pinion
shaft in two places. 1. PINION NUT
2. WASHER
3. PINION SHAFT
36
Differential Assembly Into Drive Axle Center Section

STEP 1.
Place differential assembly into drive axle center sec-
tion.
2. HYPOID GEAR
STEP 2.
to mating surface of differential assembly cover.
Place differential assembly cover in position and install

capscrews. Tighten capscrews in cross (star) pattern to
52 to 57 N•m (38 to 42 lbf ft).

CAPSCREWS
37
STEP 3.
Install the differential retainer rings. If necessary, loosen
differential retainer ring until retainer ring capscrew can
be placed in either hole.

2. DIFFERENTIAL RETAINER RING
STEP 4.
Using a retaining ring special tool, Yale Part No.
580083667, adjust the differential retainer rings in
equal rotations so the backlash of the hypoid gear is
0.20 to 0.28 mm (0.008 to 0.011 in.). See Hypoid Gear
Backlash, Adjust.
Tighten each differential retainer ring one to two

notches past the point where the differential retainer
ring makes contact with outer taper roller bearing cup.
Tighten retainer ring capscrews to 11 to 12 N•m (97 to
106 lbf in). Recheck backlash.
Check hypoid gear runout. See Hypoid Gear, Runout

Check.
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 hypoid gear tooth contact pattern. See Gear 1. DIFFERENTIAL RETAINER RING
Set, Tooth Contact Pattern Check. 3. DIFFERENTIAL ASSEMBLY COVER
4. PINION NUT
38
STEP 4. (Cont)
1. RETAINER RING SPECIAL TOOL
STEP 5.
to mating surface of the pinion cover.
Place pinion cover in position on drop box and install

washers and capscrews. Tighten capscrews to 19 to
23 N•m (168 to 203 lbf in).
1. CAPSCREW
2. WASHER
3. PINION COVER
4. PINION NUT
39
Hypoid Gear Backlash, Adjust 6. If the backlash reading is within specifications, 0.20
to 0.28 mm (0.008 to 0.011 in.), continue checking
If the old gear set is installed, adjust the backlash to tooth contact patterns.
the setting that was measured before the differential as-
sembly was disassembled. 7. If the backlash reading is not within specifications,
adjust backlash using differential retainer rings.
If a new gear set will be installed, adjust the backlash Continue on to Step 8 and Step 9.
to 0.20 to 0.28 mm (0.008 to 0.011 in.).
NOTE: To increase backlash, move hypoid gear away
To adjust/check the backlash, follow the steps outlined from drive pinion. To decrease backlash, move hypoid
below: gear toward drive pinion.
1. Install a dial indicator on bottom of drive axle center NOTE: When adjusting backlash, move hypoid gear
section. Insert plunger or pointer through oil drain only. Do not move drive pinion.
hole as shown in Figure 11.
8. Loosen one bearing adjusting ring one notch, then
2. Adjust dial indicator so that the plunger or pointer is tighten the opposite ring the same amount. See
against the tooth surface. See Figure 11. Figure 12 and Figure 13.
1. TIGHTEN RETAINER RING THIS SIDE

2. INCREASE BACKLASH
3. LOOSEN RETAINER RING THIS SIDE
Figure 12. Backlash Increase

1. DIAL INDICATOR 2. OIL DRAIN HOLE 9. Repeat Step 2 through Step 8 until backlash is
Figure 11. Gear Clearance Check within 0.20 to 0.28 mm (0.008 to 0.011 in.).
3. Adjust indicator to zero. 10. Check the tooth contact pattern. See Gear Set,
Tooth Contact Pattern Check.
4. Hold the drive pinion in position.
11. Check the hypoid gear runout. See Hypoid Gear,
5. After reading the dial indicator, rotate the differential Runout Check.
and hypoid gear a small amount in both directions,
against the drive pinion teeth.
40
1. LOOSEN RETAINER RING THIS SIDE

2. DECREASE BACKLASH
3. TIGHTEN RETAINER RING THIS SIDE
Figure 13. Backlash Decrease

1. DIAL INDICATOR
Hypoid Gear, Runout Check 2. OIL FILL HOLE
1. Attach a dial indicator to the mounting flange of the
differential assembly cover as shown in Figure 14. Figure 14. Ring Gear Runout Check
2. Adjust the dial indicator so that the plunger or Gear Set, Tooth Contact Pattern Check
pointer goes through oil fill hole and is against the
back surface of the hypoid gear. NOTE: The hypoid gear clearance can be changed
within the limits of 0.20 to 0.28 mm (0.008 to 0.011 in.).
3. Set dial indicator to zero.
NOTE: If the original hypoid gear set is installed, adjust
4. Rotate hypoid gear and check dial indicator for the the clearance to the original value recorded in Differen-
maximum needle movement. The maximum move- tial Assembly From Drive Axle Center Section Assem-
ment permitted is 0.28 mm (0.011 in.). bly. If a new gear set is installed, adjust the differential
retainer rings for 0.20 to 0.28 mm (0.008 to 0.011 in.)
5. If movement exceeds maximum limit, remove differ- clearance. Refer to Ring and Pinion Tooth Contact Ad-
ential and hypoid gear assembly from the differen- justment.
tial assembly and find the reason for the movement.
6. Install the differential and hypoid gear into the dif-

ferential assembly after the parts are repaired or re-
placed.
41
Table 2. Ring and Pinion Tooth Contact Adjustment
1. Apply a colored dye or grease to approximately 12

of the hypoid ring gear teeth.
2. Rotate hypoid 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.
42
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 hypoid
gear away from pinion may be necessary.
The pinion is too close to the center of the hypoid

gear. Remove shims to move pinion away from the
hypoid gear. Check that the clearance is correct. Some
movement of the hypoid gear toward the pinion may
be necessary.
Assemble and install the drive axle. Refer to the section

Drive Axle Repair.
43
Torque Specifications 1400 YRM 1426
Torque Specifications
Axle Shaft Capscrews Drive Axle Mounting Capscrews to Frame
52 to 62 N•m (38 to 46 lbf ft) 245 to 270 N•m (181 to 199 lbf ft)
Brake Manifold to Drive Axle Center Section Pinion Cover Capscrews

Housing Capscrews 19 to 23 N•m (168 to 204 lbf in)
19 to 21 N•m (168 to 186 lbf in)
Hypoid Gear Capscrews
Differential Cover Capscrews 152 to 167 N•m (112 to 123 lbf ft)
52 to 57 N•m (38 to 42 lbf ft)
Transmission Mount Bolt to Center Sec-
Oil Drain Plug tion Housing
Input Shaft Capscrews Wheel Nuts

Drop Box Housing Capscrews Retainer Ring Capscrews

19 to 23 N•m (168 to 204 lbf in) 11 to 12 N•m (97 to 106 lbf in)
Hanger Assembly to Drive Axle Center

Section Housing
90 to 99 N•m (66 to 73 lbf ft)
44
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
1400 YRM 1426 7/11 (5/10) Printed in U.S.A.

550013975-Drive Axle and Differential Assembly Repair-Us

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Maintenance

DRIVE AXLE AND

PART NO. 550013975 1400 YRM 1426

• 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:

©2011 Yale Materials Handling Corp. i

A. FRONT OF TRUCK B. REAR OF TRUCK

Figure 1. Drive Axle Identification Plate

Drive Axle Repair

3. Remove mast assembly as described in section 5. Remove wheels.

NOTE: BOTTOM VIEW OF DRIVE AXLE SHOWN.

Figure 2. Oil Drain Plug

12. Remove four drive axle mounting capscrews from

1. BOLTS 3. DRIVE AXLE CENTER SECTION

Figure 3. Universal Joint Removal

1. CAPSCREW 14. BRAKE ASSEMBLY

Figure 4. Drive Axle

CLEAN AND INSPECT

1. Clean all the parts of the drive axle assembly with

2. Inspect the bearings and seals for damage.

3. Inspect the drive axle shafts for wear and cracks

ASSEMBLE AND INSTALL Figure 6. Hanger Assembly Tightening Sequence

NOTE: When installing the drive axle, ensure the drive

5. Position the drive axle in the lift truck.

NOTE: It is recommended to use a torque multiplier to

6. Install four drive axle mounting capscrews and

7. Install universal joint to transmission using two

8. Install the isolators as shown in Figure 7.

9. Apply adhesive sealant, Loctite® 271, to transmis-

1. TRANSMISSION MOUNTING BRACKET 5. ISOLATOR

Figure 7. Transmission to Center Section Housing Mounting Bolt

14. Apply multipurpose grease with 2 to 4% molybde-

Legend for Figure 8

Figure 8. Oil Fill Level

Differential Assembly From Drive Axle Center Section Assembly

1. RETAINER RING CAPSCREW

1. RETAINER RING SPECIAL TOOL

1. DIFFERENTIAL ASSEMBLY COVER

Remove pinion nut and washer.

1. INPUT SHAFT (YOKE)

1. INSERT TWO CAPSCREWS

1. OUTER TAPERED ROLLER BEARING

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

1. INNER TAPERED ROLLER BEARING

1. OUTER TAPERED ROLLER BEARING CUP

1. PINION INNER TAPERED ROLLER BEARING

1. DIFFERENTIAL ASSEMBLY CASE

Inspect the differential assembly case and side gears

1. DIFFERENTIAL ASSEMBLY CASE

Drop Box Housing

1. INPUT SHAFT OUTER BEARING

Differential Assembly Cover

Drive Axle Center Section

1. DRIVE GEAR INNER BEARING

NOTE: Remove the brake manifold and bracket only if damaged.

CLEAN AND INSPECT assembly. If bearings show signs of wear, cracks, or

Drive Axle Center Section

1. DRIVE GEAR INNER BEARING

Differential Assembly Cover