FRONT AXLE

Structure ................................................................................................... 7 – 1
Removal and Installation ..................................................................... 7 – 2
Front Wheels ............................................................................................. 7 – 2
Front Axle .................................................................................................. 7 – 4
Disassembly and Reassembly ........................................................... 7 – 8
Disassembly .............................................................................................. 7 – 8
Inspection after Disassembly ..................................................................... 7 – 10
Reassembly ............................................................................................... 7 – 11
Service Data ............................................................................................. 7 – 13

7
 FRONT AXLE

Structure

1 3 4

210756

1 Front wheel hub 4 Front axle housing

2 Front axle support 5 Backing plate
3 Axle shaft 6 Reduction and differential assembly

The front axle housing 4 is bolted to the transmission

housing.
The reduction and differential assembly 6 forms
integral part of the transmission. Refer to “GROUP 6
POWERSHIFT TRANSMISSION.”

7-1
FRONT AXLE

Removal and Installation

Front Wheels

! WARNING
Be sure to use the specified tire size. See the
manufacturer’s name plate on the front cowling
or the parts manual for correct size of tire.

Removal
1 Wheel nuts
2 Front wheel

205952

Start by:
(a) Pull the parking brake lever and block the rear wheels.
(b) Loosen the wheel nuts 1 by two turns. Then, raise the
front end of the truck using a hoist or the hydraulic
system.
(1) Hoisting
Using sling and eye-bolts at both ends of the cross
member of top of the outer mast, lift the front end of
the truck with a hoist.

209939

(2) Using hydraulic system

Tilt the mast fully backward and place appropriate
wood blocks under the mast. Tilt the mast forward
back to raise the front end.

! CAUTION
After raising the front end, place wood blocks
under the frame to prevent the truck from falling.

210757
(c) Remove the wheel nuts 1.
(d) Remove the wheel 2.
7-2
 FRONT AXLE

Installation
To install, follow the removal sequence in reverse, paying
attention to the following points.

! WARNING
(1) Use the specified tire siz e from the
manufacturer’s name plate or the parts manual.
(2) Make sure the clamping surfaces of the
wheel nuts and the counterbores in the rim
are free of dirt.

(1) Install the tire and tighten the wheel nuts. Tighten each
nut until its tapered portion is in full-face contact with
the counterbore in the rim.

100835A

(2) Lower the truck until the tire touches the floor. Then
tighten the wheel nuts in number sequence, in two or
three steps, to the specified torque.

Truck Model 1 ton 2, 3 ton

Item class classes

Tightening torque for 156.9±15.7 377.6±37.8

wheel nuts (16±1.6) (38.5±3.85)
N·m (kgf·m) [lbf·ft] [116±11.6] [279±27.9]
205953

7-3
FRONT AXLE

Front Axle

11

10

12 14 13
1
5
6
7
2

210758

Sequence
1 Nuts 8 Brake pipe
2 Fork, Lift bracket 9 Parking brake cable
3 High-pressure hose for lift cylinder 10 Bolt
4 Tilt cylinder pin 11 Bolt, Nut
5 Mast support cap 12 Front axle drain plug
6 Mast 13 Front axle shaft
7 Front wheel 14 Front axle assembly

Start by:
(a) Have a lift truck ready for supporting the front axle NOTICE: It is not necessary to remove the axle
assembly. housing nor to drain the oil for removing
(b) Remove the mast. For replacement of the front the axle shaft or disassembling the
axle housing, refer to “GROUP 12 MAST AND wheel hub.
FORKS.”
(c) Jack up the truck.
(d) Support the front end of the truck with blocks or
stands at both sides to keep the truck in the
horizontal position.

7-4
 FRONT AXLE

Suggestions for Removal

1. Removing front wheel

Before removing the front wheels, place blocks or stands
under the frame and transmission to support it.

2. Removing parking brake cable

To remove the parking brake cable, remove the parking
brake lever assembly from the dashboard and disconnet the
cable from the lever

3. Removing front axle assembly

(1) Support the front axle assembly with the supporting lift
truck from under left and right sides of the differential.
(2) Place the parking brake lever of the supporting lift
truck into the “apply” position, then shut down the
engine.

! CAUTION
Never fail to place the parking brake lever of the
supporting lift truck into the “apply” position
before shutting down the engine.

(3) Remove the mounting bolts of the front axle assembly.

(4) Move the supporting lift truck backwards to remove the
front axle assembly from the vehicle.

7-5
FRONT AXLE

Installation
To install, follow the removal sequence in reverse, paying
attention to the following points.
(1) Tighten the bolt 10 and 11 to the specified torque.

116.7 to 157.9 N·m

Tightening torque for
(11.9 to 16.1 kgf·m)
bolt 10
[86.1 to 116.5 lbf·ft]
377.6±37.8 N·m
Tightening torque for
(38.5±3.9 kgf·m)
bolt 11
[279±27.9 lbf·ft]

(2) After connecting the parking brake cable, make sure

that the brake lever operating effort is within the
specification.

245 to 295 N
Parking brake operating
(25 to 30 kgf)
effort
[55 to 66 lbf·ft]

! WARNING Parking brake warning lamp

Parking
After installation of the parking brake lever, brake lever
check the following:
(1) The parking brake warning lamp glows when
the parking brake lever is in the “apply”
position.
(2) When the operator leaves the seat with the
parking brake lever remaining in the
“release” position, the Integrated Presence
System causes the parking brake warning 104212
lamp to flicker and the buzzer to sound
normally.

(3) Before installing the mast, bleed the brake fluid circuits
of trapped air. For bleeding, refer to “GROUP 9
BRAKE SYSTEM.”
(4) After installing the mast, make sure that tilt angles,
forward and backward, are correct and that the lift
chains, right and left, are equal in tension. Refer to
“GROUP 12 MAST AND FORKS.”

7-6
 FRONT AXLE

(5) Fill the front axle housing with oil up to the level / fill
hole.
(a) Apply the parking brake. Place the transmission in
neutral. Stop the engine and block wheels.
(b) Raise the lift bracket high enough to gain access to
the level/fill plug.
(c) Use blocking under the inner mast to secure the lift
bracket in this position.

202983

(d) Remove the level/fill plug. Maintain lubricant

level to the bottom of the level/fill hole.

Truck Model 1 ton 2, 3 ton

Item class classes

Refill capacity of front 4.2 liters 5.0 liters

axle housing (1.1 U.S. gal.) (1.3 U.S. gal.)

(e) Clean the level/fill plug and put it back in place. 104241
(f) Remove the blocking lower the bracket.

7-7
FRONT AXLE

Disassembly and Reassembly

Disassembly

13
14
1

2
4 3

5
6
12

7 11
10
#8 #9

210759

Sequence
1 Air bleeder 8 Oil seal retainer (except 1 ton class)
2 Level plug 9 O-ring (except 1 ton class)
3 Drain plug 10 Oil seal
4 Axle shaft 11 Tapered roller bearing
5 Lock ring, Lock nut 12 Oil seal
6 Tapered roller bearing 13 Brake assembly
7 Front wheel hub, Brake drum 14 Frame support, Axle housing

7-8
 FRONT AXLE

Suggestions for Disassembly

1. Removing lock nut

Use the lock nut wrench (special tool).
Special tool needed
Pin spanner 91A67 - 00300

Special tool

210760

2. Removing front wheel hub

Use the wheel hub puller (special tool).
Special tool needed
Special tool
1 ton class 60309 - 40100
2, 3 ton classes MH061017

NOTICE: It is not necessary to remove the oil seal from

the hub nor disassemble the oil deflector unless
the seal is defective. 210761

3. Removing bearings
The inner race of the tapered roller bearing remains in the
axle housing when the hub is drawn out. Remove this race
together with a bearing puller.
NOTICE: Trucks of 1 ton class do not have the seal
retainer.

210762

7-9
FRONT AXLE

Inspection after Disassembly

1. Axle shaft
(1) Looseness of mating splines
Mount the differential bevel gear on the splined end of
the shaft and set a dial indicator as shown. Rotate the
bevel gear in the direction shown and read the free play
(looseness of mating splines).

A: Standard value B: Repair or service limit

Free movement 0.07 to 0.15 mm

A
(looseness of mating (0.0028 to 0.0059 in.) 209948
splines) B 0.5 mm (0.020 in.)

2. Shaft deflection and flange runout

Deflection of shaft
(1) Set a dial indicator at the middle part of the axle shaft.
Rotate the shaft and read the dial indicator (deflection
of axial shaft).

A: Standard value B: Repair or service limit

Deflection of axle shaft 0.5 mm (0.020 in.)

A
(1/2 of dial indicator maximum
reading) B 1.0 mm (0.039 in.)
Face runout of flange

(2) Set a dial indicator against the flange of the axle shaft 209949
as shown. Rotate the shaft and read the face runout of
flange.

A: Standard value B: Repair or service limit

Face runout of axle shaft A 0.08 mm (0.0031 in.)

flange B 0.5 mm (0.020 in.)

3. Axle housing
(1) Check the surfaces of the axle housing that are in
contact with the mast bearing for damage.
(2) Check the entire axle housing for distortion, dents and
other defects. Pay particular attention to the welds to
see if any weld is cracked and requires repair.

4. Others
Check the oil seals and retainer for wear or damage.

7-10
 FRONT AXLE

Reassembly
To reassemble follow the disassembly sequence in reverse,
paying attention to the following points.

1. Oil seals
Replace with new one.

2. Front wheel hub

(1) Fill the front wheel hub with grease (Autolex A or
equivalent) as shown.
Grease
Press grease into the roller holder of the tapered roller
bearing (inner) using the palm of your hand.
Apply grease to the lip groove of oil seal.

! WARNING
Be carefull and do not let grease enter the brake
drums.
210763

(2) Using the installer (special tool), install the inner race
and oil seal retainer of the wheel hub bearing.
Special tool needed

Truck Model Special tool

1 ton 2, 3 ton
Item class classes

Installer 64309 - 12300 91468 - 00300

210764

(3) Apply sealant (oil resistant liquid gascket such as

ThreeBond #1104) to the flange surfaces of the axle
shaft.

7-11
FRONT AXLE

2. Hub bearing preload adjustment and lock nut

(1) Install the nut hand-tight with a pin spanner (special Nut
tool). Lock ring

Special tool needed Lock bolt

Pin spanner 91A67 - 00300

(2) Rotate the hub and tap its periphery with a soft-head
mallet for snug assembling.
(3) Fully tighten the lock nut to obtain hub bearing preload 210765
within the specified limits.
NOTICE: To check the hub bearing preload, hook a spring
scale on the wheel bolt, then pull to measure the
tangential force of the wheel bolt.

Pleload for hub bearing

Truck Model Wheel bolt

1 ton 2, 3 ton
Item class classes

Increment from when 0.5 to 4.9

preload is zero (0.05 to 0.5) Hub bearing
N·m (kgf·m) [lbf·ft] [0.37 to 3.7]
Tangential force of 5.6 to 54 4.5 to 45
wheel bolt (0.57 to 5.5) (0.46 to 4.6)
N (kgf) [lbf] [1.26 to 12.1] [1.01 to 10.1]
210766

(4) Fit the lock ring into place and tighten the lock bolt.
(5) Check the preload again.

3. Plug
Tighten the drain plug and level plug to the specified
torque.

83.4±7.8 N·m
Tightening torque for
(8.5±0.8 kgf·m)
drain plug
[61.5±5.8 lbf·ft]
127.5±9.8 N·m
Tightening torque for
(13.0±1.0 kgf·m)
level plug
[94.0±7.2 lbf·ft]

7-12
 FRONT AXLE

Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Models
1 ton class 2 ton class 3 ton class
Items
A 0.08 (0.0031)
Face runout of axle shaft flange
B 0.5 (0.020)

Deflection of axle shaft A 0.5 (0.020)

(1/2 of gauge reading) B 1.0 (0.039), maximum
Increment from when preload is zero
A 0.5 to 4.9 (0.05 to 0.5) [0.37 to 3.7]
N·m (kgf·m) [lbf·ft]
Preload for
hub bearing 1 5.6 to 54 4.5 to 45
Tangential force of wheel bolt 2
A (0.57 to 5.5) (0.46 to 4.6)
N (kgf) [lbf]
[1.26 to 12.1] [1.01 to 10.1]
Axle shaft bolts 3 A 98.1±9.8 (10.0±1.0) [72.4±7.2]
145.9±14.6 212.7±21.3
Backing plate bolts 4 A (14.9±1.5) (21.7±2.2)
Tightening [107.6±10.8] [156.9±15.7]
torque Axle support nuts 5 A 377.6±37.8 (38.5±3.9) [279±27.9]
N·m (kgf·m) 156.9±15.7 377.6±37.8
[lbf·ft] Wheel nuts 6 A (16.0±1.6) (38.5±3.9)
[116±11.6] [279±27.9]
Level plug 7 A 127.5±9.8 (13.0±1.0) [94.0±7.2]
Drain plug 8 A 83.4±7.8 (8.5±0.8) [61.5±5.8]

3
4

210767

7-13