9° GP190 VX (B909) 9 Ton. REPARO DO EIXO MOTOR E DO CONJUNTO DIFERENCIAL

Maintenance
DRIVE AXLE AND

DIFFERENTIAL
ASSEMBLY REPAIR
(WET BRAKE)
GLP/GDP60-70VX (GP/GLP/GDP135VX-155VX) [C878,
D878, E878];
GLP/GDP60-70VX (GLP/GDP135-155VX) [F878];
GLP60VX, GLP70VX, GP70VXS6
GP70VXS9 (GP135VX, GP155VX,
GP155VXS) [G878];GP60VX, GP70VX, GP70SVX,
GP70SVX9, GP80SVX (GP135VX, GP155VX,
GP155SVX, GP170SVX) [H878];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) [A909, B909];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GDP170VX, GDP175VX36, GDP190VX) [C909, D909]
PART NO. 524296605 1400 YRM 1344

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 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.
WARNING
California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can expose you to
chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information, go to
www.P65Warnings.ca.gov.
Table of Contents
TABLE OF CONTENTS
General....................................................................................................................................................................1
Identification Plate................................................................................................................................................ 1
Drive Axle Removal.................................................................................................................................................2
Planetary Reduction Gear Repair......................................................................................................................... 14
Remove and Disassemble..................................................................................................................................14
Clean and Inspect...............................................................................................................................................23
Assemble and Install...........................................................................................................................................23
Brake Repair......................................................................................................................................................... 33
Wet Brake Noise Reduction................................................................................................................................56
General............................................................................................................................................................ 56
Adding Additive To Transmission..................................................................................................................... 56
Differential Repair..................................................................................................................................................58
Remove.............................................................................................................................................................. 58
Disassemble....................................................................................................................................................... 62
Assemble............................................................................................................................................................68
Install.................................................................................................................................................................. 76
Bevel Pinion.......................................................................................................................................................... 80
Drive Axle Installation............................................................................................................................................95
Special Tools....................................................................................................................................................... 107
Torque Specifications.......................................................................................................................................... 108
©2021 Yale Materials Handling Corp. i

1400 YRM 1344 General
General
This manual covers the repair of the drive axle,
differential, and the wet disc brakes.
IDENTIFICATION PLATE
See Figure 1.
1. DANA PART NUMBER

2. DANA SERIAL NUMBER
3. YALE PART NUMBER
4. AXLE OVERALL RATIO
Figure 1. Identification Plate
1
Drive Axle Removal 1400 YRM 1344
Drive Axle Removal

• GLP/GDP80VX, GLP/GDP80VX9, GLP/
WARNING GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (C909)
When putting the lift truck on blocks, make sure
the surface is solid, even, and level. Any blocks • GLP/GDP80VX, GLP/GDP80VX9, GLP/
used to support the lift truck must be solid, one- GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (D909)
piece units.
1. Put blocks on each side (front and back) of the

steering tires to prevent movement of the lift WARNING
truck. Completely remove air from tires before removing
them from lift truck. Air pressure in tires can cause
2. Raise the lift truck and put blocks under the frame tire and rim parts to explode, which can cause
so that the drive wheels do not touch the floor. serious injury or death. Never loosen nuts that
Put blocks under the counterweight for stability. hold together inner and outer wheel halves when
there is air pressure in tire.
3. Remove the mast assembly as described in the
section 4. Remove the air from the tires and remove the
wheels.
Mast Repairs, 2- and 3-Stage Masts (S/N A513,
A514, A613, A614, A702, A703, A704, A705, NOTE: Perform Step 5 through Step 23 for lift truck
A706, A707, A751, A752, B513, B514, B586, models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
B587, B588, B589, B590, B591, B749, B750, GDP135VX, GP/GLP/GDP155VX) (C878, D878,
B751, B752, B753, B754) 4000YRM1250 for lift E878, F878) and GLP60VX, GLP70VX, GP70VXS6
truck models GP70VXS9 (GP135VX, GP155VX, GP155VXS)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ (G878). GP60VX, GP70VX, GP70SVX, GP70SVX9,
GDP135VX, GP/GLP/GDP155VX) (C878, GP80SVX (GP135VX, GP155VX, GP155SVX,
D878, E878) GP170SVX) (H878).
Mast Repair (S/N A513, A514, A613, A614, 5. Remove the drive axle main housing center fill/
A643, A644, A683, A684) 4000YRM1406 for lift level plug and O-ring. See Figure 2.
truck models.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ 6. Remove the oil fill plugs and O-rings on both
GDP90VX (GLP/GDP170VX, GLP/ sides of the drive axle. See Figure 2.
GDP175VX36, GLP/GDP190VX) (A909, B909)
7. Remove the oil drain plugs on both sides of the
Mast Repair (S/N A613, A614, A643, A644,
drive axle. Drain the oil into a suitable container.
A683, A684) 4000YRM1956 for lift truck models
See Figure 2.
• GLP/GDP60VX, GLP/GDP70VX (GLP/
GDP135VX, GLP/GDP155VX) (F878,) 8. Remove the drive axle main housing center drain
• GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 plug. Drain the oil into a suitable container. See
(GP135VX, GP155VX, GP155VXS) (G878)) Figure 2.
• GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX,
GP170SVX) (H878)
2
1400 YRM 1344 Drive Axle Removal
Figure 2. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models, GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878, F878) and GLP60VX, GLP70VX, GP70VXS6
GP70VXS9 (GP135VX, GP155VX, GP155VXS) (G878) GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX
(GP135VX, GP155VX, GP155SVX, GP170SVX) (H878)
3
Legend for Figure 2.
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE
9. Remove the parking brake cables. Refer to the 11. Disconnect the accumulator/brake booster supply
section line from the manifold on the drive axle. See
Figure 3.
Brake System - DANA 1800YRM1247 for lift
truck models
12. Disconnect the brake booster return line from the
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ manifold on the drive axle. See Figure 3.
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878) NOTE: Note placement of hose clamps prior to
Wet Brake System 1800YRM1977 for lift truck removal of hoses to aid in installation.
models 13. Disconnect the drive axle to transmission cooling
• GLP/GDP60VX, GLP/GDP70VX (GLP/ return hose from the manifold on the drive axle.
GDP135VX, GLP/GDP155VX) (F878) See Figure 3.
• GLP60VX, GLP70VX, GP70VXS6 GP70VXS9
(GP135VX, GP155VX, GP155VXS) (G878) 14. Disconnect the transmission to drive axle cooling
supply hose from the manifold on the drive axle.
See Figure 3.
GP170SVX) (H878)
10. Disconnect the brake supply line from the brake

line cross fitting on the drive axle. See Figure 3.
4
Figure 3. Drive Axle and Brake Cooling Lines and Brake Lines for Lift Truck Models, GLP/GDP60VX, GLP/
GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878, F878) and GLP60VX, GLP70VX,
GP70VXS6 GP70VXS9 (GP135VX, GP155VX, GP155VXS) (G878) GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878)
5
1. ACCUMULATOR 7. ACCUMULATOR/BRAKE BOOSTER SUPPLY LINE

2. TRANSMISSION TO DRIVE AXLE COOLING 8. BRAKE BOOSTER RETURN LINE
SUPPLY HOSE 9. BRAKE SUPPLY LINE
3. DRIVE AXLE TO TRANSMISSION COOLING 10. BRAKE COOLING LINE, RIGHT SIDE
RETURN HOSE 11. BRAKE LINE, RIGHT SIDE
4. DRIVE AXLE COOLING RETURN HOSE, LEFT 12. DRIVE AXLE COOLING RETURN HOSE, RIGHT
SIDE SIDE
5. BRAKE COOLING LINE, LEFT SIDE
6. BRAKE LINE, LEFT SIDE
15. Place blocks under the axle assembly and 17. Remove the four mounting capscrews and
connect slings and lifting device. washers from the drive axle. See Figure 4.
16. Remove the capscrews retaining the drive shaft.

Remove the drive shaft.
1. CAPSCREW 3. DRIVE AXLE

2. WASHER
Figure 4. Drive Axle Mounting Capscrews
18. Remove blocks and lower the drive axle 22. Remove the socket head screws retaining the
assembly. Pull axle forward and away from frame. brake manifold to the drive axle. Remove the
manifold. See Figure 5.
19. Place blocks under the differential assembly.
23. Disconnect the brake lines from the drive axle.
20. Disconnect the cooling hoses from the manifold Remove the brake lines with cross fitting, as an
and drive axle. Remove the cooling hoses. See assembly, from the drive axle. See Figure 5.
Figure 5.
21. Disconnect the brake cooling lines from the

manifold and the drive axle. Remove the brake
cooling lines. See Figure 5.
6
Figure 5. Manifold and Cooling Hoses Removal for Lift Truck Models, GLP/GDP60VX, GLP/GDP70VX
GP70VXS9 (GP135VX, GP155VX, GP155VXS) (G878) GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX
7
1. MANIFOLD 6. CROSS FITTING

2. DRIVE AXLE COOLING RETURN HOSE, LEFT 7. BRAKE COOLING LINE, RIGHT SIDE
SIDE 8. BRAKE LINE, RIGHT SIDE
3. BRAKE COOLING LINE, LEFT SIDE 9. DRIVE AXLE COOLING RETURN HOSE, RIGHT
4. BRAKE LINE, LEFT SIDE SIDE
5. SOCKET HEAD SCREWS
NOTE: Perform Step 24 through Step 43 for lift truck 25. Remove right side and left side drain plugs from
model GLP/GDP80VX, GLP/GDP80VX9, GLP/ drive axle. Drain oil into suitable container. See
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, Figure 6.
GLP/GDP190VX) (A909, B909) GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GDP170VX, 26. Remove drive axle main housing center drain
GDP175VX36, GDP190VX) (C909, D909) . plug from main housing, Drain oil into suitable
container. See Figure 6.
24. Remove drive axle main housing center fill plug
from main housing. See Figure 6.
8
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 4. LEFT SIDE DRAIN PLUG
PLUG 5. RIGHT SIDE FILL PLUG
2. DRIVE AXLE MAIN HOUSING CENTER FILL 6. LEFT SIDE FILL PLUG
PLUG
3. RIGHT SIDE DRAIN PLUG
Figure 6. Drive Axle Drain and Fill Plugs for Lift Truck Models, GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909), GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909. D909)
9
27. Remove the parking brake cables. Refer to the NOTE: Note placement of hose clamps prior to
section removal of hoses to aid in installation.
Brake System - DANA 1800YRM1247 for lift 28. Disconnect load sense in and load sense out
truck models hose assemblies from accumulator charge valve.
GLP/GDP80VX, GLP/GDP80VX9, GLP/ See Figure 7.
•
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909) 29. Disconnect brake line from modulating brake
valve. See Figure 7.
Wet Brake System 1800YRM1977 for lift truck
models 30. Disconnect hydraulic pressure supply hose from
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ accumulator charge valve. See Figure 7.
GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (C909) 31. Disconnect hydraulic return hose from
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ accumulator charge valve and modulating brake
GDP90VX (GDP170VX, GDP175VX36, valve. See Figure 7.
GDP190VX) (D909)
10
Figure 7. Drive Axle, Manifold, Cooling Hoses, and Brake Lines for Lift Truck Models, GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909), GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909. D909)
11
A. REAR VIEW B. FRONT VIEW
1. MODULATING BRAKE VALVE 9. MANIFOLD

2. BRAKE LINE 10. DRIVE AXLE
3. LOAD SENSE IN HOSE ASSEMBLY 11. COOLING RETURN TO TRANSMISSION HOSE
4. LOAD SENSE OUT HOSE ASSEMBLY 12. COOLING SUPPLY FROM TRANSMISSION HOSE
5. ACCUMULATOR CHARGE VALVE 13. AXLE VENT LINE
6. HYDRAULIC PRESSURE SUPPLY HOSE 14. COOLING SUPPLY LINES
7. HYDRAULIC RETURN HOSE 15. SOCKET HEAD SCREW
8. COOLING RETURN HOSE 16. BRAKE LINE
32. Place blocks under the axle assembly. Connect 34. Remove the four mounting capscrews and
slings and lifting device to axle assembly. washers from the drive axle. See Figure 8.
33. Remove the capscrews and the drive shaft from

the drive axle.

2. WASHER
12
35. Remove blocks and lower the drive axle 40. Disconnect axle vent line from drive axle. See
assembly. Pull axle forward and away from frame. Figure 7.
36. Place blocks under the differential assembly. 41. Remove cooling supply lines from manifold and
drive axle. See Figure 7.
37. Remove cooling return hoses from manifold and
drive axle. See Figure 7. 42. Remove two socket head screws and manifold
from drive axle. See Figure 7.
38. Disconnect cooling return to transmission hose
from manifold. See Figure 7. 43. Disconnect brake lines from drive axle. Remove
brake lines with cross fitting, as an assembly,
39. Disconnect cooling supply from transmission from drive axle. See Figure 7.
hose from manifold. See Figure 7.
13
Planetary Reduction Gear Repair 1400 YRM 1344
Planetary Reduction Gear Repair
REMOVE AND DISASSEMBLE

Refer to Figure 9 and Figure 10 for the following repair procedures.
1. CAPSCREW 14. INNER BEARING

2. OUTER AXLE SHAFT 15. SEAL
3. O-RING 16. HALF SHAFT - SHORT OR LONG
4. PLANETARY GEAR CARRIER 17. CAPSCREW
5. BEARING 18. SHOULDER RING
6. CENTERING RING 19. SOCKET HEAD SCREW
7. RETAINING SCREW 20. WHEEL HUB SUPPORT
8. PLANETARY GEAR 21. RING CASE
9. RETAINING RING 22. RIGHT AXLE CASE
10. SUN GEAR 23. PLUG
11. OUTER BEARING 24. HEXAGON BOLT
12. WHEEL HUB 25. MAGNET PLUG
13. WHEEL STUD 26. LEFT AXLE CASE
Figure 9. Planetary Reduction Gear Assembly for Lift Truck Models, GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) and GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)
14
1400 YRM 1344 Planetary Reduction Gear Repair
1. O-RING 14. WHEEL HUB

2. OIL LEVEL PLUG 15. BEARING
3. DRIVE AXLE HOUSING ARM 16. SEAL
4. CAPSCREW 17. CAPSCREW
5. O-RING 18. OUTER AXLE SHAFT
6. RING GEAR 19. O-RING
7. WHEEL HUB SUPPORT 20. PLANETARY GEAR CARRIER
8. AXLE SHAFT 21. CENTERING RING
9. SOCKET HEAD SCREW 22. RETAINING SCREW
10. SHOULDER RING 23. SUN GEAR
11. CAPSCREW 24. DRAIN PLUG
12. WHEEL STUD 25. RETAINING RING
13. BEARING 26. PLANETARY GEAR
Figure 10. Planetary Reduction Gear Assembly for Lift Truck Models, GLP/GDP60VX, GLP/GDP70VX
GP70VXS9 (GP135VX, GP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX
15
STEP 1.
Connect an overhead lifting device to the
planetary reduction gear assembly.
NOTE: Make an alignment mark on the axle housing and planetary carrier cover before removing the planetary
carrier cover.
STEP 2.
Remove the socket head screws retaining the
planetary carrier cover to the axle housing.
1. SOCKET HEAD SCREW
NOTE: Planetary gear images shown in Step 3 through Step 9 are for lift truck models GLP/GDP60VX, GLP/
GP70VXS6 GP70VXS9 (GP135VX, GP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) . Lift truck models GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) and GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) have four
planetary gears.
16
STEP 3.
Remove complete planetary carrier assembly
from axle housing.
1. AXLE HOUSING
2. PLANETARY CARRIER ASSEMBLY
STEP 4.
Remove and discard the O-ring from the
planetary carrier assembly.
1. O-RING
STEP 5.
Remove the retaining rings retaining the planetary
gears.
1. RETAINING RING
2. PLANETARY GEAR
17
STEP 6.
Remove the planetary gear and bearing
assemblies.
1. PLANETARY GEAR AND BEARING ASSEMBLY
STEP 7.
Remove the ring gear.
1. RING GEAR
STEP 8.
Remove the retaining screw and centering ring.
1. RETAINING SCREW
2. CENTERING RING
18
STEP 9.
Remove the planetary gear carrier.
1. PLANETARY GEAR CARRIER
STEP 10.
Place the reduction gear assembly upside down.
Remove the capscrews retaining the outer axle
shaft to the wheel hub.
1. CAPSCREW
STEP 11.
Using a plastic hammer, tap the outer axle shaft
out of the wheel hub support and wheel hub.
1. OUTER AXLE SHAFT
19
STEP 12.
Remove and discard the O-ring from the outer
axle shaft.
1. O-RING
STEP 13.
Remove the capscrews retaining the shoulder
ring.
1. CAPSCREW
STEP 14.
Remove the shoulder ring.
1. SHOULDER RING
NOTE: Use a cylindrical block, with a minimum outside diameter of 99 mm (3.90 in.) and maximum outside
diameter of 118 mm (4.65 in.), for the puller to push against the end of the wheel hub support.
20
STEP 15.
Using a suitable puller and cylindrical block,
disengage the wheel hub support from the wheel
hub.
1. WHEEL HUB
2. WHEEL HUB SUPPORT
STEP 16.
Remove the outer bearing cone.
1. OUTER BEARING CONE
STEP 17.
Remove the seal from the hub.
21
STEP 18.
Remove the inner bearing cone.
1. INNER BEARING CONE
STEP 19.
Remove the inner and outer bearing cups from
the wheel hub.
1. BEARING CUP
STEP 20.
Remove the intermediate disc.
NOTE: Make a note of the order of the brake discs and friction plates to ensure proper assembly.
22
STEP 21.
Remove the sun gear, brake discs, and friction
plates.
CLEAN AND INSPECT 2. Inspect the bearings and bearing cups for
damage. If either bearing or bearing cup is
damaged, replace both bearings and bearing
WARNING cups.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 3. Inspect the all parts for wear and damage.
solvents, always follow the solvent manufacturer's Replace parts as needed.
recommended safety precautions.
4. Inspect the brake discs and friction plates as
1. Clean all the parts with solvent. described in the section Brake Repair. Replace
as needed.
ASSEMBLE AND INSTALL

Refer to Figure 9 and Figure 10 for the following repair procedures.
STEP 1.
Install the sun gear.
NOTE: Install brake discs and friction plates in sequence noted during disassembly.
23
STEP 2.
Lightly lubricate the brake discs and friction plates
with John Deere JDM J20C.
Install the first friction plate.
1. FRICTION PLATE
STEP 3.
Install the first brake disc.
1. BRAKE DISC
STEP 4.
Before installing the last friction plate and the
intermediate disc, apply a thin coat of grease on
the contact surfaces to hold them in position when
mounting the planetary reduction gear assembly.
24
STEP 5.
Position the wheel hub under a press. Lubricate
the inner and outer bearing cups with John Deere
JDM J20C. Using the press and special tool T9,
press the bearing cups into the wheel hub.
1. INNER BEARING CUP

2. WHEEL HUB
3. SPECIAL TOOL T9
STEP 6.
Lubricate the inner bearing cone with John Deere
JDM J20C.
Position the inner bearing cone into the bearing
cup.
NOTE: Verify that the seal is correctly oriented.
STEP 7.
Position the seal in the special tool T10.
1. SEAL
2. SPECIAL TOOL T10
25
STEP 8.
Position special tool T10 and seal on the wheel
hub. Using the press, press the seal into its seat.
1. SEAL
2. SPECIAL TOOL T10
STEP 9.
Place the wheel hub in position on the wheel hub
support.
Using a plastic hammer, lightly hammer all around
the edge of the wheel hub until the bearing cone
is seated in the bearing cup.
1. WHEEL HUB
STEP 10.
Lubricate the outer bearing cone with John Deere
JDM J20C and install the outer bearing cone.
the inner edge of the bearing cone until the
bearing cone is seated in the bearing cup.
26
STEP 11.
Install the shoulder ring.
STEP 12.
Apply Loctite® 242 to the threads of the
capscrews and install the capscrews. Tighten the
capscrews in two stages in a crisscross pattern to
a final torque of 68 to 75 N•m (50 to 55 lbf ft).
STEP 13.
Lubricate a new O-ring with a lithium based
grease. Install the O-ring on the outer axle shaft.
1. O-RING
27
STEP 14.
Install the outer axle shaft while aligning the holes
in the outer axle shaft with the holes in the wheel
hub.
STEP 15.
Apply Loctite® 242 to the threads of all the
capscrews. Install the capscrews.
Tighten the capscrews in two stages using a
crisscross pattern to a final torque of
182 to 202 N•m (134 to 149 lbf ft).
1. CAPSCREW
NOTE: Planetary gear images shown in Step 16 through Step 22 are for lift truck models GLP/GDP60VX, GLP/
planetary gears.
28
STEP 16.
Install the planetary gear carrier onto the outer
axle shaft.
STEP 17.
Apply Loctite® 242 to the threads of the retaining
screw. Install the retaining screw and centering
ring. Tighten the retaining screw to
116 to 128 N•m (86 to 94 lbf ft).
1. RETAINING SCREW
2. CENTERING RING
CAUTION
The jointed portion of the internal ring of the bearing must face the bottom of the pin.
29
STEP 18.
Fit the planetary gears onto the pins of the
planetary gear carrier.
1. PLANETARY GEAR
STEP 19.
Install the retaining rings to lock the planetary
gears in position.
1. PLANETARY GEAR
2. RETAINING RING
STEP 20.
grease. Install the O-ring on the ring gear.
1. O-RING
30
STEP 21.
Install the ring gear onto the planetary gears and
wheel hub.
the ring gear until ring gear is seated onto the
planetary gears.
1. RING GEAR
STEP 22.
1. O-RING
STEP 23.
planetary reduction gear assembly. Attach the
planetary reduction gear assembly to the axle
housing.
31
STEP 24.
Apply Loctite® 242 to the threads of the socket
head screws. Install the socket head screws to
retain the planetary reduction gear assembly to
the axle housing.
Tighten the socket head screws in two stages
using a crisscross pattern to a final torque of
129 to 143 N•m (95 to 105 lbf ft).
32
1400 YRM 1344 Brake Repair
Brake Repair

Refer to Figure 11 and Figure 12 for the following procedures.
1. SOCKET HEAD SCREW 15. DRIVE AXLE MAIN HOUSING

2. WASHER 16. DISC (PART OF PISTON ASSEMBLY)
3. PARKING BRAKE LEVER 17. TUBE (PART OF PISTON ASSEMBLY)
4. NUT 18. O-RING
5. ADJUSTING SCREW 19. O-RING
6. SOCKET HEAD SCREW 20. PISTON
7. THRUST BUSHING 21. RETURN SPRING
8. CAP 22. SOCKET HEAD SCREW
9. BLEEDER VALVE 23. FRICTION PLATES
10. O-RING 24. INTERMEDIATE DISC
11. BEARING 25. BRAKE DISCS
12. THRUST LEVER 26. SOCKET HEAD/PIN SCREW
13. BEARING 27. AUTOMATIC REGULATION SPRING
14. OIL BREATHER 28. DOWEL PIN
Figure 11. Brake Assembly for Lift Truck Models, GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878, F878) and GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 (GP135VX,
GP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX,
GP155SVX, GP170SVX) (H878)
33
Brake Repair 1400 YRM 1344
Figure 12. Brake Assembly for Lift Truck Models, GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) and GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)
34
1. PARKING BRAKE LEVER 15. O-RING

2. WASHER 16. O-RING
3. SOCKET HEAD SCREW 17. SOCKET HEAD SCREW
4. THRUST BUSHING 18. FRICTION PLATES
5. BEARING 19. PLUG
6. DISC 20. BLEEDING BOLT
7. PISTON 21. THRUST LEVER
8. SOCKET HEAD SCREW 22. SPACER
9. GRUB BOLT 23. SPRING
10. NUT 24. BRAKE DISC
11. O-RING 25. INTERMEDIATE DISC
12. PLUG 26. MAIN HOUSING
13. RETURN SPRING 27. SOCKET HEAD/PIN SCREW
14. DOWEL
STEP 1.
planetary reduction gear assembly.
STEP 2.
planetary carrier cover to the axle housing.
35
NOTE: Planetary gear images shown in Step 3 and Step 4 are for lift truck models GLP/GDP60VX, GLP/
GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878, F878) andGLP60VX, GLP70VX,
planetary gears.
STEP 3.
Remove the complete planetary carrier assembly
from the axle housing.
1. AXLE HOUSING
2. PLANETARY CARRIER ASSEMBLY
STEP 4.
Remove and discard the O-ring from the
planetary carrier assembly.
1. O-RING
36
STEP 5.
Remove the intermediate disc.
NOTE: Make a note of the order of the brake discs and friction plates to ensure proper assembly.
STEP 6.
Remove the sun gear, brake discs, and friction
plates.
STEP 7.
Verify that no brake discs or friction plates remain
in the axle housing.
1. FRICTION PLATE
37
STEP 8.
Remove the axle shaft.
STEP 9.
Remove the socket head screws and return
springs from the piston.
1. PISTON
2. RETURN SPRING AND SOCKET HEAD SCREW
STEP 10.
Remove the socket head/pin screws that guide
the piston.
1. PISTON
2. SOCKET HEAD/PIN SCREW
38
WARNING
Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure
that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to
prevent injury to the eyes.
CAUTION
Hold onto the piston as it may be suddenly ejected and damaged.
STEP 11.
Slowly apply compressed air through the brake
fluid port to extract the entire piston.
1. PISTON
NOTE: The O-rings must be replaced each time the unit is disassembled.
STEP 12.
Remove and discard the O-rings from the piston.
1. O-RING
2. O-RING
NOTE: If replacing the brake discs and/or piston seals only, go to Clean and Inspect and then Assemble and
Install, Step 5.
39
STEP 13.
Remove the socket head screw and washer
retaining the parking brake lever to the thrust
lever.

2. WASHER
3. PARKING BRAKE LEVER
40
STEP 14.
Mark the position of the parking brake lever in
relation to the thrust lever.
Remove the parking brake lever.

2. ALIGNMENT MARK
41
NOTE: Prior to removing thrust bushing, clean area

around thrust bushing to prevent dirt from entering
area containing the thrust lever when thrust bushing is
removed.
STEP 15.
thrust bushing to the axle housing.

2. THRUST BUSHING
42
STEP 16.
Remove the thrust bushing.
1. THRUST BUSHING
STEP 17.
Remove and discard O-rings from the thrust
bushing.
1. O-RING
2. O-RING
43
STEP 18.
Mark the position of the thrust lever.
1. THRUST LEVER
STEP 19.
Remove the thrust lever and bearings.
1. BEARING
2. THRUST LEVER
3. BEARING
STEP 20.
Using a press, remove the bearings from the
thrust lever.
1. THRUST LEVER
2. BEARING
3. BEARING
44
CLEAN AND INSPECT 3. Inspect the all parts for wear, damage, and rust.
Replace parts as needed.
WARNING 4. Inspect the brake disc(s). Replace discs when the

Cleaning solvents can be flammable and toxic and groove depth thickness is less than
can cause skin irritation. When using cleaning 0.1 mm (0.0039 in.).
solvents, always follow the solvent manufacturer's The groove depth thickness for a new disc is
recommended safety precautions. 0.3 to 0.5 mm (0.0118 to 0.0197 in.).
1. Clean all the parts with solvent.
2. Inspect the bearings for wear or damage.

Replace as needed.

NOTE: If replacing the brake discs and/or piston seals only, go to Step 5.
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns.
STEP 1.
Heat the bearings to approximately
100°C (212°F). Install the bearings on the thrust
lever.
1. BEARING
STEP 2.
Lubricate the thrust lever and bearings with John
Deere JDM J20C. Install the thrust lever in
position previously marked during removal.
45
STEP 3.
Lubricate new O-rings with a lithium based
grease. Install the O-rings on the thrust bushing.
For lift truck models GLP/GDP60VX, GLP/
GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878, F878) and
GLP60VX, GLP70VX, GP70VXS6 GP70VXS9
(GP135VX, GP155VX, GP155VXS) (G878),
GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP170SVX) (H878) pack the area above O-ring
with multipurpose grease with 2% to 4%
molybdenum disulfide prior to installing thrust
bushing onto thrust lever.
1. O-RING
2. O-RING
3. APPLY MULTIPURPOSE GREASE HERE
STEP 4.
Install the thrust bushing.
Apply Loctite® 242 to the socket head screws.
Install the socket head screws. Tighten socket
head screws to
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft).

2. THRUST BUSHING
NOTE: Make sure the stroke automatic springs are installed flush in the piston.
46
STEP 5.
Install the stroke automatic regulation springs
flush in the piston.
1. PISTON
2. STROKE AUTOMATIC REGULATION SPRING
NOTE: The oil passage must face downwards when installed.
STEP 6.
Lubricate new O-rings with a lithium based
grease. Install new O-rings onto the piston.
1. O-RING
2. O-RING
STEP 7.
Lubricate the piston seating surface with Dexron
III oil.
NOTE: The oil passage must face downwards when installed.
47
STEP 8.
Install the piston into the axle housing. Verify that
the oil passage is towards the bottom.
1. OIL PASSAGE
CAUTION
When installing the piston, ensure that all components are free of moisture and that no water enters the
brake oil circuit.
STEP 9.
Lightly tap around the edge of the piston with a
plastic hammer until the piston is seated.
1. PISTON
NOTE: The threaded holes must be free of oil.
48
STEP 10.
head/pin screws.
Install the socket head/pin screws. Tighten socket
head/pin screws to 5 to 7 N•m (44 to 62 lbf in).
1. SOCKET HEAD/PIN SCREW
NOTE: The threaded holes must be free of oil.
STEP 11.
Apply Loctite® 270 to the threads of the return
spring socket head screws.
Install the socket head screws and return springs.
Tighten socket head screws to
5 to 7 N•m (44 to 62 lbf in).
1. SOCKET HEAD SCREW AND RETURN SPRING
STEP 12.
Install the axle shaft.
49
STEP 13.
Install the sun gear.
1. SUN GEAR
NOTE: Install brake discs and friction plates as noted during disassembly.
STEP 14.
Lightly lubricate the brake discs and friction plates
Install the first friction plate.
1. FRICTION PLATE
STEP 15.
Install the first brake disc.
1. BRAKE DISC
50
STEP 16.
Before installing the last friction plate and the
intermediate disc, apply a thin coat of grease on
the contact surfaces to hold them in position when
mounting the planetary reduction gear assembly.
NOTE: Planetary gear images shown in Step 17 are for lift truck models GLP/GDP60VX, GLP/GDP70VX
(GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) . Lift truck models GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) have four planetary
gears.
STEP 17.
1. O-RING
STEP 18.
planetary reduction gear assembly. Attach the
planetary reduction gear assembly to the axle
housing.
51
STEP 19.
head screws. Install the socket head screws to
retain the planetary reduction gear assembly to
the axle housing.
Tighten the socket head screws in two stages
using a crisscross pattern to a final torque of
129 to 143 N•m (95 to 105 lbf ft).
STEP 20.
Install the parking brake lever by aligning the
marks made during Step 14, Remove and
Disassemble.

2. ALIGNMENT MARK
52
STEP 21.
Turn the parking brake lever until the adjusting
springs correctly regulate the piston stroke.
STEP 22.
Position the parking brake levers as shown.
53
STEP 23.
Install the socket head screw and washer to retain
the parking brake lever to the thrust lever. Tighten
the socket head screw to
23.8 to 26.2 N•m (17.6 to 19.3 lbf in).

2. WASHER
STEP 24.
Apply light pressure to the parking brake lever to
bring the thrust lever to rest with the piston,
without pre-loading the inside band.
Adjust the adjusting screw to draw near to the
parking brake lever, leaving a
0.05 to 0.15 mm (0.00197 to 0.00591 in.) gap.
54
CAUTION
The idle stroke should be eliminated without pre-loading the parking brake levers.
CAUTION
After the drive axle is installed and the parking brake cables are connected and the brakes are released,
verify that the parking brake levers lean against the adjusting screws.
STEP 25.
Lock the adjusting screw in position by tightening
the nut to 20 to 25 N•m (14.75 to 18.44 lbf ft).
1. ADJUSTING SCREW
2. NUT
55
WET BRAKE NOISE REDUCTION Capacities and Specifications 8000YRM1960 for lift
truck models
General
Brake noise may occur during the first 50 hours of GDP90VX (GDP170VX, GDP175VX36,
operation on new lift trucks equipped with a wet brake GDP190VX) (C909)
axle, or on lift trucks where a new wet brake axle is Capacities And Specifications 8000YRM2297
installed. This noise may appear in various forms as
either a squeal, grunt/groan, or a shuddering noise as GLP/GDP80VX, GLP/GDP80VX9, GLP/
brakes are applied. GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (D909)
An additive oil (Yale Part No. 580066916) is available
to help reduce excessive braking noise. The amount of Adding Additive To Transmission
additive oil to use is proportional to the volume of the
system used to cool the brakes. For the lift trucks
covered in this manual, the drive axle system is used WARNING
to cool the brakes. Refer to one of the following Do not add more than 5.5 percent by volume of
manuals to determine the capacity of each drive axle additive. Adding more additive will cause brake
housing arm. system on lift truck to not operate properly and
Capacities and Specifications 8000YRM1320 for lift safely stop lift truck.
truck models
For example, if fluid capacity of one drive axle housing
• GLP/GDP60-70VX (GP/GLP/GDP135-155VX) arm is 9.0 liter (9.5 qt), 5.5 percent of that is
(C878, D878) 0.50 liter (0.52 qt), and is the most additive that can be
Capacities and Specifications 8000YRM1584 for lift added to each drive axle housing arm (left and right) to
truck models reduce brake noise. See Figure 13.
• GLP/GDP60-70VX (GP/GLP/GDP135-155VX)
NOTE: Additive has very high viscosity and must be
(E878)
warmed to 15.5°C (60°F) before adding it to
Capacities and Specifications 8000YRM1958 for lift transmission.
truck models
NOTE: Do Not add additive to center section.
• GLP/GDP60-70VX (GLP/GDP135-155VX)
(F878) 1. Add 2 percent by volume initially, to right and left
drive axle housing sections. See Figure 13. Drive
• GLP60VX, GLP70VX, GP70VXS6 GP70VXS9
lift truck for at least 40 hours or one week.
(GP135VX, GP155VX, GP155VXS) (G878),
GP60VX, GP70VX, GP70SVX, GP70SVX9,
GP80SVX (GP135VX, GP155VX, GP155SVX, 2. If brake noise continues, add another 1 percent
GP170SVX) (H878) by volume, to right and left drive axle housing
sections. Drive lift truck for another 40 hours or
Capacities and Specifications 8000YRM1408 for lift one week.
truck models
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ 3. If brake noise continues, repeat Step 2 until
GDP90VX (GLP/GDP170VX, GLP/ maximum quantity of 5.5 percent by volume has
GDP175VX36, GLP/ GDP190VX) (A909) been added to drive axle.
Capacities and Specifications 8000YRM1587 for lift
truck models
GDP175VX36, GLP/ GDP190VX) (B909)
56
NOTE: DO NOT ADD ADDITIVE TO CENTER SECTION.
A. RIGHT DRIVE AXLE HOUSING ARM C. LEFT DRIVE AXLE HOUSING ARM
B. CENTER SECTION
1. RIGHT DRIVE AXLE HOUSING ARM FILL PLUG 3. LEFT DRIVE AXLE HOUSING ARM FILL PLUG
2. CENTER SECTION
Figure 13. Adding Additive To Stop Braking Noise
57
Differential Repair 1400 YRM 1344
Differential Repair
REMOVE
1. SOCKET HEAD SCREW 15. DIFFERENTIAL CARRIER HALF

2. RING NUT 16. SOCKET HEAD SCREW
3. SEAL 17. NUT
4. SNAP RING 18. O-RING
5. O-RING 19. FLANGE (YOKE)
6. ROLLER BEARING 20. PLATE
7. CAPSCREW 21. SEAL
8. DIFFERENTIAL CARRIER HALF 22. BEARING
9. BEVEL GEAR 23. SPACER
10. THRUST WASHER 24. SHIM
11. SIDE GEAR 25. SHIM
12. SPHERICAL THRUST WASHER 26. BEARING
13. PINION GEARS 27. BEVEL PINION
14. PINION SHAFTS
Figure 14. Differential Assembly for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878, F878) and GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 (GP135VX,
GP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX,
GP155SVX, GP170SVX) (H878)
58
1400 YRM 1344 Differential Repair
1. DIFFERENTIAL CARRIER HALF 12. THRUST WASHER

2. BEVEL PINION 13. DIFFERENTIAL SIDE GEAR
3. PINION SHAFT 14. SHIMS KIT
4. SPHERICAL THRUST WASHER 15. SHIM
5. PINION GEAR 16. SPACER
6. SOCKET HEAD SCREW 17. PLATE
7. RING NUT 18. FLANGE
8. SEAL 19. NUT
9. SNAP RING 20. CAPSCREW
10. O-RING 21. DIFFERENTIAL CARRIER HALF
11. BEARING
Figure 15. Differential Assembly for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) and GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)
59
STEP 1.
Remove the complete planetary reduction gear
assemblies, brake discs, friction plates, axle
shafts, pistons, parking brake levers, and thrust
levers. See the section Brake Repair.
CAUTION
Check and make note of the static torque before
disassembly.
STEP 2.
Measure the static torque of the bevel pinion and
bearings.
STEP 3.
Sling the axle housing arm to be removed and
connect the sling to an overhead lift.
Remove the capscrews retaining the axle housing
arm to the main axle housing.
STEP 4.
Separate the axle housings. Place the axle
housing arm on a bench.
60
STEP 5.
If the differential carrier bearing cones need
replaced, remove the bearing cup from the axle
housing arm.
1. BEARING CUP
NOTE: Perform Step 6 through Step 8 only if the ring nut needs to be removed or adjusted.
STEP 6.
Measure the installation position of ring nut to
facilitate in adjustment during installation.
STEP 7.
Remove the socket head screw.
NOTE: After removing the ring nuts, make sure to thoroughly clean the threaded portions of the ring nuts.
61
STEP 8.
Using special tool T3, remove the ring nut.
1. SPECIAL TOOL T3
2. RING NUT
STEP 9.
Remove the differential assembly.
DISASSEMBLE
62
STEP 1.
Using an appropriate puller, remove the bearing
cone.
1. BEARING CONE
STEP 2.
Remove the bearing cone from the bevel gear
side of the differential carrier.
1. BEARING CONE
2. DIFFERENTIAL CARRIER
STEP 3.
Remove the capscrews retaining the bevel gear
to the differential carrier.
1. CAPSCREW
2. BEVEL GEAR
63
STEP 4.
Remove the bevel gear from the differential
carrier.
1. DIFFERENTIAL CARRIER
2. BEVEL GEAR
STEP 5.
differential halves together.
NOTE: Make alignment marks on the two differential carrier halves to ensure proper assembly.
STEP 6.
Using a plastic hammer, separate the differential
carrier halves.
1. DIFFERENTIAL CARRIER HALF
64
STEP 7.
Remove the thrust washer and first planetary
gear.
1. THRUST WASHER
2. PLANETARY GEAR
STEP 8.
Remove pinion shafts, pinion gears, and spherical
thrust washers.
1. PINION SHAFT
2. SPHERICAL THRUST WASHER
3. PINION GEAR
STEP 9.
Remove the second planetary gear and thrust
washer.
1. PLANETARY GEAR
2. THRUST WASHER
65
STEP 10.
Remove the snap ring and plug.
STEP 11.
If the bearing cone needs replaced, remove the
bearing cup from the axle housing.
1. BEARING CUP
NOTE: Perform Step 12 through Step 14 only if the ring nut needs removed or adjusted.
STEP 12.
Measure the installation position of ring nut to
facilitate in adjustment during installation.
66
STEP 13.
Remove the socket head screw.
NOTE: After removing the ring nuts, make sure to thoroughly clean the threaded portions of the ring nuts.
STEP 14.
Using special tool T3, remove the ring nut.
1. SPECIAL TOOL T3
2. RING NUT
NOTE: Perform Step 15 and Step 16 on both ring nuts.
STEP 15.
Remove the snap ring from the ring nut.
1. SNAP RING
67
STEP 16.
Remove the seal from the ring nut.
1. SEAL
CLEAN AND INSPECT • Tapered roller bearings - Inspect the cup,

cone, rollers, and cage of all tapered roller
bearings in the assembly. If bearings show
WARNING signs of wear, cracks, or damage, replace with
new bearing.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning • Bevel Pinion and bevel gear - Inspect the
solvents, always follow the recommendations of bevel pinion and bevel gear for wear or
damage. If the bevel pinion or bevel gear is
the manufacturer.
damaged, they must be replaced as a set.
• Pinions and side gears - Inspect the pinions
and side gears for wear or damage. Pinions and
WARNING side gears that are worn or damaged must be
Compressed air can move particles so that they replaced.
cause injury to the user or to other personnel. • Main differential assembly - Inspect all parts
Make sure that the path of the compressed air is of the main differential assembly for wear or
away from all personnel. Wear protective goggles damage. Parts that are damaged must be
or a face shield to prevent injury to the eyes. replaced.
Clean and inspect the following parts of the differential:

• Drive axle - Clean the parts of the axle with
solvent and dry with compressed air. Inspect all
machined surfaces and bearings for wear and
damage.
ASSEMBLE
NOTE: Perform Step 1 through Step 3 on both ring nuts.
68
STEP 1.
Lubricate the outer surface of the new seal with a
lithium based grease. Install the new seal into the
ring nut with special tool T4 to a predetermined
depth of 10.85 to 11.15 mm (0.43 to 0.44 in.).
1. SEAL
2. SPECIAL TOOL T4
STEP 2.
Install the snap ring.
Rotate the snap ring to verify that it is properly set
in the groove.
1. SNAP RING
69
STEP 3.
Lubricate a new O-ring and install the O-ring onto
the ring nut.
1. O-RING
STEP 4.
Apply Loctite® 242 to the threads of the ring nut.
Install the ring nut but do not tighten.
1. SPECIAL TOOL T3
2. RING NUT
STEP 5.
If the bearing cones and cups are being replaced,
tighten the ring nut to the previously measured
position.
70
STEP 6.
If the axle housing arms are replaced, apply
Loctite® 510 to two new setscrews. Install the
setscrews in the holes on the opposite side of the
ring nut socket head screws. Tighten setscrews
until they are flush with the axle housing.
1. SETSCREWS
STEP 7.
install the bearing cup.
1. BEARING CUP
STEP 8.
Lubricate the thrust washer and planetary gear
Install the thrust washer and planetary gear into
the differential carrier half.
1. PLANETARY GEAR
2. THRUST WASHER
71
STEP 9.
Lubricate the pinion gears, spherical thrust
washers, and pinion shafts with John Deere JDM
J20C.
Install the pinion gears and spherical thrust
washers onto the pinion shafts. Install the
assemblies into the differential carrier half.
1. PINION SHAFT
2. SPHERICAL THRUST WASHER
3. PINION GEAR
STEP 10.
Lubricate the second planetary gear and thrust
washer with John Deere JDM J20C.
Install the second planetary gear and thrust
washer.
1. THRUST WASHER
2. PLANETARY GEAR
STEP 11.
Verify that the thrust washers are correctly
positioned in the relative recesses.
72
CAUTION
Only use new socket head screws to reassemble
the differential carrier halves.
STEP 12.
Assemble the two differential carrier halves by
matching the marks made during disassembly.
Apply Loctite® 270 to the threads of new socket
head screws. Install socket head screws.
STEP 13.
Tighten the socket head screws in a crisscross
pattern to 78 to 86 N•m (57.5 to 63.4 lbf ft).
CAUTION
Only use new capscrews to reassemble the bevel
gear to the differential carrier.
STEP 14.
Place the bevel gear in position on the differential
carrier. Install new capscrews.
1. CAPSCREW
2. BEVEL GEAR
73
STEP 15.
Tighten the capscrews in a crisscross pattern to
128 to 142 N•m (94.4 to 104.7 lbf ft).
1. CAPSCREW
CAUTION
When installing the bearing cone, verify that the
shim is not contacting the outer cage of the
bearing cone.
STEP 16.
Lubricate the bearing cone with John Deere JDM
J20C.
Position the bearing cone on the bevel gear side
of the differential carrier. Position a shim with
adequate diameter on the internal ring of the
bearing cone. Using an appropriate driver, install
the bearing cone.
1. BEARING CONE
CAUTION
When installing the bearing cone, verify that the
shim is not contacting the outer cage of the
bearing cone.
STEP 17.
Lubricate the second bearing cone with John
Deere JDM J20C.
Position the second bearing cone on the opposite
side of the bevel gear side of the differential
carrier. Position a shim with adequate diameter on
the internal ring of the bearing cone. Using an
appropriate driver, install the second bearing
cone. 1. BEARING CONE
74
STEP 18.
Apply Loctite® 242 to the threads of the remaining
ring nut. Install the ring nut but do not tighten.
1. SPECIAL TOOL T3
2. RING NUT
STEP 19.
tighten the ring nut to the previously measured
position.
STEP 20.
install the remaining bearing cup.
1. BEARING CUP
75
INSTALL
NOTE: The rolling torque of the pinion must be measured without the pinion seal installed. Refer to the section
Bevel Pinion for the procedures on removing and installing the seal.
STEP 1.
Before installing the differential assembly,
measure the rolling torque of the pinion. The
rolling torque should be
1.2 to 1.8 N•m (10.6 to 15.9 lbf ft).
STEP 2.
Install the differential assembly into the main axle
housing.
STEP 3.
grease. Install the new O-ring on the axle
housing.
1. O-RING
76
STEP 4.
Apply Loctite® 242 to the capscrews used to
retain the axle housing together. Assemble the
axle housings. Install the capscrews. Tighten the
capscrews to 283 to 312 N•m (209 to 230 lbf ft).
STEP 5.
Using special tool T3, tighten the ring nut on the
bevel gear side until the clearance between the
bevel pinion and the bevel gear is 0 mm (0 in.).
Lock the bevel gear, then loosen the ring nut 1/4
to ½ turn.
1. SPECIAL TOOL T3
CAUTION
If the bearings are not new, check the static
torque and verify the static torque did not change
from the measurement recorded during removal.
If the bearings are new, check the continuous
torque.
STEP 6.
Preset the bearings by tightening the ring nut on
the opposite side of the bevel gear, increasing
pinion torque up to
1.2 to 1.8 N•m (10.6 to 15.9 lbf in).
77
STEP 7.
Position a dial indicator with a long tip through the
hole for the plug.
Position the tip on the side of a tooth of the bevel
gear, approximately 5 mm (0.197 in.) from the
outer rim. Preload by approximately
1 mm (0.039 in.) and zero the dial indicator.
1. DIAL INDICATOR TIP
STEP 8.
Hold the bevel pinion in position and move the
bevel gear in both directions to check the
clearance between the bevel pinion and bevel
gear. See Table 1.
Table 1. Bevel Set Specifications

Drive Axle Part No. Axle Overall Ratio Bevel Set Ratio Clearance
Minimum Maximum
580064079 14.8 32/13 0.20 mm 0.28 mm
(0.0079 in.) (0.0110 in.)
580064080 15.4 36/14 0.18 mm 0.23 mm
(0.0071 in.) (0.0091 in.)
580073454 16.9 31/11 0.20 mm 0.28 mm
(0.0079 in.) (0.0110 in.)
78
STEP 9.
Adjust the backlash between the bevel pinion and
the bevel gear by loosening one of the ring nuts
and tightening the opposite ring nut.
See Table 1 for specifications for your drive axle.
1. SPECIAL TOOL T3
STEP 10.
head screw. Install the socket head screw into
one of the two holes to lock the ring nut in
position. Tighten the socket head screw to
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft). Repeat on
opposite side.
STEP 11.
Apply RTV silicone to the plug. Install the plug
and snap ring.
STEP 12.
Install the complete planetary reduction gear
assemblies, brake discs, friction plates, axle
shafts, pistons, parking brake levers, and thrust
levers. See the section Brake Repair.
79
Bevel Pinion 1400 YRM 1344
Bevel Pinion

Refer to Figure 16 for the following procedures.
1. NUT 7. SPACER
2. O-RING 8. SHIM
3. FLANGE (YOKE) 9. SHIM
4. PLATE 10. BEARING
5. SEAL 11. BEVEL PINION
6. BEARING
Figure 16. Bevel Pinion Assembly
STEP 1.
Remove the differential assembly. See the section
Differential Repair.
80
1400 YRM 1344 Bevel Pinion
STEP 2.
Position special tool T5 to lock the bevel pinion
and flange in position.
Remove the nut and O-ring.
1. SPECIAL TOOL T5
2. O-RING
3. NUT
STEP 3.
Remove the flange with plate.
1. FLANGE
2. PLATE
STEP 4.
Remove the seal.
1. SEAL
81
STEP 5.
Remove the bevel pinion, inner bearing cone,
spacer, and shims as an assembly.
Remove the outer bearing cone.
1. BEVEL PINION
STEP 6.
Note the order of the spacer and shim. Remove
spacer and shim from the bevel pinion.
1. SPACER
2. SHIM
STEP 7.
Using a puller and a press, remove the inner
bearing cone from the bevel pinion.
1. BEVEL PINION
2. BEARING CONE
82
STEP 8.
Using an appropriate puller, remove the outer
bearing cup.
STEP 9.
Insert a brass drift into the appropriate holes and
remove the inner bearing cup and shims.
1. SHIMS
2. BEARING CUP
83
CLEAN AND INSPECT Clean and inspect the following parts:

• Bearings - Inspect the cup, cone, rollers, and
WARNING cage of all tapered roller bearings in the
assembly. If bearings show signs of wear,
Cleaning solvents can be flammable and toxic and cracks, or damage, replace with new bearing
can cause skin irritation. When using cleaning cone and cup.
solvents, always follow the recommendations of
• Bevel Pinion - Inspect the bevel pinion for wear
the manufacturer.
or damage. Replace as needed. If the bevel
pinion is replaced, the bevel gear must also be
replaced.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
84

Figure 17. Determining Bevel Pinion Shim Thickness
85
STEP 1.
Reset a depth gauge on a 6 mm (0.236 in.)
calibrated block.
1. CALIBRATED BLOCK
STEP 2.
With the calibrated block on a faceplate, allow the
bearing to set by rotating them in both directions
and applying a vertical thrust to position the
calibrated block on the outer bearing cups. Check
the overall thickness of the bearing (D).
Example:
D = 42.25 mm
STEP 3.
Check the nominal dimension INT as marked on
the pinion. Add or subtract from the INT the
variation indicated as Y to obtain the actual bevel
pinion mounting distance I. See Figure 17.
Example:
I = INT − Y
• 130 − 0.15 = 129.85 mm
1. Y MEASUREMENT
2. INT MEASUREMENT
86
STEP 4.
Calculate the shims S for insertion under the
bearing cup of the inner bearing cone using the
following formula:
S = 172.8 (I + D)
172.8 = fixed value
I = actual pinion center distance
D = total bearing thickness
Example:
S = 172.8 − (129.85 + 42.25) = 0.70 mm
1. SHIMS "S"
STEP 5.
Partially insert the shims and the inner bearing
cup into the axle housing. Then partially insert the
outer bearing cup into the axle housing.
Install special tool T6 through the bearing cups
and shims in the axle housing.
NOTE: Special tool T6 and the bearing cups are

shown out of the axle housing to show the proper
setup of special tool T6.
1. OUTER BEARING CUP

2. INNER BEARING CUP
3. SPECIAL TOOL T6
87
STEP 6.
Connect tension rod of special tool T6 (see
Special Tools) through the hydraulic press.
Energize the press to pull the bearing cups into
the seats of the axle housing. Release hydraulic
press.
1. SPECIAL TOOL T6
2. HYDRAULIC PRESS
STEP 7.
Assemble the special tool T7 with bearings into
the bevel pinion housing as shown. Hand tighten
until the axial gap is eliminated.
1. OUTER BEARING
2. SPECIAL TOOL T7
3. INNER BEARING
STEP 8.
Insert the tip of the depth gauge into the side hole
of the special tool T7.
Reset the depth gauge with a preload of
approximately 3 mm (0.12 in.).
1. SPECIAL TOOL T7
88
STEP 9.
Remove special tool T7 and the bearings from the
axle housing.
Reassemble special tool T7 with a spacer
between the bearings as shown in Step 10.
1. SPECIAL TOOL T7
2. INNER BEARING
3. SHIM
4. SPACER
5. OUTER BEARING
STEP 10.
Insert the tip of the depth gauge into the side hole
and measure the deviation H from the previous
reset in Step 8.
Example:
H = A − B = 1.4 mm
1. SPECIAL TOOL T7
2. DEPTH GAUGE
NOTE: Refer to Figure 16.
89
STEP 11.
The deviation H measured must be added to the
fixed value X to define the pack S1, installed
between the bearings and the spacer. The value
S1 must be rounded to the upper 5/100.
Example:
S1 = H + X
H = A − B = 1.4 mm
X = 0.10 to 0.12 mm (fixed value)
S1 = 1.4 + (0.10 to 0.12) = 1.50 to 1.52 mm
1. SHIMS S1
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
STEP 12.
Heat the inner bearing cone to approximately
100°C (212°F) and install the bearing onto the
bevel pinion.
Once the bearing has cooled down, lightly
lubricate the bearing with John Deere JDM J20C.
STEP 13.
Install the shims S1 and the spacer as shown.
1. SPACER
2. SHIMS S1
90
STEP 14.
Install the bevel pinion, inner bearing cone, shims
S1, and spacer as an assembly into the axle
housing.
1. BEVEL PINION ASSEMBLY
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
STEP 15.
Heat the outer bearing cone to approximately
100°C (212°F) and install the bearing cone onto
the bevel pinion.
Once the bearing cone has cooled down, lightly
lubricate the bearing with John Deere JDM J20C.
1. BEVEL PINION
STEP 16.
Install the flange onto the bevel pinion without the
seal.
1. BEVEL PINION
2. FLANGE
91
STEP 17.
Install the nut onto the bevel pinion. Using the
special tool T5 to lock the bevel pinion in place.
Tighten the bevel pinion nut to
700 to 750 N•m (516 to 553 lbf ft).
1. SPECIAL TOOL T5
CAUTION
If the rolling torque exceeds the maximum value,
then the size of the shim S1 between the bearing
and spacer needs to be increased. See Figure 16.
If the rolling torque does not reach the set value,
increase the torque setting of the ring nut in
different stages to obtain a maximum value of
700 to 750 N•m (516 to 553 lbf ft).
CAUTION
If the rolling torque does not reach the minimum
value, then the size of the shims S1 between the
bearing and spacer needs to be decreased. See
Figure 16.
CAUTION
When calculating the increase or decrease of
shims S1, keep in mind that a variation of a shim
of 0.01 mm corresponds to a variation of
6 N•m (53 lbf in) in the torque of the bevel pinon.
STEP 18.
Measure the rolling torque of the bevel pinion.
The rolling torque should be
1.2 to 1.8 N•m (10.6 to 15.9 lbf in).
92
STEP 19.
Remove the nut and flange from the bevel pinion.
1. BEVEL PINION
2. FLANGE
STEP 20.
Apply gasket cement or equivalent to the outer
surface of the new seal.
Using the special tool T8, install the seal.
1. SEAL
2. SPECIAL TOOL T8
NOTE: Only apply oil to the lip of the seal using John Deere JDM J20C.
STEP 21.
Lubricate the lip of the seal with John Deere JDM
J20C. Install the flange.
Install a new O-ring onto the bevel pinion. Apply
Loctite® 242 to the threads of the bevel pinion and
install the nut.
1. NUT
2. O-RING
3. FLANGE
93
STEP 22.
Using the special tool T5 to lock the bevel pinion
in place. Tighten the bevel pinion nut to
700 to 750 N•m (516 to 553 lbf ft).
1. SPECIAL TOOL T5
STEP 23.
Install the differential assembly. See the section
Differential Repair.
94
1400 YRM 1344 Drive Axle Installation
Drive Axle Installation

NOTE: Perform Step 1 through Step 19, and Step 40 2. Position the manifold on the drive axle. Install the
through Step 45 for lift truck models GLP/GDP60VX, socket head screws to the manifold and the drive
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ axle. Tighten the socket head screws to
GDP155VX) (C878, D878, E878, F878) and 26 to 29 N•m (19 to 21 lbf ft). See Figure 18.
GLP60VX, GLP70VX, GP70VXS6 GP70VXS9
(GP135VX, GP155VX, GP155VXS) (G878), GP60VX, 3. Connect the brake cooling lines to the manifold
GP70VX, GP70SVX, GP70SVX9, GP80SVX and the drive axle. See Figure 18.
(GP135VX, GP155VX, GP155SVX, GP170SVX)
(H878). 4. Connect the cooling hoses to the manifold and
1. Position the brake lines with cross fitting, as an
assembly, on the drive axle. Connect the brake
lines to the drive axle. See Figure 18.
95
Drive Axle Installation 1400 YRM 1344
Figure 18. Manifold and Cooling Hoses Connections for Lift Truck Models, GLP/GDP60VX, GLP/GDP70VX
96
1. MANIFOLD 6. CROSS FITTING

2. DRIVE AXLE COOLING RETURN HOSE, LEFT 7. BRAKE COOLING LINE, RIGHT SIDE
SIDE 8. BRAKE LINE, RIGHT SIDE
3. BRAKE COOLING LINE, LEFT SIDE 9. DRIVE AXLE COOLING RETURN HOSE, RIGHT
4. BRAKE LINE, LEFT SIDE SIDE
5. SOCKET HEAD SCREWS
5. Connect slings and lifting device to drive axle. 6. Position the drive axle in the lift truck.
NOTE: When installing the drive axle, ensure the NOTE: It is recommended to use a torque multiplier to
drive axle is held with the upper surface of the drive achieve the torque specification in Step 7.
axle against the frame. This will prevent any gap
7. Install the four mounting capscrews and washers.
between the frame and the drive axle mount, and will
Tighten the mounting capscrews to
ensure even weight distribution.
820 to 902 N•m (605 to 665 lbf ft). See Figure 19.

2. WASHER
8. Install the drive shaft and capscrews to the drive 11. Connect the brake booster return line to the
axle. Tighten the capscrews to manifold. See Figure 20.
55 to 63 N•m (41 to 46 lbf ft).
12. Connect the accumulator/brake booster supply
NOTE: Ensure hose clamps are installed onto hoses line to the manifold. See Figure 20.
as noted during removal.
13. Connect the brake supply line to the brake line
9. Connect the transmission to drive axle cooling
cross fitting on the drive axle. See Figure 20.
supply hose to the manifold. See Figure 20.
10. Connect the drive axle to transmission cooling

return hose to the manifold. See Figure 20.
97
Figure 20. Drive Axle and Brake Cooling Lines and Brake Lines for Lift Truck Models, GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878, F878) and GLP60VX,
GLP70VX, GP70VXS6 GP70VXS9 (GP135VX, GP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX,
GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878)
98
1. ACCUMULATOR 7. ACCUMULATOR/BRAKE BOOSTER SUPPLY LINE

2. TRANSMISSION TO DRIVE AXLE COOLING 8. BRAKE BOOSTER RETURN LINE
SUPPLY HOSE 9. BRAKE SUPPLY LINE
3. DRIVE AXLE TO TRANSMISSION COOLING 10. BRAKE COOLING LINE, RIGHT SIDE
RETURN HOSE 11. BRAKE LINE, RIGHT SIDE
4. DRIVE AXLE COOLING RETURN HOSE, LEFT 12. DRIVE AXLE COOLING RETURN HOSE, RIGHT
SIDE SIDE
5. BRAKE COOLING LINE, LEFT SIDE
6. BRAKE LINE, LEFT SIDE
14. Install the parking brake cables. Refer to section • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
Brake System - DANA 1800YRM1247 D878)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ Periodic Maintenance 8000YRM1583 for lift
truck models
D878, E878)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
Wet Brake System 1800YRM1977
GDP135VX, GP/GLP/GDP155VX) (E878)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
Periodic Maintenance 8000YRM1957 for lift
GDP135VX, GP/GLP/GDP155VX) (F878) and
GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 truck models
(GP135VX, GP155VX, GP155VXS) (G878) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GP60VX, GP70VX, GP70SVX, GP70SVX9, GDP135VX, GP/GLP/GDP155VX) (F878) and
GP80SVX (GP135VX, GP155VX, GP155SVX, GLP60VX, GLP70VX, GP70VXS6 GP70VXS9
GP170SVX) (H878) (GP135VX, GP155VX, GP155VXS) (G878)
15. Install the drive axle main housing center drain GP80SVX (GP135VX, GP155VX, GP155SVX,
plug. Tighten plug to 30 to 50 N•m (22 to 37 lbf ft). GP170SVX) (H878)
See Figure 21.
18. Install the oil fill plugs with new O-rings on both
16. Install the oil drain plugs on both sides of the sides of the drive axle. Tighten plugs to
drive axle. Tighten plugs to 30 to 50 N•m (22 to 37 lbf ft). See Figure 21.
19. Install the drive axle main housing center fill/level
17. Fill the drive axle sections with the proper fluid. plug with new O-ring. Tighten plug to
For the correct fluid, quantity, and fill procedure 30 to 50 N•m (22 to 37 lbf ft). See Figure 21.
see
Periodic Maintenance 8000YRM1322 for lift
truck models
99
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE
Figure 21. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models, GLP/GDP60VX, GLP/GDP70VX
100
NOTE: Perform Step 20 through Step 45 for lift truck 22. Connect slings and lifting device to drive axle.
model GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, NOTE: When installing drive axle, ensure drive axle is
GLP/GDP190VX) (A909, B909) and GLP/GDP80VX, held with the upper surface of drive axle against frame.
GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, This will prevent any gap between frame and drive
GDP175VX36, GDP190VX) (C909, D909) . axle mount, and will ensure even weight distribution.
20. Position brake lines with cross fitting, as an 23. Position drive axle in lift truck.
assembly, on the drive axle. Connect brake lines
to drive axle. See Figure 23. NOTE: It is recommended to use a torque multiplier to
achieve the torque specified in Step 24.
21. Position manifold on drive axle. Install socket 24. Install four washers and capscrews into drive axle
head screws to manifold and drive axle. Tighten and frame. See Figure 22. Tighten capscrews to
socket head screws to 820 to 902 N•m (605 to 665 lbf ft).

2. WASHER
101
25. Install drive shaft and capscrews. Tighten drive 30. Connect cooling return hoses to manifold and
shaft capscrews to 55 to 63 N•m (41 to 46 lbf ft). drive axle. See Figure 23.
NOTE: Ensure hose clamps are installed onto hoses 31. Connect hydraulic return hose to modulating
as noted during removal. brake valve and accumulator charge valve. See
Figure 23.
26. Connect cooling supply lines to manifold and
32. Connect hydraulic pressure supply hose to
accumulator charge valve. See Figure 23.
27. Connect axle vent line to drive axle. See
Figure 23.
33. Connect brake line to modulating brake valve.
See Figure 23.
28. Connect cooling supply from transmission hose to
34. Connect load sense out and load sense in hose
assemblies to accumulator charge valve. See
29. Connect cooling return to transmission hose to
Figure 23.
102
Figure 23. Drive Axle, Manifold, Cooling Hoses, and Brake Lines for Lift Truck Model GLP/GDP80VX, GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)
103
A. REAR VIEW B. FRONT VIEW
1. MODULATING BRAKE VALVE 9. MANIFOLD

2. BRAKE LINE 10. DRIVE AXLE
3. LOAD SENSE IN HOSE ASSEMBLY 11. COOLING RETURN TO TRANSMISSION HOSE
4. LOAD SENSE OUT HOSE ASSEMBLY 12. COOLING SUPPLY FROM TRANSMISSION HOSE
5. ACCUMULATOR CHARGE VALVE 13. AXLE VENT LINE
6. HYDRAULIC PRESSURE SUPPLY HOSE 14. COOLING SUPPLY LINES
7. HYDRAULIC RETURN HOSE 15. SOCKET HEAD SCREW
8. COOLING RETURN HOSE 16. BRAKE LINE
35. Install the parking brake cables. Refer to the Periodic Maintenance 8000YRM1407 for lift
section truck model
Brake System - DANA 1800YRM1247 for lift • GLP/GDP80VX, GLP/GDP80VX9, GLP/
truck models GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909)
GDP90VX (GLP/GDP170VX, GLP/ Periodic Maintenance 8000YRM1586 for lift
GDP175VX36, GLP/GDP190VX) (A909, B909) truck model
Wet Brake System 1800YRM1977 for lift truck • GLP/GDP80VX, GLP/GDP80VX9, GLP/
models GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (B909)
GDP90VX (GDP170VX, GDP175VX36, Periodic Maintenance 8000YRM1959for lift truck
GDP190VX) (C909) model
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GDP80VX, GDP80VX9, GDP90VX (GLP/
GDP90VX (GDP170VX, GDP175VX36, GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (D909) GDP190VX) (C909)
36. Install drive axle main housing center drain plug Periodic Maintenance 8000YRM2296
into drive axle. See Figure 24. GLP/GDP80VX, GLP/GDP80VX9, GLP/
37. Install right side oil drain plug and left side oil GDP190VX) (D909)
drain plug into drive axle. See Figure 24.
39. Install drive axle main housing center fill plug.
38. Fill the drive axle sections with the proper fluid. See Figure 24.
For the correct fluid, quantity, and fill procedure
see
104
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 3. RIGHT SIDE OIL DRAIN PLUG
PLUG 4. LEFT SIDE OIL DRAIN PLUG
2. DRIVE AXLE MAIN HOUSING CENTER FILL
PLUG
Figure 24. Drive Axle Fill/Drain Plugs for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) and GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)
105
40. Remove the air from the brake system as Mast Repairs, 2- and 3-Stage Masts (S/N A513,
described in the section A514, A613, A614, A702, A703, A704, A705,
A706, A707, A751, A752, B513, B514, B586,
Brake System - DANA 1800YRM1247 for lift
B587, B588, B589, B590, B591, B749, B750,
truck models.
B751, B752, B753, B754) 4000YRM1250 for lift
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ truck models
D878, E878) • , GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ D878, E878)
GDP175VX36, GLP/GDP190VX) (A909, B909) Mast Repair (S/N A513, A514, A613, A614,
A643, A644, A683, A684) 4000YRM1406 for lift
Wet Brake System 1800YRM1977 for lift truck
truck models
models.
• , GLP/GDP80VX, GLP/GDP80VX9, GLP/
• GLP/GDP60VX, GLP/GDP70VX (GLP/
GDP135VX, GLP/GDP155VX) (F878)
GDP175VX36, GLP/GDP190VX) (A909, B909)
GLP60VX, GLP70VX, GP70VXS6 (GP135VX.
GP155VX, GP155VXS) (G878) Mast Repair (S/N A613, A614, A643, A644,
• GP60VX, GP70VX, GP70SVX, GP70SVX9, A683, A684) 4000YRM1956 for lift truck models
GP80SVX (GP135VX, GP155VX, GP155SVX, • GLP/GDP60VX, GLP/GDP70VX (GLP/
GP170SVX) (H878) GDP135VX, GLP/GDP155VX) (F878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ GLP60VX, GLP70VX, GP70VXS6 (GP135VX.
GDP90VX (GDP170VX, GDP175VX36, GP155VX, GP155VXS) (G878)
GDP190VX) (C909) • GP60VX, GP70VX, GP70SVX, GP70SVX9,
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ GP80SVX (GP135VX, GP155VX, GP155SVX,
GDP90VX (GDP170VX, GDP175VX36, GP170SVX) (H878)
GDP190VX) (D909) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP190VX) (C909)
WARNING • GLP/GDP80VX, GLP/GDP80VX9, GLP/
Add air to the tires only in a safety cage. Inspect GDP90VX (GDP170VX, GDP175VX36,
safety cage for damage before use. When adding GDP190VX) (D909)
air, use a clip-on chuck with enough hose to let the
operator stand clear of the cage. 43. Raise the lift truck and remove blocks from under
frame and from under the counterweight. Lower
NOTE: When tightening the wheel nuts, use lubricant the lift truck.
on the studs or nuts.
44. Remove the blocks on each side (front and back)
41. Inflate the tires using a safety cage. Install the
of the steering tires.
wheels and nuts and tighten the nuts to
610 to 680 N•m (450 to 502 lbf ft). 45. Operate the lift truck and check for proper
operation and leaks.
42. Install the mast assembly as described in the
section
106
1400 YRM 1344 Special Tools
Special Tools
Description Part Number Description Part Number

Service Tool T3 580082460 Service Tool T8 580082465
Differential Nut Pinion Seal
Service Tool T4 580082461 Service Tool T9 580082466
Differential Seal Pneumatic Hub Bearing
Service Tool T5 580082462 Cup
Pinion Wrench Service Tool T10 580082467
Service Tool T6 580082463 Pneumatic Hub Seal
Pinion Bearing Cup Service Tool - Handle 580082468
Service Tool T7 580082464
Pinion Bearing Inspection
107
Torque Specifications 1400 YRM 1344
Torque Specifications
Bevel Pinion Nut Planetary Gear Carrier to Outer Axle Shaft Retaining
700 to 750 N•m (516 to 553 lbf ft) Screw
116 to 128 N•m (86 to 94 lbf ft)
Bevel Gear Capscrews
128 to 142 N•m (94.4 to 104.7 lbf ft) Planetary Reduction Gear Assembly to Axle
Housing Socket Head Screws
Differential Adjustment Ring Nut Socket Head Screw 129 to 143 N•m (95 to 105 lbf ft)
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft)
Return Spring Socket Head Screws
Differential Carrier Halves Socket Head Screws 5 to 7 N•m (44 to 62 lbf in)
78 to 86 N•m (57.5 to 63.4 lbf ft)
Shoulder Ring to Wheel Hub Support Capscrews
Drive Axle Housing Arm to Drive Axle Main Housing 68 to 75 N•m (50 to 55 lbf ft)
Capscrews
283 to 312 N•m (209 to 230 lbf ft) Thrust Bushing Socket Head Screws
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft)
Drive Axle Main Housing Center Drain Plug
30 to 50 N•m (22 to 37 lbf ft) Wheel Nuts (Lubed)
610 to 680 N•m (450 to 502 lbf ft)
Drive Axle Main Housing Center Fill/Level Plug
30 to 50 N•m (22 to 37 lbf ft)
Drive Axle to Frame Mounting Capscrews

820 to 902 N•m (605 to 665 lbf ft)
Drive Axle to Transmission Mounting Bracket

Capscrews
225 to 250 N•m (166 to 184 lbf ft)
Drive Shaft Capscrews

55 to 63 N•m (41 to 46 lbf ft)
Manifold to Drive Axle Housing Socket Head Screws

26 to 29 N•m (19 to 21 lbf ft)
Oil Drain Plug, Left and Right Side

30 to 50 N•m (22 to 37 lbf ft)
Oil Fill Plug, Left and Right Side

30 to 50 N•m (22 to 37 lbf ft)
Outer Axle Shaft to Wheel Hub Capscrews

182 to 202 N•m (134 to 149 lbf ft)
Parking Brake Lever Adjustment Screw Nut

20 to 25 N•m (14.75 to 18.44 lbf ft)
Parking Brake Lever Socket Head Screw

23.8 to 26.2 N•m (17.6 to 19.3 lbf in)
Piston Guide Socket Head/Pin Screws

5 to 7 N•m (44 to 62 lbf in)
108
1400 YRM 1344 6/21 (3/20)(11/19)(2/18)(2/17)(10/15)

9° GP190 VX (B909) 9 Ton. REPARO DO EIXO MOTOR E DO CONJUNTO DIFERENCIAL

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9° GP190 VX (B909) 9 Ton. REPARO DO EIXO MOTOR E DO CONJUNTO DIFERENCIAL

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Maintenance

DRIVE AXLE AND

PART NO. 524296605 1400 YRM 1344

©2021 Yale Materials Handling Corp. i

1. DANA PART NUMBER

Figure 1. Identification Plate

Drive Axle Removal

1. Put blocks on each side (front and back) of the

Legend for Figure 2.

10. Disconnect the brake supply line from the brake

Legend for Figure 3.

1. ACCUMULATOR 7. ACCUMULATOR/BRAKE BOOSTER SUPPLY LINE

16. Remove the capscrews retaining the drive shaft.

1. CAPSCREW 3. DRIVE AXLE

Figure 4. Drive Axle Mounting Capscrews

21. Disconnect the brake cooling lines from the

Legend for Figure 5.

1. MANIFOLD 6. CROSS FITTING

Legend for Figure 7.

A. REAR VIEW B. FRONT VIEW

1. MODULATING BRAKE VALVE 9. MANIFOLD

33. Remove the capscrews and the drive shaft from

1. CAPSCREW 3. DRIVE AXLE

Figure 8. Drive Axle Mounting Capscrews

Planetary Reduction Gear Repair

REMOVE AND DISASSEMBLE

1. CAPSCREW 14. INNER BEARING

1. O-RING 14. WHEEL HUB

1. SOCKET HEAD SCREW

1. PLANETARY GEAR AND BEARING ASSEMBLY

1. PLANETARY GEAR CARRIER

1. OUTER AXLE SHAFT

1. OUTER BEARING CONE

1. INNER BEARING CONE

ASSEMBLE AND INSTALL

1. INNER BEARING CUP

1. INNER BEARING CONE

NOTE: Verify that the seal is correctly oriented.

1. OUTER BEARING CONE

1. PLANETARY GEAR CARRIER

1. SOCKET HEAD SCREW

REMOVE AND DISASSEMBLE

1. SOCKET HEAD SCREW 15. DRIVE AXLE MAIN HOUSING

Legend for Figure 12.

1. PARKING BRAKE LEVER 15. O-RING

1. SOCKET HEAD SCREW

1. SOCKET HEAD SCREW

1. PARKING BRAKE LEVER

NOTE: Prior to removing thrust bushing, clean area

1. SOCKET HEAD SCREW

WARNING 4. Inspect the brake disc(s). Replace discs when the

2. Inspect the bearings for wear or damage.

ASSEMBLE AND INSTALL

1. SOCKET HEAD SCREW

NOTE: The oil passage must face downwards when installed.

NOTE: The oil passage must face downwards when installed.

NOTE: The threaded holes must be free of oil.

1. SOCKET HEAD/PIN SCREW

NOTE: The threaded holes must be free of oil.

1. SOCKET HEAD SCREW AND RETURN SPRING

1. PARKING BRAKE LEVER

1. SOCKET HEAD SCREW

NOTE: DO NOT ADD ADDITIVE TO CENTER SECTION.