This document provides workshop instructions for removing and rebuilding wheel hubs on Sisu trucks. The main steps include draining oil, removing the hub cover and locking ring, pulling out the planetary carrier and half shaft, and undoing the bearing adjustment nut. The wheel hub, bearings, and seal can then be removed. Reassembly involves pressing in new bearing races if needed, installing the seal and bearings, adjusting the bearing with a torque wrench, and inspecting half shafts before installation.

1. SM 622
CDP 100/164
Service Manual

2. Contents of this Manual
Group Index
Group SA .......................................................................................... Safe Maintenance
Group PS ............................................................................................ Periodic Service
Group 00 ................................................................................................. Diesel Engine
Group 01 .............................................................................................. Cooling System
Group 02 .................................................................................................... Fuel System
Group 03 ..................................................................................... Air Induction System
Group 06 .................................................................................................. Transmission
Group 12 .............................................................................................. Ignition System
Group 13 ................................................................................................... EGS Control
Group 14 ............................................................................................ Electrical System
Group 20 ...................................................................................................... Drive Axle
Group 21 ............................................................................................... Universal Joint
Group 22 ............................................................................................ Wheels and Tires
Group 23 .................................................................................... Parking Brake System
Group 24 .................................................................................. Wet-disc Brake System
Group 25 ............................................................................. Steering Column and Gear
Group 26 ........................................................................ Steer Axle and Steer Cylinder
Group 29 ................................................................ Hydraulic Pump, Sump and Filters
Group 30 ............................................................. Hydraulic Control Valve/Lift Circuit
Group 32 ................................................................................................. Tilt Cylinders
Group 34 ...................................................................... Uprights, Carriages, and Forks
Group 38 ..................................................... Counterweights, Sheet Metal and Chassis
Group 39 ................................................................ Decal Replacement and Placement
Group 40 ................................................................................................. Specifications
Alphabetical Index
Air Induction System.. ......................... Group 03
Alternator.. ........................................... Group 14
Brake System.. ..................................... Group 23
Cooling System ................................... Group 01
Counterweight ..................................... Group 38
Decals .................................................. Group 39
Drive Axle ........................................... Group 20
EGS ...................................................... Group 13
Electrical System ................................. Group 14
Engine (Diesel) .................................... Group 00
Fuel System ......................................... Group 02
Hydraulic Control Valve ..................... Group 30
Instrument Panel .................................. Group 13
Lift Cylinder ........................................ Group 34
Oil Change ........................................... Group 00
Radiator ............................................... Group 01
Safety .................................................. Group SA
Sheet Metal & Chassis.. ....................... Group 38
Shop Supplies ...................................... Group 40
Specifications ...................................... Group 40
Starter .................................................. Group 14
Steer Axle ............................................ Group 26
Steering Column and Gear .................. Group 25
Tilt Cylinders ....................................... Group 32
Transmission.. ...................................... Group 06
Tune-up.. .............................................. Group 00
Universal Joint ..................................... Group 21
Uprights, Carriages, Forks ................... Group 34
Water Pump ................................... Group 01, 00
Wheels and Tires ................................. Group 22
SM 622, Nov ‘98 Contents-l

3. Major Component Location
Use this illustration to help locate components included in the PM procedures.
r 2
1. Engine
2. Cooling
3. Fuel
4. Exhaust
5. Transmission
6. Drive Axle-Differential
7. Wheels and Tires
6. Upright and Carriage
9. Frame and Counterweight
10. Sheet Metal
11. Cab Overhead Structure
12. Prop Shaft
Contents-2 SM 622, Nov ‘98

4. GROUP PS
PERIODIC SERVICE
Maintenance Schedules ........................................................... Section 1
The Planned Maintenance Program ...................................... Section 2
The PM Inspection Form ........................................................ Section 3
SM 622, Nov ‘98 Periodic Service

5. Group PS, Periodic Service
Section 1.
INTRODUCTION
Proper maintenance and care are essential if your Clark truck
is to be always ready for use.
These preventative maintenance procedures provide a basic
guide which should be followed when servicing your Clark
truck.
A lubrication guide and recommended preventative mainte-
nance program is included in this section and for further
information regarding adjustment procedures, specifications,
etc., please refer to the index in the front of this manual.
IMPORTANT
Your Clark dealer has both the facilities, parts, and
adequately trained personnel enabling them to carry
out all necessary service procedures, including com-
plete inspections, maintenance and lubrication pro-
grams, all aimed at ensuring your Clark Lift truck
will perform safety and efficiently and most impor-
tantly, maximizing its availability for your day to
day work schedules.
RECOMMENDED MAINTENANCE PROCEDURE
Particular attention should be paid to the conditions under
which your CDP 100/164 forklift truck is used as those
conditions play a significant role in determining how long the
interval between each maintenance task should be.
It is quite clear that a truck used in sandy, dusty, dirty
locations will require more frequent maintenance than one
being used in a clean warehouse situation.
The maintenance schedules and recommendations made in
this book apply for use under normal operating conditions.
The following classifies the different types of operating
conditions..
Class 1 - Normal conditions of use
Basically transfer and loading of goods and materials for
eight hours per day in buildings or in the open air.
Class 2 - Longer hours of use or continuous
3 shift operation.
Class 3 & 4 - Extreme conditions
a) Use in sandy or dusty places, such as cement works, steel
mills, saw mills, flour mills, brick factories, or rock
breaking applications.
b) Use in areas of high temperature including steel works,
foundries, etc.
c) Use in areas of frequent temperature changes such as
loading bays handling frozen goods, at refrigeration
plants, or making frequent trips from a building into the
open air and back again.
IMPORTANT
Your Clark truck is designed for work in all of the
above conditions, however if your particular appli-
cation should fall into Class 2,3 or 4 then appropri-
ate changes to service frequencies must be made to
all maintenance procedures.
LUBRICATION
Greasing should be carried out every 250 hours, or after any
washing.
SAFETY PRECAUTIONS DURING MAINTENANCE
When lifting parts or assemblies, make sure that all
slings, chains or cables are correctly fastened and that the
load being lifted is balanced. Make sure that 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 ground cable.
Always use correct blocks to prevent the unit from
rolling or falling.
Keep the unit and working area clean and in order.
Use the correct tools for the job.
Keep the tools clean and in good condition.
Always use original Clark parts when making repairs.
Make sure that all nuts, bolts, snap rings and other
fastening devices are removed before using force to
remove parts.
Always fasten a DO NOT OPERATE sign to the controls
of the unit when making repairs or if the unit needs
repairs.
Make sure you follow the DANGER WARNING and
CAUTION notes in the instructions.
Diesel is aflammable fuel. Make sure that you follow the
necessary safety precautions when handling fuel and
when working on the fuel system.
Batteries generate flammable gas when they are being
charged. Keep fire and sparks away from the area. Make
sure the area has ventilation.
SM 622, Nov ‘98 Psi-1-1

6. Grout PS. Periodic Service
SAFETY PRECAUTIONS DURING LIFTING, JACK-
ING & BLOCKING
Lifting or jacking any large piece of equipment, such as your
Clark fork truck, presents obvious hazards. It must be with
great care and forethought. Consult the truck weight tabula-
tions in the specifications sections of this manual to ensure
that your lifting equipment is of adequate capacity.
The correct way to lift the front of the CDP100064 is by
rigging a chain pull lift or hoist to the upright through the
lift eyes provided. Chock the steer wheels before lifting.
Place wheel stands under the drive tires or solid blocking
under the base of the upright rails.
A WARNING
The upright should be fully down before lifting.
On uprights with negative drop such as Marina
trucks, clamp or chain the rails together so they
cannot move if at all possible, remove the forks
before lifting by the upright.
The rear of the truck may be lifted by the counterweight.
Chock the drive wheels before lifting and be sure lifting
equipment is of adequate capacity.
A WARNING
Check to see if the counterweight bolt is in place
and property torqued before lifting. Never at-
tempt to lift the rear of the truck with another
fork truck.
3. Place wheel stands under the steer tires or put solid
blocking under the truck frame.
A WARNING
Take care to place block under the frame back
far enough from the truck center of gravity so
that it is stably supported.
INITIAL SERVICING & MAINTENANCE RECORDS
a) Initial Service
An initial service should be carried out after your Clark
forklift truck has been in operation for fifty hours.
In this service, the following work must be carried out: Check that all capacity, safety and warning plates or decals
(Check the Preventative Maintenance schedule) are attached and legible.
Check, before and after starting engine, for any sign of
external leakage; fuel, engine coolant, transmission fluid, etc.
Check for hydraulic oil leaks and loose fitting.
Engine (at operating temperature)
l Check engine oil level
l Check fan belt tension
l Start engine and check for obvious leaks in fuel system,
lubricating oil system and cooling system stem.
l Check that all external screws, nuts, and securing parts
are firm.
Transmission (at operating temperature 83’ - 94 “C)
l Change transmission- oil filter
l Take sample of transmission oil (if on S.O.S. system)
l Check all screws, nuts and securing parts are tight and
have a firm seat.
General
.
.
Crease all grease points (steer axle, upright, etc.)
Check that all screws, nuts and securing parts are firm
and pay particular attention to the wheel and upright
studs and nuts. (See Critical Torque areas on following
page).
IMPORTANT This work should be carried out by aqualified
Clark service mechanic.
b) Maintenance Records
Any preventative maintenance system relies on the pro-
grammed planning of all service work and also on correct, up
to date records being held, enabling systematic scheduling
and tracking of maintenance costs per unit. This does not
vary from systems which are of a manual nature or computer
assisted.
To ensure that the daily inspections and periodical preventa-
tive maintenance services are properly performed, werecom-
mend the use of inspection forms. Such forms not only
provide a guide for the person carrying out such inspections
and services, but serve as a record in keeping track of
maintenance requirements for each vehicle. Moreover, such
records eventually assist you in determining when to sched-
ule downtime for major component overhaul without the
disruptive effects of unscheduled downtime. Your Clark
dealer is always able to provide assistance in setting up
maintenance systems and also in keeping maintenance records
on your behalf.
A typical maintenance schedule is provided in this manual.
This should be used as a guide to the minimum requirements
and should be adapted to suit local conditions and operational
experience.
VISUAL CHECKS
PS-l-2 SM 622, Nov ‘98

7. Group PS, Periodic Service
A WARNING
Do not use bare hands to check. Oil may be hot or
under pressure.
Be sure that the devices safety devices are in place, undam-
aged and attached securely. For example: seat belt, horn, load
safety rail, beacon etc.
Then check all of the critical components that handle or carry
the load.
Inspect the upright and lift chains. Check for obvious wear
and maintenance problems such as damaged or missing parts,
leaks, slack or broken chains, bent parts, etc.
Carefully inspect the load forks for cracks, breaks, bending,
twists and wear. Be surd that the forks are correctly Installed
and looked In their proper position.
Inspect the wheels and lyres for safe mounting, wear condi-
tion and correct inflation pressure.
Function Checks
Test warning devices, horn, lights and other safety equipment
and accessories. Start the engine and be sure all controls and
systems are functioning correctly. Check the hour meter for
operation. Operate the service and parking brakes, all hy-
draulic controls: lift, tilt and auxiliary functions. accelerator,
directional control and steering system. Be sure all controls
operate freely and return to neutral properly. Operate the lift
mechanism and auxiliary functions, accelerator, directional
control and steering system. Be sure all controls operate
freely and return to neutral properly. Operate the lift mecha-
nism and auxiliary function (if Installed).
Standard Shut Down Procedure
When parking and leaving truck unattended, lift mechanism
shall be fully lowered, controls placed in neutral, engine shut
off, brakes set and key removed. Chock the wheels if truck
is parked on an incline or has the possibility of moving.
Make a record on the Drivers Daily Checklist of all the
operating and truck problems that you find. Review the
checklist to be sure it has been completed and turn It In to the
person responsible for lift truck maintenance. Be sure any
unusual noises or problems are investigated immediately.
Do not operate a lift truck that has a maintenance
problem, or is not safe to operate.
Remove the key from the-ignition switch and put an “Out of
Service” tag on the truck.
If all of the “Before Operation” checks were normal or
satisfactory, the truck can be operated.
FUEL SAFETY PRACTICES
Take care when filling, not to allow any fuel to spill or flow into the
engine compartment. Fuel in the engine compartment is afire hazard
and should be completely removed immeadiately.
Use clean, properly marked fuel cans.
Clean up spills.
SM 622, Nov ‘98 PS-1-3

8. SnmY
Workshop instructions
WHEEL HUBS
Removal:
- Lift axle up and support it onto axle stands. Take
wheel off.
- Remove drain plugs (arrow in picture 1) and drain oil
from the planetary gears to suitable container.
Picture 3. Planetary carrier removed
Picture 1
- Unscrew hub cover retaining screws (5 PCS)and
remove the cover.
- Remove locking ring (arrow) in picture No. 2. Now the
planetary carrier can be pulled out.
- Pull the half shaft out from axle casing.
Take care of the protection plate, which is under the
sun gear on the axle threads.
- Remove lock screws from the bearing adjustment nut
and straighten lock plate tab in the groove of the nut.
Undo the nut and take care of it and the lock plate
under it. See picture No. 4.
Picture 4
Picture 2
- Now it is possible to pull the ring wheel with the hub
out from the axle tube. Outer hub bearing will follow
with the ring wheel hub. To make removal easier, do
support the wheel hub a little.
Oy Sisu-Auto Ab 2

9. Workshop instructions
-After removal of the planetary ring wheel and its hub you can pull the wheel hub out. The inner wheel hub bearing
and the hub seal will follow.
It is possible to remove brake drums separately ifnecessary, for example to make wheel hub assembly lift easier.
Picture 5. Removal of the wheel hub. Brake drum is already removed
Dismantling:
Remove first the hub seal and after this you can take the inner wheel hub bearing out. Remove bearing outer
races from hub by using soft drift, if bearing replacement is required.
Dismantle the planetary carrier by pressing the pins of the planetary gears out from inside by using a workshop
press. After pin removal are the planetary gears with bearing needles, trust washers and spacers all loose and do
this carefully and take care of all parts. Take care of the pin locking balls too. (See picture 6)
Picture 6. Planetary carrier unit in parts
3

10. Bnzm
Workshop instructions
Assembly:
Inspect the wheel hubs carefully before the assembly. The wheel hub seal should be replaced always. Bearings
have to be inspected carefully and replaced if any defects, as scratches, wear spots or discolouring. Check also
that bearing outer races are tight in their seat. If races are loose in the hub, the hub has to be replaced. Inspect
condition of the planetary ring wheel and its fixing into the hub. If any defects are found in the ring wheel it has to
be replaced. Before removal of the ring wheel you have remove the retaining ring (9 in picture 8)
Install bearing races by a workshop press to assure their correct installation into their seats. When the races are
installed, place inside bearing onto the race and install the wheel hub seal. Lubricate seal inside and the bearing
rollers and surfaces prior the installation. Now the wheel hub is assembled and ready for installation.
Lift the wheel hub onto the axle tube. Install lubricated outer hub bearing as well. Place the lock plate and bearing
adjustment nut and tighten the slightly bywrench No. 7143 015 020. Tighten the nut and rotate the hub few turns to
both direction.
Perform adjustment of the wheel hub bearing as follows:
Wheel hub bearing adjustment:
Tighten the adjustment nut to 200 Nm torque while
rotating the hub and after this loosen the nut to next
possible locking place and lock the nut in this position
by bending a lock plate tab into the nut groove and by
two lock screws. Use Loctite locking liquid and tighten
lock screws to 12 Nm torque by a torque wrench.
Half shaft inspection and installation:
The half shafts and associated sun wheels have to be
inspected prior the installation.
Special attention has to be paid to condition of teeth of
the sun wheel. No cracks are allowed. If defects are
found sun wheel has to be replaced.
If excessive clearance is found in the splines between
the sun gear and half shaft sun gear and/or half shaft
have to be replaced.
Install half shaftafterwheel hub bearing adjustment.
Prior installation place the protection plate (item 15 in
picture 8) onto the shaft or the axle tube threads and
assure correct installation.
Assembly of planetary carrier
Inspect all planetary gear components and discard all
excessively worn or damaged parts. Start assembly by
inserting bearing needles (20 in picture 8) inside the
planetary gears (21 in picture 8). There are two rows of
needles and a spacer (22 in picture 8). Use grease in
assembly to make it easier and assure lubrication at the
beginning of use.
When bearing needles and spacers are inserted you can
place planetary gears with trust washers (19 in picture
8) inside the planetary carrier casing and press in
respective pins (25 in picture 8) so that locking balls (26
in picture 8) may enter into their slots in the casing.
Oy Sisu-Auto Ab 4

11. msm
Workshop instructions
Installation of planetary carrier
Assembled planetary carrier may be installed after installation of the half shaft and the protection plate.
Before and under the installation of the planetary carrier, make sure that sun gear thrust ring (23 in picture 8) is
properly seated in the casing.
During installation of the casing rotate it back and forth a little so that all gears do engage and you can push it in.
When the planetary carrier is seated, lock it by retaining ring (27 in picture 8). Finally install the hub cover and the
screws and tighten them to prescribed torque. (see table on page 16). O-ring (28 in picture 8) and copper
washers of the screws (33 in picture 8) have to be replaced always with repairs.
Figure 8. Wheel hub planetary gear in parts
5 Oy Sisu-Auto Ab

12. Bnzm
Workshop instructions
DRIVE GEAR
Removal
Drain drive gear oil.
Remove the axle from the vehicle (The drive gear alone can be removed while the axle remains in the vehicle by
a special lift).
Place the axle assembly on the repair stand so that the pinion flange is upwards. Unscrew drive gear retaining
screws and screw in two of them, which at this stage act as extractors, in threaded holes (these are protected by
plastic plugs) in the casing and withdraw drive gear unit by suitable lifting gear and place it on the repair stand
crown wheel up.
Picture 9. Drive gear unit removed and fixed on repair stand
DIFFERENTIAL LOCK
(Optional)
Dismantling (Item nos. in text are found in picture IO on page 7)
Remove the lock cylinder cover retaining screws (5 PCS)first and take the cover and the diaphragm (44) under it
away. Undo the diaphragm support cup screw (43) and remove the cup (42) and the spring (41). Loosen the fork
lock screw (48) approx. 2 turns (for access to the screw remove the plug 39 first from casing) and take the fork
shaft (4) out by rotating it anticlockwise by suitable open wrench. When the shaft is removed loosen the slide
bush lock screw (55) and remove the snap ring (53). After this you can remove the fork (49) and the slide bush
(32) with slide shoes (50).
Assembly
Inspect that all lock components are in good condition and they are not excessively worn. Replace all damaged
components. Assemble by carrying out in reverse order the operations described for dismantling.
Oy Sisu-Auto Ab 6

13. Workshop instructions
Picture 10. Differential lock in parts
Lock adjustment
The operation mechanism of the differential lock have
to be adjusted as follows:
While adjustment following parts have to be removed:
(see illustration below)
1. Cover
2. Diaphragm
3. Screw
4. cup
5. Spring
Adjustment:
1. Engage the dog clutch of the differential lock by
pushing the fork shaft all the way in.
2. Place the cup (4) on the shaft without retaining
screw.
3. Adjust the fork shaft by rotating it so that the cup
touches both the shaft end and the bottom of the
casing.
4. Check again by rotating pinion and pushing the fork
shaft simultaneously if the shaft may go further in.
5. If the shaft and the fork went further in, pls. repeat
operations from item 3.
6. When the shaft does not go further in, turn it 114
turns clockwise.
7. Tighten the fork lock screw.
8. Install the cup and retaining screw and make sure
that the cup rim touches the bottom of the casing.
So the adjustment is performed. Remove the cup once
more and do assemble the lock. Tighten cup retaining
screw to 30 Nm torque. Use sealant in the plug (39 in
picture 10) installation
DIFFERENTIAL
Dismantling
If the crown wheel and the pinion are in good condition
and they will be reused, check and note the gear
backslash before dismantling.
NOTE ! If the bearings are damaged this measured
clearance cannot be used when assembling.
Picture 11. Mark bearing caps by suitable means
in spot indicated by an arrow
7

14. snsm
Workshop instructions
NOTE ! If the differential if fitted with locking device, it
should be removed first. See item “Dismantling
differential lock”.
Mark side bearing caps with respective places of the
casing so that caps cannot be interchanged. Unscrew
and remove bearing cap screws and take off bearing
caps and withdraw the bearing outer races.
Lift differential unit complete with crown wheel off from
housing. Fix unit in vise or on special fixture crown
wheel down.
Picture 12. Differential unit with crown wheel
NOTE !
If the bearings have to be replaced, remove old ones
using a bronze drift at the housing groove. Arrow in
picture 12.
Unscrew the nuts of the screws joining the half casing
and fixing the crown wheel and lift the upper half of the
casing off. If crown wheel/pinion gears have to be
replaced lift the lower half of the casing off from the
crown wheel.
PINION UNIT
Dismantling
Take off the pinion flange retaining nut, after first
loosening it. When loosening the nut use suitable
reaction lever to prevent rotation of the flange.
Picture 14. Pinion flange installed
Picture 13. Differential housing upper half
removed
Picture 15. Removal of pinion in workshop press
Oy Sisu-Auto Ab 8

15. Workshop instructions
dismantling cont.
When the nut (2) and the washer (3) are removed position the pinion complete in the press and push the pinion off
the housing. With the pinion will follow conical roller bearing (18), spacer (15) and shims (16). In the housing will
remain outer bearing complete (a/9), seal (7), shim (17) and outer race of inner bearing (18).
Take good care of adjustment shims , if the bearings and the gears are not replaced, previous shims are best
suitable. Also when components are replaced it is most easy to perform first assembly with previous shims, which
are suitable in most of cases. Using suitable means, remove seal from the housing then remove front bearing as
well bearing races and the shim (17) under the inner bearing race if required.
Picture 16. Drive gear housing and pinion in parts
Assembly
Prior the assembly inspect all parts carefully and
assure that all to be reused parts are in good condition.
Only faultless bearings may be reused. If pinion/crown
wheel pair is replaced the bearings have to be replaced
too.
Start assembly by pressing inner conical bearing onto
the pinion. Place the spacer bush with previous shim(s)
on top of the bearing onto the pinion. Press then
bearing outer races into the casing and place previous
shims (17) between inner race and the casing.
Picture 17. Pinion with installed inner bearing. In
the picture can be seen the spacer bush and a shim

16. snsw
Workshoo instructions
Lift the casing onto the pinion and place the outer
conical bearing onto the pinion. Use suitable drift and
press carefully on the outer bearing inner race in
simultaneously rotating the casing. increase the force
to 160 kN(16 ton). If the bearings become completely
stiff, press pinion out and replace shim and/or the
spacer ring by more suitable and repeat previous step.
Following spacer bushes and shims are available:
Description Spare no. Thickness
Spacer 099 557 1026 53,70 mm
Spacer 099 557 1027 53,72
Spacer 099 557 1028 53,74
Spacer 099 557 1029 53,76
Spacer 099 557 1030 53,78
Shim 099 517 1000 0,3 mm
Shim 099 517 1001 0,4 mm
Shim 099 517 1002 0,5 mm
Picture 18. Pinion installed in the housing. Press
on the inner race on the spot indicated by an arrow
by a suitable drift first until it stops and then for
testing of adjustment by a force of 16 ton.
Picture 20. Pinion seal ready for installation.
When bearings rotate inspect the pinion roiling torque
without seals by following way:
Rotate a few turns string around the pinion flange
(between the flange and seal protection plate) and use
a spring scale fixed in the string. Measure rolling torque
in the movement. Correct measure value is 60 - 100
Nm (6,0 - 10,O kp). Change adjustment shims if so
required until correct rolling torque value is reached.
Picture 19. Rotate a length of a string around the
flange in the place indicated by an arrow.
Picture 21. Seal protection plate ready for
installation.
Oy Sisu-Auto Ab 10

17. snsm
Workshop instructions
Then install the seal and fill space under it by grease;
install the pinion flange with seal protection ring and V-
seal, screw the pinion nut finger tight.
Picture 23. Pressing of a conical roller bearing to a
differential casing half.
Picture 22. Seal protection plate installed onto the
flange. V-seal ready for installation.
If a workshop press in not available for assembly,
adjustment can be performed as follows:
Assembly usually, but instead of pressing use the
flange and the nut, tighten the nut to 1300 Nm torque.
After this do measure and adjust bearing rolling torque
as previously described.
When rolling torque is correctly adjusted, install the
pinion flange with seals.
Finally tighten the pinion nut to 1300 Nm torque and
secure the nut by a cotter pin.
DIFFERENTIAL
Assembly
Prior the assembly inspect all parts carefully and
assure that all to be reused parts are in good condition.
Start assembly by pressing the conical outer bearings
onto housing halves if they are replaced.
Then place crown wheel side housing half on the crown
wheel and place differential side gear with the thrust
washer into the housing half. Place then planetary
gears with their thrust washers inseried onto spider
onto the side gear in the housing half.
If differential if fitted with the lock, side gear with lock
splines have to be installed first in the bottom.
Picture 24. Differential components installed in
the casing half
Place other side gear with its thrust washer on the top
of planetary gears. See picture 24.
Then fit the upper casing half according to markings
and insert screws and fit nuts. Use Loctite locking liquid
and tighten nuts to 320 Nm torque. (Nuts have to be
replaced always when undone).
11

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19. Workshop instructions
The pinion already assembled with previous shims in
the drive gear housing:
Installation of the differential assy
Place drive gear housing pinion flange down.
Use suitable Minggear and a lifting hook and position
differential assy with crown wheel on the housing and
fit bearing races simultaneously.
Picture 25. Assembled differential without the
crown wheel
DRIVE GEAR
Assembly
Picture 27. Differential assembly placed onto the
drive gear housing
Fit the bearing caps according to markings. Use
Locktite in screws and tighten a little. Fit now bearing
adjustment nuts and adjust position of the crown wheel
as close to correct as possible.
Picture 26. Drive gear housing ready for
installation of the differential assembly
Picture 28. Installation of the bearing cap.
Oy Sk-Auto Ab 12

20. SamD
Workshop instructions
Tighten now cap screws to a torque of 530 Nm. Measure gear backlash by dial gauge and adjust it by
Position a dial gauge with magnetic base as shown in turning both adjustment nut equally,so that bearing
figure 29, and tighten the bearing adjustment nuts until preload remains as adjusted previously. Adjust gear
end play is eliminated. backlash to 0,15 - 0,35 mm
When the play is eliminated, tighten crown wheel teeth
side adjustment nut 1 - 1,5 slots further by wrench no
7143 024 010.
Picture 29. Adjustment of the differential side
bearings
Picture 30. Adjustment of the gear backlash
REPLACEMENT OF PINION I CROWN WHEEL ASSEMSLY
Where a new pinion/crown wheel assembly has to be installed, it is necessary, in order to determine the correct
location of the pinion, to know the meaning of the information marked on the pinion and on the crown wheel.
1.Part number
2. Pinion/crown wheel pair number and tooth combination number.
3. Variation value to determine the thickness of shim(s) between the pinion inner bearing race and the drive gear
housing. This value is marked on inside surface of the pinion.
-Part number, Pair number and tooth combination number are die cul in the outer surface of all pinions. On crown
wheels these numbers are marked on outside diameter. Tooth combination number (for example 30/12) indicates
that the pinion has 12 teeth and the crown wheel 30, equal to a drive ratio of 2.500 : 1.
Available pinion/crown wheel assemblies and respective drive ratios:
Spare no. Tooth Drive ratio Axle total drive ratio
combination
143 240 2911 30/l 2 2.500 : 1 10.59 : 1
1432402921 31i8 3.875 : 1 16.41 : 1
143 240 2931 3417 4.857 : 1 20.57 : 1
143 240 2941 29i14 2.071 :1 8.77 :1
1432402951 3717 5.286 :I 22.39 :1
143 240 2961 3li9 3.444 : 1 14.58 . 1
1432402981 4119 4.556 :1 19.29 : 1
1432402991 4oi7 5.714 :1 24.20 :I
-All pinion/crown wheel assemblies are supplied in matched pairs and both parts have same pair number. On
pinions this number is die cut in the inner end of the pinion.
13

21. mmY
Workshop instructions
Never use a pinion and a crown wheel which do not
have a same pair number.
- Each crown wheel is marked with a variation number,
which indicates the nominal assembly distance. This
variation number shall be used in calculating the
shims to placed between the pinion inner bearing race
and the drive gear housing. Variation number (for
example +O.l or -0.1) is marked on the outside
diameter of the crown wheel.
To calculate the thickness of the shims used under
the bearing race, perform as follows:
1. Measure the shims used with previous pinion/crown
wheel assy.
2. Note the variation number on the new crown wheel.
If this number has a plus value (+) subtract it from
measurement calculations below. If this number has
a minus value (-)add it to measurement calculations
below.
Take note of this measurement.
CALCULATION EXAMPLES
Example 1
- Thickness of original shim(s) 0.75 mm
- Variation no. on crown wheel +0.05 -0.05
- Measurement obtained mm 0.70
- Variation no on new wheel+O.lO +O.lO
- New thickness of shim to be used 0.80 mm
Example 2
- Thickness of original shim(s)
- Variation no. on crown wheel -0.05
- Measurement obtained
- Variation no on new wheel+0.15
0.65 mm
+0.05
mm 0.70
+0.15
- New thickness of shim to be used 0.85 mm
Example 3
- Thickness of original shim(s)
- Variation no. on crown wheel +0.05
- Measurement obtained
- Variation no on new wheel-O.05
0.70 mm
-0.05
mm 0.65
-0.05
- New thickness of shim to be used 0.60 mm
Available shims for determining the location of the
pinion
Spare no. Thickness
90731 12010 0,l mm
90731 12020 0,2 mm
90731 12050 0,5 mm
90732 12010 1.0 mm
NOTE. Check next the tooth contact and correct it as
required. To obtain correct contact pattern may need a
move of the pinion, which changes gear backlash and
adjustment of it has to be performed simultaneously.
Correct tooth contact is more important and gear
backlash has to be set within 0,15 - 0,35 mm with new
pinion/crown wheel assembly.
With old assembly the tooth contact and the gear
backlash have to be set as they were prior the
dismantling.
Check tooth contact by using lead oxide paint (red
lead).
Following pictures illustrates tooth contacts unloaded.
Picture 31. With a brush, apply a thin coat of
suitable contact paint
Picture 32. Good contact pattern without load
Indicates that the pinion is set correctly. This gives a
silent drive operation and long life time.
Use these shims single or in combinations as required.
Oy Sisu-Auto Ab 13