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1. SERVICE REPAIR
H20.00-32.00F/FS (H440-700F/FS) [E008]
PART NO. 897458 8000 SRM 489

2. 8000 SRM 489 Container Attachment Weights
Lift Truck Weights
Unit kg lb
H20.00F 31,875 70,209
H22.00F 33,311 73,373
H25.00F 34,830 76,718
H28.00F 42,218 92,992
H32.00F 43,060 94,846
H440FS 31,234 68,798
H550FS 33,956 74,792
H550F 34,830 76,718
H620F 42,218 92,992
H620FS 41,463 91,329
H650F 41,635 91,708
H700FS 41,609 91,649
H700F 43,060 94,846
NOTE: Lift trucks equipped with 4877 mm (192 in.) mast and sideshift carriage on all units except H440-
700FS.
Container Attachment Weights
Attachment Weight Before Serial Number
E8E01811
Weight Serial Number
E8E01811 and After
6.1 m (20 ft) Fixed 1860 kg (4100 lb) 2600 kg (5732 lb)
12.2 m (40 ft) Fixed 4218 kg (9300 lb) 4100 kg (9039 lb)
6.1 to 12.2 m (20 to 40 ft)
Extendable
5830 kg (12,850 lb) 6000 kg (13228 lb) w/o lift eyes
6150 kg (13558 lb) with lift eyes
1

3. Mast Speeds 8000 SRM 489
Mast Speeds
TIER 1
Lifting Lowering
No Load Rated Load No Load Rated LoadUnit
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
H20.00F 0.67 131 0.31 61 0.23 45 0.46 91
H22.00F 0.67 131 0.31 61 0.23 45 0.47 94
H25.00F 0.67 131 0.31 61 0.23 45 0.48 96
H28.00F 0.54 106 0.23 46 0.33 65 0.45 90
H32.00F 0.54 106 0.23 46 0.33 65 0.48 96
H440FS 0.67 131 0.31 61 0.23 45 0.46 91
H550F/FS 0.67 131 0.31 61 0.23 45 0.48 96
H620F/FS 0.54 106 0.23 46 0.33 65 0.45 90
H650F 0.54 106 0.23 46 0.33 65 0.47 94
H700F/FS 0.54 106 0.23 46 0.33 65 0.48 96
TIER 2/3
Lifting Lowering
No Load Rated Load No Load Rated LoadUnit
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
H25.00F 0.51 99 0.25 48 0.23 45 0.49 96
H28.00F 0.41 80 0.18 35 0.33 65 0.46 90
H32.00F 0.41 80 0.18 35 0.33 65 0.49 96
H550F/FS 0.51 99 0.25 48 0.23 45 0.49 96
H620F/FS 0.41 80 0.18 35 0.33 65 0.46 90
H650F 0.41 80 0.18 35 0.33 65 0.48 94
H700F/FS 0.41 80 0.18 35 0.33 65 0.49 96
2

4. 8000 SRM 489 Engine Specifications
Engine Specifications
Item Tier 1 - Cummins
6CT8.3
Tier 2 - Cummins
QSC8.3
Tier 3- Cummins
QSC8.3
Number of Cylinders 6 6 6
Firing Order
Fan to Flywheel 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4
Bore 114 mm (4.49 in.) 114 mm (4.49 in.) 114 mm (4.49 in.)
Stroke 135 mm (5.32 in.) 144 mm (5.69 in.) 135 mm (5.32 in.)
Displacement 8.3 liter (506.5 in.3
) 8.3 liter (506.5 in.3
) 8.3 liter (506.5 in.3
)
Compression Ratio 17.3 to 1 16.6 to 1 17.5 to 1
Oil Pressure
(Minimum at idle)
69 kPa (10 psi) 69 kPa (10 psi) 69 kPa (10 psi)
Governed Speed
(No Load)
2700 rpm 2430 rpm 2200 rpm
Idle Speed 850 rpm 800 rpm 800 rpm
Stall Speed 2000 ±50 rpm 2000 ±50 rpm 1940 ±50 rpm
Valve Clearance (Cold)
Intake 0.3048 mm (0.012 in.) 0.3048 mm (0.012 in.) 0.3048 mm (0.012 in.)
Exhaust 0.61 mm (0.024 in.) 0.5588 mm (0.022 in.) 0.5588 mm (0.022 in.)
Weight (Dry) 636 kg (1400 lb) 706 kg (1556 lb) 723 kg (1594 lb)
3

5. Capacities 8000 SRM 489
Specifications
Item Specification
Hydraulic Pump Output at 2350 rpm and
13.8 MPa (2000 psi)
Tandem Pump (Steering) 242 liter/min (64 gal/min)
Tandem Pump (Brakes) 91 liter/min (24 gal/min)
Auxiliary Circuit Pump 106 liter/min (28 gal/min)
Pressure Reduction Valves
Pilot Circuits 2.1 MPa (300 psi)
Brake System 10.3 MPa (1500 psi)
Relief Pressures at 2500 rpm
Control Valves 16.7 to 17.6 MPa (2450 to 2550 psi)
Two-Speed Cartridge 13.5 to 14.1 MPa (1950 to 2050 psi)
Flow Amplifier (Steering) 16.9 to 18.3 MPa (2450 to 2650 psi)
External Relief Valves
Steering Circuit 21.7 to 22.4 MPa (3150 to 3250 psi)
Auxiliary Circuit 21.7 to 22.4 MPa (3150 to 3250 psi)
Main Hydraulic Filters
Relief Steering 69 to 130 kPa (10 to 15 psi)
Tank Capacity
Dipstick FULL mark 325 liter (85.8 gal)
Capacities
Item Tier 1 Specification Tier 2 Specification Tier 3 Specification
Engine Oil 22.4 liter (23.7 qt) 18.9 liter (20.0 qt) 18.9 liter (20.0 qt)
Cooling System 40.0 liter (42.3 qt) 40.0 liter (42.3 qt) 35.4 liter (37.4 qt)
Hydraulic System Oil 325.0 liter (85.8 gal) 325.0 liter (85.8 gal) 325.0 liter (85.8 gal)
Transmission Oil 25.5 liter (27.0 qt) 25.5 liter (27.0 qt) 25.5 liter (27.0 qt)
Drive Axle Planetaries
20-25 ton truck, each
side
3.8 liter (4.0 qt) 3.8 liter (4.0 qt) 3.8 liter (4.0 qt)
28-32 ton truck, each
side
5.2 liter (5.5 qt) 5.2 liter (5.5 qt) 5.2 liter (5.5 qt)
Differential 22.7 liter (24.0 qt) 22.7 liter (24.0 qt) 22.7 liter (24.0 qt)
Steer Wheel Hubs 2.8 liter (3.0 qt) 2.8 liter (3.0 qt) 2.8 liter (3.0 qt)
4

6. 8000 SRM 489 Transmission Pressures
Electrical System
All Models - 24 Volt, Negative Ground
Tier 1 Engine Tier 2/3 Engine
Alternator Output
50 Amps (At Idle)
Alternator Output
70 Amps (At Idle)
Transmission Pressures
Function Pressure Normal Pressure Range
1. Clutch 1865 to 1930 kPa
(240 to 280 psi)
2. Torque Converter Out* 172 kPa (25 psi) Minimum
@ 2000 rpm
482 kPa (70 psi) Maximum
@ 2600 rpm
3. Forward Pilot 1655 to 1930 kPa
(240 to 280 psi)
4. Forward Clutch 1655 to 1930 kPa
(240 to 280 psi)
5. Reverse Clutch 1655 to 1930 kPa
(240 to 280 psi)
6. Reverse Pilot 1655 to 1930 kPa
(240 to 280 psi)
7. First-Speed Pilot 1655 to 1930 kPa
(240 to 280 psi)
8. Second-Speed Clutch 1655 to 1930 kPa
(240 to 280 psi)
9. Second-Speed Pilot 1655 to 1930 kPa
(240 to 280 psi)
10. Third-Speed Clutch 1655 to 1930 kPa
(240 to 280 psi)
Transmission
Shift Control Valve
*Check pressure at fitting for temperature sending unit on left side of the transmission.
NOTE: All pressure checks with engine speed at 2000 rpm and transmission oil temperatures at least 83 C
(180 F).
5

7. Torque Specifications 8000 SRM 489
Tires
Model
Drive Tire
Size and Pressure
Steer Tire
Size and Pressure
14.00 × 24 - 20 ply 827 kPa
(120 psi)
14.00 × 24 - 20 ply 827 kPa
(120 psi)
14.00 × 24 - 28 ply 1034 kPa
(150 psi)
14.00 × 24 - 28 ply 1034 kPa
(150 psi)
H20.00-25.00F (H440-550F/FS)
14.00 × 24/10 Solid Tires 14.00 × 24/10 Solid Tires
H28.00-32.00F (H620-700F/FS)
16.00 × 25 - 24 ply 758 kPa
(110 psi)
16.00 × 25 - 24 ply 758 kPa
(110 psi)
Torque Specifications
BRAKE SYSTEM
Brake Caliper to Bracket Capscrews
108 to 122 N•m (80 to 90 lbf ft)
Brake Rotor Capscrews
40 to 45 N•m (33 to 37 lbf ft)
Caliper Cylinder Heads
100 N•m (75 lbf ft)
Caliper End Plate Capscrews
230 N•m (170 lbf ft)
CONTAINER ATTACHMENT
Twist Lock Retainer Capscrews
149 N•m (110 lbf ft)
Twist Lock Crank Capscrews
87 N•m (64 lbf ft)
Wear Plate Capscrews (top and bottom)
81 N•m (60 lbf ft)
Wear Plate Capscrews (sides)
54 N•m (40 lbf ft)
Twist Lock Cylinder Retainer
407 to 475 N•m (300 to 350 lbf ft)
Slew Cylinder Retainer
475 to 542 N•m (350 to 400 lbf ft)
Nut, Slew Cylinder Rod
407 to 441 N•m (300 to 325 lbf ft)
DIFFERENTIAL
(See the section Differential 1400 SRM 46)
DRIVE LINE AND AXLE
Axle to Frame Bolts
1627 to 2034 N•m (1200 to 1500 lbf ft)
Rim Clamp Nuts
305 to 339 N•m (225 to 250 lbf ft)
Universal Yoke Capscrews
122 to 136 N•m (90 to 100 lbf ft)
Universal Yoke Flange Capscrews
(at park brake)
122 to 136 N•m (90 to 100 lbf ft)
ENGINE
Alternator Link
24 N•m (18 lbf ft)
Alternator Support (Upper)
24 N•m (18 lbf ft)
Belt Tensioner to Bracket
43 N•m (32 lbf ft)
Belt Tensioner Bracket to Block
24 N•m (18 lbf ft)
Crankshaft Damper
200 N•m (148 lbf ft)
Exhaust Manifold
43 N•m (32 lbf ft)
Fan Bracket Mounting
24 N•m (18 lbf ft)
Fan Hub
43 N•m (32 lbf ft)
6

8. 8000 SRM 489 Torque Specifications
Flywheel
137 N•m (101 lbf ft)
Flywheel Housing
60 N•m (45 lbf ft)
Fuel Pump Mount Nut
43 N•m (32 lbf ft)
Fuel Pump to Bracket
24 N•m (18 lbf ft)
Fuel Pump Bracket to Cylinder Block
43 N•m (32 lbf ft)
Fuel Solenoid Mount
10 N•m (84 lbf in)
Fuel Solenoid Bracket
43 N•m (32 lbf ft)
Fuel Injector Drain Manifold
9 N•m (84 lbf in)
Fuel Injector Retaining Capscrew
24 N•m (18 lbf ft)
Intake Manifold Cover
24 N•m (18 lbf ft)
Lifting Bracket
77 N•m (57 lbf ft)
Oil Cooler Cover
24 N•m (18 lbf ft)
Oil Sump Drain Plug
80 N•m (60 lbf ft)
Oil Pressure Regulator Valve
80 N•m (60 lbf ft)
Oil Thermostat
50 N•m (37 lbf ft)
Starter Mounting
77 N•m (57 lbf ft)
Thermostat Housing
24 N•m (18 lbf ft)
Turbocharger Mounting Nut
32 N•m (24 lbf ft)
Water Pump Mounting
24 N•m (18 lbf ft)
Valve Cover
24 N•m (18 lbf ft)
FRAME
Counterweight Bolts
814 N•m (600 lbf ft)
Fender Bolts
814 N•m (600 lbf ft)
HYDRAULIC SYSTEM SELECTOR VALVE
Solenoid Capscrews
6 N•m (56 lbf in)
Mount Capscrews
14 N•m (10 lbf ft)
MAST AND CARRIAGES
Load Roller Retainer Capscrews
108 to 115 N•m (80 to 85 lbf ft) Final
Pivot Pin Nuts
163 N•m (120 lbf ft)
Retainer Capscrews on Apron (sideshift
carriage)
420 N•m (310 lbf ft)
Lift Cylinder Retainer (Rod End)
880 N•m (650 lbf ft)
Piston Nut, Sideshift Cylinder
678 to 746 N•m (500 to 550 lbf ft)
Fork Positioner Cylinder Nut (Piston End)
305 to 373 N•m (225 to 275 lbf ft)
Tilt Cylinder Nut (Piston End)
1500 to 1600 N•m (1107 to 1181 lbf ft)
Tilt Cylinder Retainer (Rod End)
450 to 550 N•m (332 to 406 lbf ft)
STEERING
Steering Wheel Nut
35 to 45 N•m (26 to 33 lbf ft)
Cylinder Mount Capscrews
1085 to 1220 N•m (800 to 900 lbf ft)
Cylinder Tie Rod Nuts
320 N•m (236 lbf ft)
Spindle Bearing Cap Capscrews
47 N•m (35 lbf ft)
7

9. Torque Specifications 8000 SRM 489
Wheel Bearing Nuts
Inner Nut 200 N•m (150 lbf ft) Initial
Outer Nut 136 to 272 N•m (100 to 200 lbf ft) Final
Rim Clamp Nuts
270 to 340 N•m (200 to 250 lbf ft)
TORQUE CONVERTER
Hub to Stator Capscrews
69 N•m (50 lbf ft)
Flange to Impeller Capscrews
25 N•m (18 lbf ft)
Turbine Hub Capscrews
49 N•m (36 lbf ft)
Impeller to Impeller Capscrews
25 N•m (18 lbf ft)
Input Flange Capscrews
49 N•m (36 lbf ft)
TRANSMISSION
Third Speed Piston Housing Capscrew
69 N•m (50 lbf ft)
Output Yoke Capscrews
49 N•m (36 lbf ft)
Sun Gear Shaft Nut
360 N•m (266 lbf ft)
Diaphragm Spring Retainer Capscrews
25 N•m (18 lbf ft)
Forward Piston Housing Capscrews
69 N•m (50 lbf ft)
Input Shaft Nut
400 N•m (295 lbf ft)
Stator Tube Capscrews
69 N•m (50 lbf ft)
Front Housing Capscrews
49 N•m (36 lbf ft)
Pump Drive Housing Capscrews
25 N•m (18 lbf ft)
Front Cover Capscrews
25 N•m (18 lbf ft)
Input Yoke Capscrews
35 N•m (26 lbf ft)
Torque Converter Cover Capscrews
49 N•m (36 lbf ft)
Regulator Cover Capscrews
25 N•m (18 lbf ft)
Control Valve Capscrews
25 N•m (18 lbf ft)
Drive Plate Capscrews
36 N•m (27 lbf ft)
Transmission Mount Capscrews
285 N•m (210 lbf ft)
8

10. 1400 SRM 46 Description
General
This section contains description and repair procedures for the differential. There is a Specifications section
and a Troubleshooting section at the end of this section.
Description
This differential is fastened to the drive axle hous-
ing of the lift truck. The differential provides a sin-
gle-speed reduction for an increase in torque to the
drive wheels. There is a housing, a ring and pinion
gear set, and the differential assembly. The ring gear
transfers power from the pinion through the differen-
tial assembly to the axles. The differential assembly
permits the drive wheels to rotate at different speeds
during a turn. See Figure 1.
Figure 1. Typical Differential Assembly
1

11. Differential Repair 1400 SRM 46
Legend for Figure 1
NOTE: *SOME AXLES DO NOT HAVE THE PARTS DESCRIBED.
1. PINION NUT
2. WASHER*
3. INPUT YOKE*
4. DEFLECTOR
5. TRIPLE-LIP OIL SEAL
6. DIFFERENTIAL CARRIER
7. FILL PLUG
8. ADJUSTMENT RING
9. LOCK PLATE
10. CAPSCREW
11. SIDE GEAR
12. THRUST WASHER
13. CASE HALF
14. BEARING CONE
15. BEARING CUP
16. PINION
17. SPIDER
18. CAPSCREW OR RIVET*
19. RING GEAR
20. CASE HALF, FLANGE
21. NUT*
22. NUT
23. WASHER
24. THRUST BLOCK*
25. BEARING CAP
26. COTTER PIN (ADJUSTING
RING)*
27. JAM NUT*
28. THRUST SCREW*
29. RETAINING RING
30. WASHER
31. SPIGOT BEARING
32. PINION
33. SPACER
34. SHIM
35. PINION CARRIER
36. COVER
37. BOLT
38. SHIFT FORK
39. SPRING
40. SHIFT SHAFT
41. PIN
42. AIR CYLINDER TUBE
43. SCREW IN DIFFERENTIAL
LOCK CYLINDER
44. CYLINDER COVER
45. GASKET
46. PLUG
47. SHIFT COLLAR
48. PISTON
49. O-RING
Differential Repair
REMOVE
NOTE: The repair procedures cover all units unless
otherwise indicated.
Differential Carrier From Axle Housing,
Remove
NOTE: The differential assembly can normally be
removed without removing the drive axle. On some
trucks, including the H7.00-12.50H (H150-275H),
the drive axle must be removed to remove the dif-
ferential assembly. If removal of the drive axle is
necessary, see the Drive Axle service manual for
your lift truck model.
1. Remove the mast. See the Mast section for your
lift truck model for the removal procedures.
2. Raise the end of the vehicle where the axle is
mounted. Use a jack or other lifting tool, and
place safety stands under each side of the axle.
See Figure 2.
WARNING
Block the wheels to prevent the lift truck
from moving. Support the lift truck with
safety stands. DO NOT work under a lift truck
supported only by jacks. Jacks can slip and
fall over. Serious personal injury can result.
3. Place jack stands under each spring seat of the
axle, to hold the lift truck in the raised position.
1. SAFETY STANDS
Figure 2. Lift Truck Support
2

12. 1400 SRM 46 Differential Repair
4. Remove plug from the bottom of the axle housing
and drain the oil from the axle assembly.
5. Disconnect the drive shaft at the differential. If
a speed reducer or gear box is installed, remove
the speed reducer or gear box.
6. Some units have a drum or disc brake attached to
the output yoke. Disconnect any brake linkage or
brake lines. See the Brake section for your unit.
7. Disconnect the driveline universal joint from the
pinion input yoke or flange on the differential
carrier. See Figure 3.
8. Remove the axle shafts from the axle housing.
See the Drive Axle section for your model of lift
truck for the procedures.
a. On Straddle Trucks™, disconnect the drive
axle universal joints at the differential
yokes. Remove the capscrews that fasten the
bearing retainers to the differential hous-
ing. Pull the yoke, stub shaft and bearing
retainer from the housing.
9. Place a transmission jack under the differential
carrier for support. See Figure 4.
1. BEARING CUPS
2. END YOKE
3. YOKE SADDLE
4. WELD YOKE
5. BEARING STRAP
6. CAPSCREWS
7. U-JOINT CROSS
8. SLIP YOKE
9. TUBING
Figure 3. Typical Driveline Universal Joint
3

13. Differential Repair 1400 SRM 46
1. WOOD BLOCK
2. TRANSMISSION JACK
3. CAPSCREWS
Figure 4. Differential Carrier Support
10. Remove all but the top two differential carrier
housing capscrews. See Figure 4.
11. Loosen the top two differential carrier housing
capscrews and leave them attached to the assem-
bly. The capscrews will hold the differential car-
rier in the housing.
12. Loosen the differential carrier in the axle hous-
ing. Use a leather mallet to hit the mounting
flange of the differential carrier at several points.
13. After the differential carrier is loosened, remove
the top two capscrews.
CAUTION
When using a pry bar, be careful not to dam-
age the differential carrier or housing flange.
Damage to these surfaces will cause oil leaks.
14. Remove the differential carrier from the axle
housing. Use a pry bar with a round end, to help
remove differential carrier from housing.
15. Remove the differential carrier assembly from
under the lift truck.
16. Use a lifting device and lift the differential car-
rier by the input yoke or flange and place the as-
sembly on a repair stand. See Figure 5.
1. DIFFERENTIAL CARRIER
2. REPAIR STAND
Figure 5. Differential Carrier Stand
Differential and Ring Gear From
Differential Carrier, Remove
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
NOTE: Before working on the differential carrier, in-
spect the hypoid gear set for damage. If inspection
shows no damage, the same gear set can be used
again. Measure the backlash of the gear set and
make a record of the dimension. See the section Ring
Gear Backlash, Adjust. During differential reassem-
bly, adjust the backlash to the original recorded di-
mension when the gear set is installed into the dif-
ferential carrier.
1. Loosen the jam nuts on the thrust screw.
2. Remove the thrust screw and jam nut from the
differential carrier. See Figure 6.
4

14. 1400 SRM 46 Differential Repair
Figure 6. Thrust Screw and Jam Nut Removal
3. Rotate the differential carrier until the ring gear
is at the top of the assembly.
4. Mark one differential carrier leg and bearing cap
to correctly match the parts during differential
carrier assembly. Mark the parts using a center
punch and hammer. See Figure 7.
1. BEARING CAP
2. DIFFERENTIAL CARRIER LEG
3. MATCHMARKS
Figure 7. Mark Differential Carrier Leg and
Bearing Cap
5. Remove the cotter pins that hold the bearing ad-
justing rings in position. Some differential car-
rier models have dowel pins or lock plates hold-
ing the bearing adjusting rings in position. Each
lock plate is held in position by two capscrews.
See Figure 8.
6. Remove capscrews and washers holding the two
bearing caps on the differential carrier. See Fig-
ure 8.
1. COTTER PIN 2. LOCK PLATE
Figure 8. Bearing Adjusting Ring Removal
7. Remove the bearing caps and bearing adjusting
rings from the differential carrier. See Figure 9.
5

15. Differential Repair 1400 SRM 46
1. BEARING CAP
2. BEARING ADJUSTING RING
Figure 9. Bearing Cap Removal
8. Use a lifting device and lift the main differential
and ring gear assembly from the differential car-
rier. See Figure 10.
1. BEARING CUP
2. DIFFERENTIAL CARRIER
3. BEARING BORE
4. PUT ADHESIVE HERE (INSTALLATION ONLY)
Figure 10. Main Differential and Ring Gear
Assembly Removal
Drive Pinion and Pinion Carrier From
Differential Carrier, Remove
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Fasten a yoke or flange bar to the input yoke or
flange. When the nut is removed, the bar will
hold the drive pinion in position. See Figure 11.
2. Remove the nut and washer from the drive pin-
ion.
3. Remove the yoke or flange bar.
1. FLANGE BAR 2. YOKE BAR
Figure 11. Flange and Yoke Bar
CAUTION
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mal-
let can damage the parts and cause driveline
runout or driveline imbalance problems after
carrier to driveline assembly.
4. Remove the yoke or flange from the drive pinion.
If the yoke or flange is tight on the pinion, use a
puller for removal. See Figure 12.
5. Remove the capscrews and washers that hold the
pinion carrier in the differential carrier. See Fig-
ure 13.
6

16. 1400 SRM 46 Differential Repair
A. YOKE PULLER B. FLANGE PULLER
Figure 12. Yoke and Flange Puller Tools
1. DRIVE PINION AND PINION CARRIER
2. SHIMS
3. CAPSCREWS
Figure 13. Pinion Carrier Removal
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
CAUTION
Do not use a pry bar to remove the pinion car-
rier from the carrier. A pry bar can damage the
bearing case, shims, and differential carrier.
6. Remove the drive pinion, pinion carrier, and
shims from the differential carrier. See Fig-
ure 13. If the pinion carrier is tight on the
differential carrier, hit the pinion carrier at sev-
eral points around the flange area with a leather,
plastic or rubber mallet.
7. Inspect the shims. If they are in good condition,
keep the shims together for use during differen-
tial carrier assembly.
8. If the shims are to be replaced, first measure the
total thickness of the pack. Make a note of the
dimension. The dimension will be needed to cal-
culate the depth of the drive pinion in the differ-
ential carrier when the gear set is installed.
DISASSEMBLE
Differential and Ring Gear Assembly,
Disassemble
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
NOTE: Make sure there are matching marks on the
case halves of the differential assembly. See Step 4
in the section Differential and Ring Gear From Dif-
ferential Carrier, Remove. See Figure 7.
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
1. Remove the capscrews and washers that hold
the case halves together and separate the case
halves. If necessary, use a brass, plastic, or
leather mallet to loosen the parts.
7

17. Differential Repair 1400 SRM 46
2. Remove the differential spider, four pinion gears,
two side gears, and six thrust washers from in-
side the case halves. See Figure 14.
1. THRUST WASHER
2. SIDE GEAR
3. SPIDER, PINIONS, AND THRUST WASHERS
Figure 14. Ring Gear Disassembly
3. If the ring gear needs to be replaced, remove
bolts, nuts, and washers holding the ring gear to
the flange case half.
CAUTION
Do not remove the rivets or rivet heads with a
chisel and hammer. Using a flat edge tool can
cause damage to the flange case. See Figure 15.
4. If your differential model uses rivets to hold the
ring gear to the flange case half, remove the riv-
ets as follows:
a. Center punch each rivet head in the center,
on the ring gear side of the assembly.
b. Drill each rivet head on the ring gear side of
the assembly to a depth equal to the thick-
ness of one rivet head. Use a drill bit that is
1/32 of an inch smaller than the body diame-
ter of the rivets. See Figure 15.
c. Press the rivets through holes in the ring
gear and flange case half. Press from the
drilled rivet head.
A. CORRECT DRILLING RIVETS FROM HEAD
B. WRONG CHISELING RIVETS FROM HEAD
Figure 15. Rivet Removal
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
5. Separate the case half and ring gear using a
press. Support the assembly under the ring gear
with metal or wood blocks and press the case
half through the gear. See Figure 16.
1. CASE HALF
2. PRESS
3. PLATE
4. SUPPORTS
Figure 16. Case Half and Ring Gear Separation
8

18. 1400 SRM 46 Differential Repair
6. If the differential bearings need to be replaced,
remove the bearing cones from the case halves.
Use a bearing puller or press. See Figure 17.
A. PULLER B. PRESS
Figure 17. Differential Bearings Replacement
Drive Pinion and Pinion Carrier,
Disassemble
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Place drive pinion and pinion carrier in a press.
The pinion shaft must be toward the top of the
assembly. Add supports for the pinion carrier
under the flange area. See Figure 18.
2. Press the drive pinion through the pinion carrier.
See Figure 18.
1. PRESS
2. DRIVE PINION
3. OIL SEAL
4. PINION CARRIER
5. SUPPORT
6. SPIGOT BEARING
7. FLANGE SUPPORT
Figure 18. Drive Pinion Disassembly
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
NOTE: The inner bearing cone and bearing spacer
will remain on the pinion shaft. See Figure 19.
3. If a press is not available, use a leather, plastic
or rubber mallet to drive the pinion through the
pinion carrier.
CAUTION
When removing the oil seal, Do not damage the
wall of the bore. Damage to the bore wall can
result in oil leaks.
NOTE: Always replace the oil seal with a new seal
during reassembly.
4. Remove the oil seal from the pinion carrier. See
Figure 19.
9

19. Differential Repair 1400 SRM 46
1. DRIVE PINION
2. OIL SEAL
3. OUTER BEARING (CUP AND CONE)
4. INNER BEARING (CUP AND CONE)
5. SPIGOT BEARING
6. SNAP RING
7. BEARING SPACER
Figure 19. Drive Pinion
5. Inspect the pinion bearings and replace if neces-
sary. If the pinion bearings need to be replaced,
perform the following:
a. Remove the inner and outer bearing cups
from the inside of the cage. Use either a press
and sleeve, bearing puller, or a small drift
pin. See Figure 17 and Figure 20. If a press
is used, provide support for the pinion car-
rier under the flange area with metal or wood
blocks.
CAUTION
The puller must fit under the inner race of
the cone to remove the cone correctly without
damage.
b. Remove the inner bearing cone from the
drive pinion with a press or bearing puller.
See Figure 21.
6. If the spigot bearing needs to be replaced, place
the drive pinion in a vise. Install a soft metal
cover over each vise jaw to protect the drive pin-
ion.
7. Remove the snap ring from the end of the drive
pinion. See Figure 22.
NOTE: Some spigot bearings are fastened to the drive
pinion with a special peening tool. See Figure 23.
NOTE: Some spigot bearings are a two-piece assem-
bly. Remove the inner race from the pinion with a
bearing puller. Remove the outer race/roller assem-
bly from the pinion carrier with a drift or a press. See
Figure 24.
8. Remove the spigot bearing from the drive pinion
with a bearing puller.
A. BEARING DRIVER B. BEARING PULLER
Figure 20. Pinion Bearing Replacement
10

20. 1400 SRM 46 Differential Repair
1. PRESS
2. DRIVE PINION
3. BEARING PULLER
4. SUPPORTS
5. INNER BEARING
CONE
Figure 21. Pinion Bearing Replacement
1. SPIGOT BEARING 2. SNAP RING
Figure 22. Snap Ring Removal
1. PEENING POINTS
Figure 23. Spigot Bearing Peening Points
1. REMOVE OUTER RACE AND ROLLER
ASSEMBLY FROM CARRIER
2. REMOVE INNER RACE FROM PINION
Figure 24. Two-Piece Spigot Bearing
11

21. Differential Repair 1400 SRM 46
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the recom-
mendations of the manufacturer.
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.
Clean and inspect the following parts of the differen-
tial:
• Yoke- Clean the surface of the yoke journal with a
cleaning solvent and inspect the original yoke seal
surface for any grooves.
• Drive axle- Clean the parts of the axle with sol-
vent and dry with compressed air. Inspect all ma-
chined surfaces and bearings for wear and damage.
• Tapered Roller Bearings- Inspect the cup, cone,
rollers, and cage of all tapered roller bearings in the
assembly. If bearings show signs of wear, cracks, or
damage, replace with new bearing.
• Pinions and Gears- Inspect the pinions and gears
for wear or damage. Gears that are worn or dam-
aged must be replaced.
• Axle shafts- Inspect the axle shafts for wear and
cracks at the flange, shaft and splines. If axle
shafts show signs of wear or damage, replace the
axle shafts.
• Main differential assembly- Inspect all parts of
the main differential assembly for wear or damage.
Parts that are damaged must be replaced. See Fig-
ure 25 for parts to inspect.
A. DIFFERENTIAL CASE HALVES
B. DIFFERENTIAL GEAR NEST ASSEMBLY
1. INSPECT INSIDE SURFACES
2. PINION AND THRUST WASHER
3. SIDE GEAR AND THRUST WASHER
4. SPIDER
Figure 25. Main Differential Assembly
Inspection
12

22. 1400 SRM 46 Differential Repair
ASSEMBLE
Pinion, Bearings, and Pinion Carrier,
Assemble
NOTE: Some of the parts described below are not
found on some differential carrier models. See Fig-
ure 1.
1. Put differential oil on the bearings and cups. In-
stall the cups in the pinion carrier. See Figure 1.
2. Install the inner bearing and spigot bearing
against the pinion shoulders. Use a sleeve and
press to push against the inner bearing race.
CAUTION
If a new pinion is installed, a new ring gear
must also be installed. The pinion and ring
gear are a set (see Figure 32) and must be in-
stalled together.
NOTE: During assembly at the factory, one spacer is
used. Two thinner spacers are used if the pinion or
bearings are replaced. These spacers are selected for
correct bearing preload.
NOTE: Some spigot bearings are fastened to the pin-
ion with a snap ring, and some are fastened with a
punch. Others can have a two-piece bearing. See Fig-
ure 24.
3. Install the spigot bearing washer and snap ring.
Put the pinion assembly in the pinion carrier. In-
stall the spacers on the pinion. See Figure 19.
4. Use a press to install the outer bearing against
the spacer. Rotate the carrier to make sure the
bearings are installed correctly.
5. Use either the Press Method or the Yoke or
Flange Method, and apply the correct preload.
See Specifications, Table 6. Check the bearing
preload as described in Pinion Bearings, Adjust
Preload of this section.
Pinion Bearings, Adjust Preload
Press Method
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
NOTE: If a press is not available, or the press does
not have a pressure gauge, use the Yoke or Flange
Method to adjust pinion bearing preload.
1. Place the drive pinion and carrier assembly in a
press with the gear head (teeth) toward the bot-
tom.
2. Install a sleeve of the correct size against the in-
ner race of the outer bearing. See Figure 19.
3. Apply and hold the correct amount of pressure to
the pinion bearings. See Specifications, Table 6.
As pressure is applied, rotate the pinion carrier
several times so that the bearings make normal
contact.
4. While pressure is held against the assembly,
wrap a cord several times around the pinion
carrier. Fasten a Newton or pound scale to the
cord. See Figure 26.
1. PRESS
2. SLEEVE
3. PINION BEARING
Figure 26. Bearing Preload Check
13

23. Differential Repair 1400 SRM 46
5. Pull the scale to unwind the cord. Check
the reading on the scale as the cord unwinds
smoothly. Do not read starting torque. Read
only the torque value after the pinion carrier
starts to rotate. The starting torque will provide
a false reading.
CAUTION
On H7.00-12.50H (H150-275H) trucks, DO NOT
use the washer that is on the new pinion. Use
the thicker spacer (Hyster PN 125277). The
threads can be damaged or the nut can loosen
if the washer is used.
6. The scale reading must indicate 2.2 to 7.0 kg (5
to 15 lb).
A pinion carrier that has a 76.2 mm (3 in.) ra-
dius and a 2.2 kg (5 lb) scale reading is equal
to 1.70 N•m (15 lbf in). Select a bearing spacer
set for the correct preload. A thinner set will in-
crease the preload. A thicker bearing spacer set
will decrease preload.
7. Use the following procedure to calculate the bear-
ing preload (torque):
• Pounds pulled × radius (inches) = lb-in preload.
- Preload × 0.113 = N•m preload.
• Kilograms pulled × radius (cm) = kg-cm lb-in
preload
- Preload × 0.098 = N•m preload.
OR
EXAMPLES:
• Reading from spring scale = 3.4 kg (7.5 lb).
• Diameter of pinion carrier = 16.8 cm (6.62 in.).
• Radius of pinion carrier = 8.4 cm (3.31 in.).
7.5 lb × 3.31 in = 24.8 in-lb preload.
Preload × 0.113 = 2.8 N•m preload.
OR
3.4 kg × 8.4 cm = 28.6 kg-cm preload.
Preload × 0.098 = 2.8 N•m preload.
Yoke or Flange Method
WARNING
Observe all warnings and cautions provided
by the press manufacturer to avoid damage to
components and serious personal injury.
CAUTION
Do not install tight fit yokes or flanges on shafts
using a hammer or mallet. A hammer or mallet
will damage the yoke or flange.
NOTE: Use a press to install the yoke or flange.
1. Install the input yoke or flange, nut, and washer
on the drive pinion. The yoke or flange must
be seated against the outer bearing for proper
preload.
2. Temporarily install the drive pinion and pinion
carrier assembly into the differential carrier. Do
not install shims under the pinion carrier. See
Figure 34.
3. Install the pinion carrier to the differential car-
rier by installing the capscrews and tightening
them by hand. Do not install the washers, they
are not required.
4. Fasten a yoke or flange bar to the input yoke or
flange. See Figure 11. The bar will hold the drive
pinion in position when the nut is tightened.
5. Tighten the nut on the drive pinion to the correct
torque value as shown in Specifications, Table 6.
Remove the yoke or flange bar.
6. Attach a torque wrench on the drive pinion nut.
Rotate the drive pinion and read the value indi-
cated on the wrench. See Figure 27.
Figure 27. Torque Value Reading
7. If the preload (torque) of pinion bearings is not
within specifications, remove the pinion and
pinion carrier from the differential carrier. Per-
form Step a and Step b below, then repeat Step 1
through Step 6.
14

24. 1400 SRM 46 Differential Repair
a. To increase preload, install a thinner bearing
spacer.
b. To decrease preload, install a thicker bearing
spacer.
Triple-Lip Seal, Install
Once the preload has been adjusted, remove the drive
pinion and pinion carrier from the differential carrier
as outlined in the first five steps in the section Drive
Pinion and Pinion Carrier From Differential Carrier,
Remove.
CAUTION
Make sure that the seal lips are clean and free
from dirt and particles that will cause a leak
between the yoke and the seal.
Install a new triple-lip oil seal as described below:
1. Apply lubricant to the outer surface of the seal
and the seal bore in the pinion carrier. See Fig-
ure 28.
1. APPLY GREASE
2. TRIPLE-LIP OIL SEAL
3. APPLY LUBRICANT TO SEAL BORE
4. PINION CARRIER
5. DRIVE PINION
Figure 28. Triple-Lip Oil Seal Lubrication
NOTE: If a press is not available, use a mallet and a
sleeve or driver to install the oil seal.
2. Place the drive pinion and carrier assembly in a
press, with seal bore toward the top.
3. Press the seal into pinion carrier until flange of
seal is flat against the top of pinion carrier. Use
a sleeve or seal driver of the correct size that fits
against the metal flange of oil seal. The diameter
of the sleeve must be larger than the diameter of
the flange. See Figure 29.
1. PRESS
2. SLEEVE
3. SUPPORTS
4. OIL SEAL
5. PINION CARRIER
6. DRIVE PINION
Figure 29. Triple-Lip Oil Seal Installation
15

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