service repair manual download

1. SERVICE REPAIR
H165XL H190XL H210XL [D007]

2. 1400 SRM 46 Differential Repair
General
This section has the description and repair procedures for the differential. There are Specifications and a
Troubleshooting table at the end of this section.
Description
This differential is fastened to the axle housing of the
lift truck. The differential gives a single-speed re-
duction 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 differential as-
sembly to the axles. The differential assembly per-
mits the drive wheels to rotate at different speeds
during a turn.
Differential Repair
REMOVE
NOTE: The repair procedures cover all units unless
otherwise indicated.
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 differ-
ential assembly.
1. Disconnect the drive shaft at the differential. If
a speed reducer or gear box is installed, remove
the speed reducer or gear box.
2. Some units have a drum or disc brake attached to
the output yoke. Be sure to disconnect any brake
linkage or brake lines. See the brake section for
your unit.
3. Remove the axle shafts from the axle housing.
See the drive axle section for your unit. On
STRADDLE TRUCKS, disconnect the drive
axle universal joints at the differential yokes.
Remove the capscrews that fasten the bearing
retainers to the differential housing. Pull the
yoke, stub shaft, and bearing retainer from the
housing.
DISASSEMBLE
1. Use a lifting device as a support for the differen-
tial. Remove the housing capscrews and remove
the differential from the axle housing.
2. If the unit has a drum or disc brake attached
to the output yoke, remove it. See the brakes
section for your unit.
3. If the ring and pinion gears will be used again,
check the clearance between the gears and make
a record of the value. See Figure 5.
4. A complete disassembly is not normally neces-
sary. Disassemble the differential to make nec-
essary repairs. See Figure 1. Put marks on one
bearing cap and the case half so that it can be in-
stalled in the same place. Put marks on each half
of the differential case so that they can be assem-
bled in the same way. Keep the shim set for the
pinion carrier assembly.
CAUTION
Never use a hammer and chisel to remove the
rivets. Damage to the holes can occur.
5. If it is necessary, remove the ring gear from
the case. Make sure the rivet holes in the case
are not damaged. Use a center punch and drill
smaller than the rivets to remove the rivets.
Keep the old ring gear and pinion set.
ASSEMBLE
Pinion, Bearings, and Pinion Carrier,
Assemble
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 pilot bearing
against the pinion shoulders. Use a sleeve and
press to push against the inner bearing race.
1

3. Differential Repair 1400 SRM 46
1. PINION NUT
2. WASHER*
3. INPUT YOKE*
4. DEFLECTOR
5. SEAL
6. HOUSING
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. LOCK PIN
27. JAM NUT*
28. THRUST SCREW*
29. SNAP RING
30. WASHER
31. PILOT BEARING
32. PINION
33. SPACER
34. SHIM
35. PINION CARRIER
*SOME AXLES DO NOT HAVE THE PARTS DESCRIBED
Figure 1. Differential Assembly with Generoid Gears
2

4. 1400 SRM 46 Differential Repair
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 4) and MUST be in-
stalled together.
3. Install the pilot bearing washer and snap ring.
Put the pinion assembly in the pinion carrier. In-
stall the spacers on the pinion.
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 pilot 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.
4. Use a press to install the outer bearing against
the spacer. Rotate the carrier to make sure the
bearings are installed correctly. Use the press
to apply the correct preload. See Specifications,
Rivet Installation Pressure. Check the bearing
preload as described in Pinion Bearings, Adjust
Preload of this section.
Pinion Bearings, Adjust Preload
1. Wrap a cord several times around the pinion car-
rier. Fasten a Newton or pound scale to the cord.
See Figure 2. Pull the scale to unwind the cord.
Check the reading on the scale as the cord un-
winds smoothly. Do NOT use the reading as the
cord just begins to unwind. 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 spacer set for the
correct preload. A thinner set will increase the
preload.
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.
2. If a press cannot be used for preload, install all
the parts that are held by the pinion nut. Tighten
the pinion nut to the correct torque shown in Ta-
ble 1. Check the preload as described in Step 1.
1. PRESS
2. SLEEVE
3. PINION BEARING
Figure 2. Bearing Preload Check
Pinion Carrier Shim Set, Adjust Thickness
(Depth of Pinion)
NOTE: Use this procedure if a new ring gear and pin-
ion set is installed, or if the depth of the pinion has
to be adjusted.
1. After the preload is correctly adjusted using the
spacer set, adjust the pinion. The pinion is ad-
justed using shims on the pinion carrier assem-
bly. If the same ring gear and pinion are used,
use the old shim set. See Figure 3. If a new ring
gear and pinion are used, adjust the pinion as de-
scribed.
CAUTION
Always use a minimum of three shims for the
shim set. Use the thinnest shims on the outside
of the set for a better seal.
2. The correct shim set thickness can be found by
using the old and new parts. Use the old shim set
thickness and the numbers on the old and new
pinion and ring gear sets. For the location and
identification of the numbers, see Figure 4.
3

5. Differential Repair 1400 SRM 46
1. SHIM SET (CONTROLS DEPTH OF PINION)
2. BEARING CARRIER
3. DIFFERENTIAL HOUSING
4. SPACER(S) (CONTROLS BEARING PRELOAD)
Figure 3. Shim Set Location
1. PART NUMBERS
2. GEAR TEETH NUMBERS
3. GEAR SET NUMBERS
4. PINION CONE NUMBERS
Figure 4. Pinion Set Numbers
NOTE: Always check the gear set for the correct
marks to make sure the gears are a matched set.
3. The location of the pinion and ring gear marks
are shown in Figure 4. The description of the
marks is as follows:
PART NUMBER. The part numbers are the
part number of the manufacturer. The part num-
ber for the ring gear is always an even number.
The part number for the pinion is the next odd
number. Check to make sure the pinion and ring
gear are in a sequence. Examples of gear set part
numbers: ring gear, 36786; drive pinion, 36787.
If a gear set number has a letter that follows the
number, the letters must be the same for both the
ring gear and pinion.
GEAR TEETH NUMBER. The gear teeth
numbers are the numbers of the teeth on the
pinion and ring gear. The number of pinion teeth
is the first number. An example of this number
is 5-37. In the example, the drive pinion has 5
teeth and the ring gear has 37 teeth.
GEAR SET NUMBER. The gear set number
is a letter and number. Make sure the letter and
number are the same on the drive pinion and ring
gear. An example of a gear set number is M29.
PINION CONE NUMBER. The pinion cone
number, is the variation from the design cen-
ter. The design center is the exact design dis-
tance from the end of the pinion cone to the
ring gear centerline. See Figure 5.
1. PINION CONE NUMBER (VARIATION)
Figure 5. Pinion Cone Number Location
NOTE: The pinion cone number is not used when the
gear set number is being checked. The pinion cone
number is used when you adjust the depth of the pin-
ion in the carrier.
Example: PC+3, PC−3, +3, or −3 equals .003 inch
(variation). PC+.03, PC−.03, +.03, or −.03 equals
.03 mm (variation).
Find the correct thickness of the shim set as fol-
lows:
4. Use a micrometer to measure the total thickness
of the old shim set that was removed from under
4

6. 1400 SRM 46 Differential Repair
the pinion carrier. Make a note of the measure-
ment for later use.
5. Check the pinion cone number for the old pinion.
See Figure 5. If this number is a plus (+) value,
subtract the value from the value in Step 4. If
the pinion cone number is a minus (−) value, add
the number to the value in Step 4. The number
shown is in 0.00X inch (+2 = +0.002 inch). The
result is the standard thickness for a shim set.
NOTE: The value calculated in Step 5 is the thickness
of the standard shim set, without a variation.
6. Check the pinion cone number for the new pin-
ion. Add or subtract this number to the standard
thickness value of Step 5. Add the number if the
value is a plus (+) value. Subtract the number if
the value is a minus (−) value. The result is the
correct thickness for the new shim set. See the
examples.
NOTE: The value calculated in Step 6 is the thick-
ness of the new shim set that will be installed. See
the examples shown in Specifications, Pinion Adjust-
ment.
CAUTION
Always use a minimum of three shims for the
shim set. Use the thinnest shims on the outside
of the set for a better seal.
7. Install the pinion carrier assembly using the cor-
rect shim set. See Figure 6. Tighten the cap-
screws to the correct value shown in Table 1.
a. If there is a bracket for a disc brake caliper,
install the bracket and tighten the cap-
screws.
b. If there is a speed reducer or drop box, install
it on the pinion carrier assembly. Use John
Crane No. 2® as a sealant. Tighten the nuts
to the correct value shown in Table 1.
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 Part Number
125277). The threads can be damaged or the
nut can loosen if the washer is used.
8. Install the universal joint yoke, flange for the
brake rotor or brake drum, or the gear for the
speed reducer. See Figure 7. Install the spacer
and pinion nut. Tighten the pinion nut to the cor-
rect torque as shown in Table 1.
Differential and Ring Gear, Assemble
CAUTION
Assembly of ring gear on the differential case
must be correct for correct gear adjustment
and maximum wear.
Make sure the ring gear is part of the set of the pinion
and ring gear. See Figure 4.
CAUTION
Do not install a cold ring gear on the flange
case half. A cold ring gear will damage the
case half because of the close tolerance. Metal
particles between the parts will cause gear
runout that will exceed the specification of
0.2 mm (0.008 in.).
1. Heat the ring gear in 71 to 82 C (160 to 180 F)
water for approximately ten minutes. Heating
the gear makes it fit easier on the differential
case.
1. PINION AND BEARING CARRIER
2. SHIMS
3. DIFFERENTIAL HOUSING
Figure 6. Pinion Carrier Assembly Installation
5

7. Differential Repair 1400 SRM 46
1. BRAKE DISC
2. BRAKE CALIPER
3. AIR CHAMBER
4. BRACKET
5. YOKE
6. BEARING CARRIER
7. SEAL
Figure 7. Units with Air Operated Disc Brakes
WARNING
Wear protective clothing to prevent injury
when handling the hot ring gear.
CAUTION
Never use a press or hammer to install the ring
gear.
2. Take care and lift the ring gear from the water
using a lifting tool.
3. Install the ring gear on the flange case half im-
mediately after the gear is heated. If the ring
gear does not fit easily on the case half, heat the
gear again.
4. Align fastener holes of the ring gear and flange
case half. Rotate the ring gear as needed.
5. If SPECIAL CAPSCREWS are used to fasten the
ring gear to the flange case half, install the cap-
screws, washers, and nuts as shown in Figure 8.
The capscrew heads MUST be against the ring
gear. Use pairs of capscrews opposite each other
to tighten the case and ring gear together. For
capscrew torque specifications, see Table 1.
6. If RIVETS are used to fasten the ring gear to
the flange case half, install the rivets cold. Do
not heat the rivets. For the correct pressure
to press the rivets, see Specifications, Pinion
Preload Pressure. The maximum pressure must
be applied for approximately one minute at the
end of the press cycle. Do not use more than the
maximum pressure. Damage to the holes can
occur. A correctly installed rivet will have a head
at least 3.18 mm (0.125 in.) larger than the hole
diameter. Install the rivets in pairs opposite
each other (A-A, B-B), from the case half side of
the assembly. See Figure 9.
7. Use a thickness gauge that has a thickness of
0.08 mm (0.003 in.) to check for correct instal-
lation. Put the gauge between the ring gear and
the case at four points that are separated by 90 .
The gauge cannot go in more than half the dis-
tance between the flange outer diameter and the
pilot diameter for the gear. If the gauge goes
more than half the distance, the ring gear must
be removed and installed again. See Figure 10.
6

8. 1400 SRM 46 Differential Repair
1. FLANGE CASE HALF
2. RING GEAR
3. BOLT HEAD AGAINST GEAR
Figure 8. Installation with Capscrews
1. RING GEAR 2. CASE HALF
Figure 9. Installation with Rivets
8. Install the bearing cones on both of the case
halves. Use a press and a sleeve of the correct
size.
9. Apply axle lubricant to the inside surfaces of both
case halves, spider (cross), thrust washers, side
gears, and differential pinions.
10. Put the flange case half on a bench with the ring
gear teeth toward the top.
1. CHECK FOR CLEARANCE FOUR PLACES WITH
0.08 mm (0.003 in.) GAUGE
Figure 10. Gear and Case Half Installation
Check
Differential Pinion and Side Gear
Assembly, Assemble
1. Install one thrust washer and side gear in the
case. Put the pinion gears and thrust washers
on the spider. Install the spider assembly in
the case. Install the other side gear and thrust
washer.
2. Align the marks and assemble the two halves of
the differential case. See Figure 11.
3. Use Loctite No. 272® on the threads of the cap-
screws. Install four of the capscrews, washers
and nuts into the case halves in a cross pattern.
The distance between the fasteners MUST be
equal. Tighten the fasteners to the correct torque
value in a pattern opposite each other. See Fig-
ure 12. Also see Table 1.
7

9. Thank you very much
for your reading. Please
Click Here Then Get
More Information.
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

10. Differential Repair 1400 SRM 46
1. THRUST WASHER
2. SIDE GEAR
3. SPIDER GEARS
4. CASE HALF
5. ALIGNMENT
MARKS
Figure 11. Differential Pinion and Side Gears
Figure 12. Fasteners Tightening Sequence
4. Install the other fasteners into the case halves.
Tighten the fasteners to the correct torque value.
5. Check that the differential gears can freely ro-
tate in the case.
Differential Gears Rotating Torque, Check
NOTE: Make a tool for checking the rotating torque
of the differential gears. The tool can be made from
an axle shaft that has the same spline size of the
differential side gear. See Figure 13.
1. Put the differential and ring gear assembly in a
vise. Be sure to install soft metal covers for the
jaws of the vise to protect the ring gear.
1. APPROXIMATELY 305 mm (12 in.)
2. WELD NUT TO END OF SHAFT
Figure 13. Tool to Check Differential Gears
2. Install the tool into the differential until the
splines of the tool engage one side of the gear.
3. Attach a torque wrench to the nut on the tool
and rotate the differential gears. Read the value
indicated on the torque wrench as the differen-
tial gears rotate. See Figure 14. The maximum
torque applied to one side gear must not exceed
68 N•m (50 lbf ft). If the torque value exceeds
this specification, disassemble the differential
gears from the case halves.
1. TOOL 2. READ TORQUE
VALUE
Figure 14. Rotating Torque Check
4. Check the case halves, spider, gears, and thrust
washers for the problem that caused the incor-
rect torque value. Repair or replace parts as nec-
essary. Assemble the parts after repair and re-
peat Step 1 through Step 3.
8

11. 1400 SRM 46 Differential Repair
Differential and Ring Gear Assembly,
Install
1. Clean the oil and dirt from the outer diameters of
the bearing cups and bearing bores in the carrier
and bearing caps. There is no special cleaning
required.
2. Apply axle lubricant to the bearing cones and the
inner diameters of the bearing cups of the main
differential. Do NOT get oil on the outer diame-
ter of the bearing cup, and Do NOT permit oil to
drop onto bearing bores.
NOTE: Adhesives normally become hard (dry) in ap-
proximately two hours. Be sure to complete the as-
sembly process within this time period. If two hours
have passed since application of the adhesive, clean
the parts again and apply new adhesive.
3. Apply a continuous bead of adhesive to the bear-
ing bores in the carrier and bearing caps. Ap-
ply the adhesive completely around the smooth,
ground surfaces ONLY. DO NOT put adhesive on
threaded areas.
4. Install the bearing cups over the bearing cones
that are assembled on the case halves. See Fig-
ure 15.
1. BEARING CUP
2. CARRIER
3. BEARING BORE
4. PUT ADHESIVE
HERE
Figure 15. Differential Assembly Installation
5. Use a lifting device that has the capacity to lift
the weight of the differential assembly and in-
stall the assembly into the carrier. The bearing
cups MUST be flat against the bores between the
carrier legs. See Figure 15. Make sure that the
ring gear does not touch the pinion.
6. Install both of the bearing adjusting rings into
position between the carrier legs. Turn each ad-
justing ring until hand tight against the bearing
cups. See Figure 16.
1. BEARING CAP
2. BEARING BORE
3. ADJUSTMENT RING
4. ALIGNMENT MARKS
Figure 16. Bearing Caps Installation
7. Install the bearing caps over the bearings and ad-
justment rings in the correct location as marked
before removal.
WARNING
Wear eye protection. Do not hit steel parts with
a steel hammer. Parts can break and cause in-
jury.
8. Use a light leather, plastic, or rubber hammer
and seat each bearing cap to move it into position.
The caps MUST fit easily against the bearings,
adjustment rings, and carrier. DO NOT FORCE
THE BEARING CAP INTO POSITION.
9. Install the capscrews and washers that hold
bearing caps to the carrier. Tighten the cap-
screws by hand four to six turns, then tighten
the capscrews to the correct torque value. See
Table 1.
9

12. Differential Repair 1400 SRM 46
CAUTION
If bearing caps are not installed in the correct
original locations, the bores and threads in
caps will not match the carrier. Assembling
mismatched caps into the carrier can result in
carrier damage after reassembly to axle and
during vehicle operation. Do not force the
bearing caps into unmatched bore locations in
the carrier.
10. If the bearing caps do not correctly fit into po-
sition, check the alignment marks between the
caps and the carrier. Remove the caps and re-
peat Step 5.
NOTE: Do not install the cotter keys, pins, or lock
plates (as furnished on axle model) that hold the
bearing adjusting rings in position. First, adjust the
preload of the differential bearings, adjust the gear
clearance, and check the tooth contact pattern.
Differential Bearings, Preload Adjust
1. Make sure the ring gear is not touching the pin-
ion. Install a dial indicator as shown in Fig-
ure 17. Adjust the dial indicator so that the
plunger or pointer is against the back surface of
the ring gear.
1. DIAL INDICATOR
Figure 17. Bearing Preload Adjustment
2. Loosen the bearing adjustment ring that is on the
same side as the dial indicator.
CAUTION
Always use a tool that engages two or more op-
posite notches in the adjustment ring. A T-bar
spanner type wrench can be used for this pur-
pose. Be sure the wrench fits correctly so that
the lugs will not be damaged.
3. Push the differential assembly left and right to
see that axial movement shows on the dial in-
dicator. Use two pry bars, one between the dif-
ferential case and carrier, and one between ring
gear side and the carrier. For the method used,
see Figure 18.
4. Tighten the bearing adjustment ring that was
just loosened so that there is no movement of the
differential assembly. Now, tighten each adjust-
ment ring one notch to obtain the preload. The
maximum axial movement permitted is 0.15 to
0.33 mm (0.006 to 0.013 in.) (see NOTE that
follows). The maximum torque required to turn
the differential bearings is 1.7 to 3.9 N•m (15 to
35 lbf in).
NOTE: Use 0.08 to 0.22 mm (0.003 to 0.009 in.) on
Rockwell RS-140 and RS-145 axles.
5. Continue assembly and check the runout of the
ring gear.
1. BAR MUST NOT TOUCH BEARINGS
Figure 18. Gear Movement Check
Ring Gear, Runout Check
1. Attach a dial indicator to the mounting flange of
the carrier as shown in Figure 17. Adjust the
dial indicator so that the plunger or pointer is
against the back surface of the ring gear. Set the
indicator to zero.
10

13. 1400 SRM 46 Differential Repair
2. Rotate the ring gear and check the dial indi-
cator for the maximum needle movement. The
maximum movement permitted is 0.20 mm
(0.008 in.). If the movement exceeds the maxi-
mum limit, remove the differential and ring gear
assembly from the carrier and find the reason
for the movement.
3. Install the differential and ring gear into the
carrier after the parts are repaired or replaced.
Use the procedure in the section Differential and
Ring Gear Assembly, Install. Repeat the preload
adjustment of the differential bearings.
Gear Clearance, Adjust
1. Install a dial indicator as shown in Figure 19. Be
sure the plunger or pointer touches the tooth sur-
face. Make sure the preload adjustment of the
differential bearing is complete before the clear-
ance is adjusted.
2. The gear clearance adjustment is done by loosen-
ing one bearing adjustment ring and tightening
the other adjustment ring the same amount.
Figure 19. Gear Clearance Check
Gear Set, Tooth Contact Pattern Check
NOTE: The gear clearance can be changed within
the limits of 0.13 to 0.38 mm (0.005 to 0.015 in.) for
better tooth contact.
NOTE: If the original gear set is installed, adjust the
clearance to the original value recorded in Step 1 of
Disassemble. If a new gear set is installed, adjust the
adjustment rings for 0.25 mm (0.010 in.).
NOTE: If the unit has a thrust block, tighten the
adjustment screw. The thrust block must be tight
against the ring gear. Turn the adjustment screw
90 counterclockwise and tighten the jam nut. The
clearance between the thrust block and ring gear
will be 0.25 to 0.38 mm (0.010 to 0.015 in.). On
H6.00-7.00XL (H135-155XL) units, set the clearance
by turning the thrust screw counterclockwise 180 .
Tighten the jam nut to the specification shown in
Table 1. The correct clearance between the thrust
screw and the ring gear is 0.635 to 0.889 mm (0.025
to 0.035 in.). Refer to Figure 20.
Install into Axle Housing
NOTE: For correct torque values for the fasteners
used in this installation, see Table 1. For general lo-
cation of the fasteners, see Figure 21.
1. Use Loctite Sealant No. 504 or silicone RTV
sealant on the flange of the differential assem-
bly housing. Install the differential assembly in
the axle housing. Tighten the nuts or capscrews.
Do the following as required:
a. ON UNITS WITH AIR OPERATED DISC
BRAKES, install mounting brackets for
slack adjusters. Install the air chamber
rod pins and the cotter pin in the splined
coupling.
b. ON UNITS WITH HYDRAULIC DISC
BRAKES, install the parts of the brake as
described in the brake section for your unit.
Connect the drive shaft and tighten the
capscrews at the yoke to 120 N•m (90 lbf ft).
c. On H7.00-12.50H (H150-257H) units, assem-
ble the axle. Install the axle in the lift truck
if it was removed. Connect the drive shaft.
Make sure to use a 11 mm (0.4375 in.) spacer
between the speed reducer gear and the pin-
ion nut. Tighten the nut to 1342 to 1790 N•m
(990 to 1320 lbf ft) without lubricant. Always
use a new nut.
11

14. Differential Repair 1400 SRM 46
Figure 20. Ring Gear and Pinion Tooth Contact Adjustment (Generoid Gears)
12

15. 1400 SRM 46 Differential Repair
d. On STRADDLE TRUCKS, install the bear-
ing and seal in the bearing retainer. Install
the universal joint yoke in the bearing re-
tainer. Install the snap ring to hold the yoke.
Install the stub shaft in the differential. Use
a new gasket and install the yoke and bear-
ing retainer. Install the capscrews for the
bearing retainer. Install the yoke capscrew.
Tighten the capscrews.
2. Do the following for H26.00-32.00C (H550-700C)
and H36.00-48.00C (H800-1050C) units with a
drum brake installed on the differential:
NOTE: Special tools (a pilot shaft, a collar, and an
installation nut) are required to install the yoke cor-
rectly. See Figure 21.
a. Apply axle lubricant on the yoke seal.
b. Check all surfaces of the yoke hub for dam-
age. If necessary, polish the yoke hub with
emery cloth or crocus cloth.
c. Install the pilot shaft on the input shaft of
the differential. See Figure 21.
CAUTION
Do not use a hammer or mallet to install the
yoke onto the shaft. A hammer or mallet can
damage the yoke.
d. Slide the yoke over the pilot shaft. Align the
yoke splines with the shaft splines. Slide the
collar onto the pilot shaft and against the
yoke. See Figure 21.
CAUTION
Do not use the yoke assembly nut for the instal-
lation procedure. Use a similar nut for the pro-
cedure described in Figure 21.
e. Install the nut on the pilot shaft. Tighten the
nut against the collar until the yoke is in the
correct position on the input shaft. The nut
can require torque up to 271 N•m (200 lbf ft)
to install the yoke correctly.
CAUTION
Make sure the seal is not damaged as the yoke
passes through the seal.
f. Remove the nut, collar, and pilot shaft. In-
stall the assembly nut for the yoke on the end
of the input shaft. Tighten the assembly nut
to 1627 N•m (1200 lbf ft).
g. Install the brake drum and fasten with the
eight capscrews.
h. Attach the linkage to the brake adjuster arm.
Connect the drive shaft from the yoke flange
on the brake drum.
1. INPUT SHAFT
2. YOKE
3. BRAKE DRUM
4. NUT*
5. COLLAR*
6. PILOT SHAFT*
7. DIFFERENTIAL
HOUSING
*SPECIAL TOOL
Figure 21. Yoke Installation
13