service repair manual

1. SERVICE REPAIR
H300HD2 H330HD2 H360HD2 H360HD2-EC [J019]

2. SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the prod-
uct. Updated technical service information may be available from your local authorized Hyster® dealer. Service
Manuals provide general guidelines for maintenance and service and are intended for use by trained and expe-
rienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service
Manual could result in damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load
being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the
load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON
BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure
to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make
sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

3. 8000 SRM 1596 Counterweight Weights
Counterweight Weights
Unit Main Counterweight
H170HD 2900 kg (6393 lb)
H190HD/H8.00XM 3070 kg (6768 lb)
H210HD/H9.00XM 3385 kg (7463 lb)
H230HD/H10.00XM-6 4295 kg (9469 lb)
H250HD 4470 kg (9855 lb)
H280HD/H12.00XM 5150 kg (11,354 lb)
H300HD/H13.00XM 5360 kg (11,817 lb)
H330HD/H14.00XM/H10.00XM-12EC 5995 kg (13,217 lb)
H360HD/H16.00XM-6/H12.00XM-12EC/
H360HD-EC
7050 kg (15,543 lb)
Table 1. Counterweight Weights
Model Weight
H8XM-6 (H190HD2) 3,070 kg (6,768 lb)
H9XM-6 (H210HD2) 3,385 kg (7,463 lb)
H10XM-6 (H230HD2) 4,295 kg (9,469 lb)
H10XMS (H250HD2/H230HD2S) 4,470 kg (9,855 lb)
H12XM-6 (H280HD2) 5,150 kg (11,354 lb)
H13XM-6 (H300HD2) 5,360 kg (11,817 lb)
H14XM-6/H10XM-EC (H330HD2) 5,995 kg (13,217 lb)
H16XM-6/H12XM-EC (H360HD2 H360HD2-EC) 7,050 kg (15,543 lb)
1

4. Lift Truck Weights 8000 SRM 1596
Lift Truck Weights
Table 2. Basic Truck
Model "MIN" Weight "MAX" Weight
H190HD2 H8-12XM 9,400 kg (20,723 lb) 10,150 kg (22,376 lb)
H210HD2 H8-12XM 9,700 kg (21,384 lb) 10,450 kg (23,038 lb)
H230HD2 H8-12XM 10,700 kg (23,589 lb) 11,450 kg (25,242 lb)
H250HD2 H8-12XM 10,900 kg (24,030 lb) 11,600 kg (25,573 lb)
H280HD2 H8-12XM 11,550 kg (25,463 lb) 12,300 kg (27,116 lb)
H300HD2 H13-14XM 12,500 kg (27,557 lb) 13,700 kg (30,203 lb)
H330HD2 H13-14XM 13,200 kg (29,101 lb) 14,350 kg (31,636 lb)
H360HD2 H16XM-6 14,250 kg (31,415 lb) 15,400 kg (33,951 lb)
NOTE: Add 90 kg (198.4 lb) for a completely topped off fuel tank.
NOTE: The minimum weight indicates the weight for trucks with an open cab and pneumatic tires. The
maximum weight indicates the weight for trucks with an open cab and solid tires. To calculate the total
weight of the basic truck include the weight of following options:
• Add 200 kg (440.9 lb) for a closed cab.
• Add 50 kg (110 lb) for air conditioning.
• Add 90 kg (198.4 lb) for a completely topped up fuel tank.
2

5. 8000 SRM 1596 Capacities
Capacities
Item Quantity
Engine Oil, Tier 3, QSB6.7L 16 liter (16.9 qt)
Engine Oil, Tier 4, QSB4.5L 10.5 liter (11.0 qt)
Engine Oil, Tier 4, QSB6.7L 14.5 liter (15.3 qt)
Cooling System 25.5 liter (27 qt)
Hydraulic Tank (FULL mark) 125 liter (33 gal)
Hydraulic System (Total Capacity) 160 liter (42.3 gal)
Transmission ZF 20 liter (21.1 qt)
Drive Axle and Differential
8 to 12 ton 19 liter (5 gal)
12 to 16 ton 21 liter (5.5 gal)
Planetary Gears
8 to 12 ton 2.8 liter (2.95 qt)
12 to 16 ton 2.4 liter (2.5 qt)
Fuel Tank 128 liter (33.8 gal)
3

6. Engine Specifications 8000 SRM 1596
Engine Specifications
Table 3. Cummins QSB4.5
Item Specification
Type Cummins QSB4.5
Number of Cylinders 4
Firing Order 1-3-2-4
Bore 107 mm (4.2 in.)
Stroke 120 mm (4.7 in.)
Displacement 4.5 liter (275 in.3
)
Compression Ratio 17.2:1
Oil Pressure (Minimum, at Low Idle) 52 kPa (7.5 psi)
Oil Pressure (At low idle) 69 kPa (10 psi)
Governed Speed (Full power at Normal Operating
Temperature)
2450 rpm with load
± 50 rpm no load
Idle Speed 800 rpm ±2%
Stall Speed (Broken-in Engine) 2016 + 100/-50 rpm
Thermostat
Begin to open 82°C (179°F)
Fully open 91°C (196°F)
Valve Clearance (Cold)
Intake 0.25 mm (0.01 in.)
Exhaust 0.51 mm (0.02 in.)
Minimum Cranking Speed 120 rpm
Weight (Dry) 371 kg (818 lb)
4

7. 8000 SRM 1596 Engine Specifications
Table 4. Cummins QSB6.7
Item Specification
Type Cummins QSB6.7
Number of Cylinders 6
Firing Order 1-5-3-6-2-4
Bore 102 mm (4.02 in.)
Stroke 120 mm (4.62 in.)
Displacement 6.7 liter (409 in.3
)
Compression Ratio 17.2:1
Oil Pressure (Minimum, at 2500 rpm and normal
operating temperature)
345 kPa (50 psi)
Oil Pressure (At low idle) 69 kPa (10 psi)
Governed Speed (Full power at Normal Operating
Temperature)
2300 rpm with load
2450 ±30 no load
Idle Speed 800 rpm ±2%
Stall Speed (Broken-in Engine) 1950 to 2100 rpm
Thermostat
Begin to open 83°C (181°F)
Fully open 91°C (196°F)
Valve Clearance (Cold)
Intake 0.25 mm (0.01 in.)
Exhaust 0.51 mm (0.02 in.)
Minimum Cranking Speed 125 rpm
Weight (Dry) 485 kg (1069 lb)
5

8. Tire Sizes 8000 SRM 1596
Hydraulic System
Item Quantity
Cummins Diesel Hydraulic Pump Capacity @ 2300 rpm
90 cc (3 oz) 196 liter/min (51.7 gal/min)
120 cc (4 oz) 262 liter/min (69.2 gal/min)
25 cc (0.8 oz)
Wet Brake Cooling Pump
57 liter/min (15.0 gal/min)
Relief Pressures *
Main Control Valve 22.5 MPa (3262.5 psi)
Steering Circuit 16 ±1 MPa (2320 ±145 psi)
*Oil temperature 60°C (140°F)
Electrical System
All Models 24 Volt, Negative Ground
Alternator Output at 24°C (75°F)
21 amps at 750 rpm
All Engines
76 amps at 2200 rpm
Tire Sizes
NOTE: Refer to Truck Nameplate for correct tire
pressure.
Model Tire Size Tire Pressure
H8.00-9.00XM-6 (H170-210HD2) 9.00 × 20-14 ply 900 kPa (130 psi)
H10.00-12.00XM-6 (H230-280HD2) 10.00 × 20-16 ply 900 kPa (130 psi)
H10.00-12.00XM-EC (H360HD2-EC) 12.00 × 20-16 ply 1000 kPa (145 psi)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2)
12.00 × 20-16 ply 1000 kPa (145 psi)
All Michelin XZM Radial Tires 1000 kPa (145 psi)
6

9. 8000 SRM 1596 Mast Speeds
Mast Speeds
Lifting and Lowering Speeds
90 cc/Rev @2050 rpm
120 cc/Rev @2050
rpm
m/
sec
ft/
min
m/
sec
ft/
min
Unit
Rated Load Rated Load
H190HD2 2 STG NFL 0.46 90.5 0.55 108
H8XM 3 STG FFL
(2ND/FREE)
0.33/0.30 65/59 0.37/0.32 72.8/63
H210HD2 2 STG NFL 0.46 90.5 0.55 108
H9XM 3 STG FFL
(2ND/FREE)
0.33/0.30 65/59 0.37/0.32 72.8/63
H230HD2 2 STG NFL 0.35 69 0.42 82.7
H10XM 3 STG FFL
(2ND/FREE)
0.32/0.28 63/55 0.39/0.34 77/67
2 STG NFL 0.35 69 0.42 82.7
H250HD2
3 STG FFL
(2ND/FREE)
0.32/0.28 63/55 0.39/0.34 77/67
H280HD2 2 STG NFL 0.35 69 0.42 82.7
H12XM 3 STG FFL
(2ND/FREE)
0.32/0.28 63/55 0.39/0.34 77/67
2 STG NFL 0.28 55 0.33 65
H300HD2
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 0.30/0.29 59/57
2 STG NFL 0.28 55 0.33 65
H13XM
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 0.30/0.29 59/57
2 STG NFL 0.28 55 0.33 65
H330HD2
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 0.30/0.29 59/57
2 STG NFL 0.28 55 0.33 65
H14XM
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 0.30/0.29 59/57
2 STG NFL 0.28 55 0.33 65
H360HD2
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 0.30/0.29 59/57
2 STG NFL 0.28 55 0.33 65
H16XM
3 STG FFL
(2ND/FREE)
0.25/0.24 49.2/47.2 0.30/0.29 59/57
7

10. Torque Specifications, General 8000 SRM 1596
Torque Specifications, Cummins Diesel
LUBRICATION SYSTEM
Plug, Oil Sump, Steel Oil Pan
80 N•m (59 lbf ft)
All other Torque Specifications are found in Cum-
mins Engine Manual. Contact Cummins Engine for
any torque specifications not listed for this engine.
Torque Specifications, General
TRANSMISSION ZF
Nuts, Locking System Pressure Tubes Into
Rear Transmission Cover
42 N•m (31 lbf ft)
Screw, Holding Segment on Pressure Tubes
23 N•m (17 lbf ft)
Capscrews, Screen Into Front Trans-
mission Cover
23 N•m (17 lbf ft)
Capscrews, Tubes and Suction Tube Into
Front Transmission Cover
23 N•m (17 lbf ft)
Capscrews, Rear Transmission Cover to
Front Transmission Cover
4 N•m (34 lbf ft)
Capscrews, Output Flange to Trans-
mission Housing
34 N•m (25 lbf ft)
Capscrews, Torque Converter Bell Housing
to Transmission Housing
46 N•m (34 lbf ft)
Oil Fill Tube with Dipstick and Oil Drain Plug
80 N•m (59 lbf ft)
Capscrews, Torque Converter Bell Housing
to Transmission Housing
46 N•m (34 lbf ft)
Capscrews, Transmission Oil Filter Head
23 N•m (21 lbf ft)
Capscrews, Torque Converter Housing
to Flywheel Housing
46 N•m (34 lbf ft)
Capscrews, Hydraulic Pumps to Transmission
25 N•m (18 lbf ft)
See the sectionTransmission, Repair (ZF-WG161)
1300 SRM 1456 for other torque values.
DRIVELINE AND AXLE
Capscrews, Universal Yoke
50 N•m (37 lbf ft)
Bolts, Axle to Frame
920 N•m (679 lbf ft)
COUNTERWEIGHT
Top Capscrews
1500 N•m (1106 lbf ft)
Rear Capscrews
1500 N•m (1106 lbf ft)
DIFFERENTIAL
See the section Differential 1400 SRM 46 .
BRAKES - WET
See the sections Planetary Drive Axle, (Wet Sys-
tem) 1400 SRM 944 and Brake and Hydraulic
Cooling System 1800 SRM 1498 .
STEERING
Nut, Steering Wheel
68 N•m (50 lbf ft)
Capscrews, Steer Cylinder Mount
435 N•m (321 lbf ft)
Capscrews, Bearing Cap
75 N•m (55 lbf ft)
8

11. 8000 SRM 1596 Torque Specifications, General
Nut, Wheel Bearing
Initial 203 N•m (150 lbf ft)
Final 34 N•m (25 lbf ft)
Note: Torque lock nut to Initial torque while
rotating wheel hub. Back off lock nut until wheel hub
turns freely with no end play. (Torque at this point
should be less than 27 N•m (20 lbf ft)). Retorque
to Final torque and lock in place at first alignment
position which occurs at or above final torque spec.
Capscrews, Steer Axle Mount
270 N•m (199 lbf ft)
WHEEL NUTS
Drive Wheels (Final Torque Value)
615 to 710 N•m (454 to 524 lbf ft)
Steer Wheels (Final Torque Value)
615 to 710 N•m (454 to 524 lbf ft)
HYDRAULIC SYSTEM
Priority Valve (A)
217to 231 N•m (160 to 170 lbf ft)
Check Valve (K)
27 to 34 N•m (20 to 25 lbf ft)
Check Valve (L)
122 to 136 N•m (90 to 100 lbf ft)
Check Valve (Q)
9 to 12 N•m (7 to 9 lbf ft)
Shuttle Valves
26 to 30 N•m (34 to 40 lbf ft)
Full Flow Relief Valve (C) and (G)
217to 231 N•m (160 to 170 lbf ft)
Pilot Supply Valve (F)
45 to 50 N•m (33 to 37 lbf ft)
Load Sense Selector Valve (D)
35 to 40 N•m (26 to 30 lbf ft)
Coil Retaining Nut for Load Sense
Selector Valve (D)
4 to 6 N•m (35 to 53 lbf in)
Lift Pressure Selector Valve (B)
35 to 40 N•m (26 to 30 lbf ft)
Coil Retaining Nut for Lift Pressure
Selector Valve (B)
4 to 6 N•m (35 to 53 lbf in)
Solenoid Capscrews
6.3 N•m (56 lbf in)
Mount Capscrews
14 N•m (124 lbf in)
Pump Flangehead Screws
46 to 49 N•m (34 to 36 lbf ft)
Pump to Motor Capscrews
25 N•m (221 lbf in)
Suction Hose Adapter to Hydraulic Pump
91 to 100 N•m (67 to 74 lbf ft)
Pressure Line Fitting to Hydraulic Pump
49 to 59 N•m (36 to 44 lbf ft)
Counterbalance Valves
60 N•m (44.3 lbf ft)
MAST
Capscrews, Pivot Pin
435 N•m (321 lbf ft)
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nuts, Wear Plate
53 N•m (39 lbf ft)
Retainer, Lift Cylinder
H8-9XM-6 (H170-210HD2) 400 to 475 N•m
(295 to 350 lbf ft)
H10-12XM-6 (H230-280HD2) 475 to 550 N•m
(350 to 406 lbf ft)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
550 to 625 N•m (406 to 461 lbf ft)
9

12. Torque Specifications, General 8000 SRM 1596
CARRIAGE
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nut, Sideshift Cylinder Rod
675 N•m (498 lbf ft)
TILT CYLINDERS
Nut, Cylinder Rod
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
949 to 983 N•m (700 to 725 lbf ft)
H13-16XM-6 (H300-360HD2) 1105 to
1140 N•m (815 to 841 lbf ft)
Retainer
H8-12XM-6 (H170-280HD2) 542 to 610 N•m
(400 to 450 lbf ft)
H13-14XM-6 (H300-330HD2); H16XM-6
(H360HD2); H10-12XM-12EC (H360HD2-EC)
610 to 675 N•m (450 to 498 lbf ft)
Lock Nut, Rod End
66 N•m (49 lbf ft)
Capscrew, Pin Anchor
165 N•m (122 lbf ft)
WIPER ARMS, FRONT
Capscrews, Bracket to Cab
20 to 25 N•m (14.7 to 18.4 lbf ft)
Capscrews, Arm to Bracket
22 to 27 N•m (16.2 to 19.9 lbf ft)
Capscrews, Blade to Arm
8 to 10 N•m (6 to 7.4 lbf ft)
Capscrew, Arm Set
35 to 45 N•m (25.8 to 33.2 lbf ft)
10

13. 8. Remove the axle shafts from the axle housing.
See the Drive Axle manual 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 housing.
Pull the yoke, stub shaft and bearing re-
tainer from the housing.
9. Place a transmission jack under the differential
carrier for support. See Figure 4.
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 as-
sembly. The capscrews will hold the differential
carrier 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, re-
move the top two capscrews.
CAUTION
When using a pry bar, be careful not to damage
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
assembly on a repair stand. See Figure 5.
Differential Repair 1400 SRM 0046
6

14. 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,
inspect the hypoid gear set for damage. If inspec-
tion 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 re-
assembly, adjust the backlash to the original recor-
ded dimension when the gear set is installed into
the differential 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.
Figure 6. Thrust Screw and Jam Nut Removal
1400 SRM 0046 Differential Repair
7

15. 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 differ-
ential 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
adjusting rings in position. Some differential
carrier models have dowel pins or lock plates
holding the bearing adjusting rings in position.
Each lock plate is held in position by two cap-
screws. See Figure 8.
6. Remove capscrews and washers holding the two
bearing caps on the differential carrier. See
Figure 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.
Differential Repair 1400 SRM 0046
8

16. 1. BEARING CAP
2. BEARING ADJUSTING RING
Figure 9. Bearing Cap Removal
8. Use a lifting device and lift the main differen-
tial and ring gear assembly from the differen-
tial carrier. See Figure 10.
Figure 10. Main Differential and Ring Gear
Assembly Removal
Legend for Figure 10
1. BEARING CUP
2. DIFFERENTIAL CARRIER
3. BEARING BORE
4. PUT ADHESIVE HERE (INSTALLATION ONLY)
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
1400 SRM 0046 Differential Repair
9

17. CAUTION
Do not use a hammer or mallet to loosen and re-
move the yoke or flange. A hammer or mallet 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 pin-
ion. If the yoke or flange is tight on the pinion,
use a puller for removal. See Figure 12.
A. YOKE PULLER
B. FLANGE PULLER
Figure 12. Yoke and Flange Puller Tools
5. Remove the capscrews and washers that hold
the pinion carrier in the differential carrier. See
Figure 13.
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 carrier
from the carrier. A pry bar can damage the bear-
ing case, shims, and differential carrier.
Differential Repair 1400 SRM 0046
10

18. 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 dif-
ferential 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
calculate the depth of the drive pinion in the
differential carrier when the gear set is instal-
led.
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 Differential 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.
2. Remove the differential spider, four pinion
gears, two side gears, and six thrust washers
from inside 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
rivets as follows:
a. Center punch each rivet head in the center,
on the ring gear side of the assembly.
1400 SRM 0046 Differential Repair
11

19. 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 com-
ponents 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
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
Differential Repair 1400 SRM 0046
12

20. Drive Pinion and Pinion Carrier, Disassemble
WARNING
Observe all warnings and cautions provided by
the press manufacturer to avoid damage to com-
ponents 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 car-
rier. 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 re-
sult 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.
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
1400 SRM 0046 Differential Repair
13

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22. 5. Inspect the pinion bearings and replace if nec-
essary. If the pinion bearings need to be re-
placed, 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
carrier under the flange area with metal or
wood blocks.
A. BEARING DRIVER B. BEARING PULLER
Figure 20. Pinion Bearing Replacement
CAUTION
The puller must fit under the inner race of the
cone to remove the cone correctly without dam-
age.
b. Remove the inner bearing cone from the
drive pinion with a press or bearing puller.
See Figure 21.
1. PRESS
2. DRIVE PINION
3. BEARING PULLER
4. SUPPORTS
5. INNER BEARING CONE
Figure 21. Pinion Bearing Replacement
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
pinion.
7. Remove the snap ring from the end of the drive
pinion. See Figure 22.
1. SPIGOT BEARING 2. SNAP RING
Figure 22. Snap Ring Removal
Differential Repair 1400 SRM 0046
14

23. NOTE: Some spigot bearings are fastened to the
drive pinion with a special peening tool. See Fig-
ure 23.
NOTE: Some spigot bearings are a two-piece as-
sembly. Remove the inner race from the pinion
with a bearing puller. Remove the outer race/roller
assembly from the pinion carrier with a drift or a
press. See Figure 24.
8. Remove the spigot bearing from the drive pin-
ion with a bearing puller.
1. PEENING POINTS
Figure 23. Spigot Bearing Peening Points
1. REMOVE OUTER RACE AND ROLLER ASSEM-
BLY FROM CARRIER
2. REMOVE INNER RACE FROM PINION
Figure 24. Two-Piece Spigot Bearing
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations 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 differ-
ential:
• 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 solvent 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 dam-
age, replace with new bearing.
• Pinions and Gears
- Inspect the pinions and gears for wear or
damage. Gears that are worn or damaged
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 as-
sembly for wear or damage. Parts that are
damaged must be replaced. See Figure 25 for
parts to inspect.
1400 SRM 0046 Differential Repair
15

24. 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
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.
Install the cups in the pinion carrier. See Fig-
ure 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 installed 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
pinion with a snap ring, and some are fastened
with a punch. Others can have a two-piece bearing.
See Figure 24.
3. Install the spigot bearing washer and snap
ring. Put the pinion assembly in the pinion car-
rier. Install the spacers on the pinion. See Fig-
ure 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 com-
ponents 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
inner race of the outer bearing. See Figure 19.
Differential Repair 1400 SRM 0046
16