service repair manual

1. SERVICE REPAIR
H80FT H90FT H100FT H110FT H120FT [P005]

2. 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
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3. 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
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4. 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
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5. 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.
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6. 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.
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7. 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.
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8. 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.
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9. 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

10. 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

11. 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
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12. 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
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13. 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

14. 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

15. 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

16. 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

17. Differential Repair 1400 SRM 46
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.
4. Once the triple-lip oil seal has been installed,
check the gap between the flange and pinion car-
rier with a feeler gauge, at several points around
the seal. See Figure 30. The gap must be within
0.38 to 0.76 mm (0.015 to 0.030 in.). The differ-
ence between the largest and smallest gap mea-
surement must not exceed 0.0254 mm (0.010 in.).
NOTE: SHOWN WITHOUT BEARINGS AND PINION
1. GAP MEASUREMENT = 0.38 to 0.76 mm
(0.015 to 0.030 in.)
Figure 30. Oil Seal Gap Measurement
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.
After the preload is correctly adjusted using the
spacer set, adjust the pinion. The pinion is adjusted
using shims on the pinion carrier assembly. If the
same ring gear and pinion are used, use the old shim
set. See Figure 31. If a new ring gear and pinion are
used, adjust the pinion as described below.
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.
1. 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 32.
1. SHIM SET (CONTROLS DEPTH OF PINION)
2. PINION CARRIER
3. DIFFERENTIAL HOUSING
4. SPACER(S) (CONTROLS BEARING PRELOAD)
Figure 31. Shim Set Location
1. PART NUMBERS
2. GEAR TEETH NUMBERS
3. GEAR SET NUMBERS
4. PINION CONE NUMBERS
Figure 32. Pinion Set Numbers
16

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19. 1400 SRM 46 Differential Repair
NOTE: Always check the gear set for the correct
marks to make sure the gears are a matched set.
2. The location of the pinion and ring gear marks
are shown in Figure 32. A 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 pin-
ion, 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 num-
bers 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 num-
ber is the variation from the design center.
The design center is the exact design distance
from the end of the pinion cone to the ring gear
centerline. See Figure 33.
1. PINION CONE NUMBER (VARIATION)
Figure 33. 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 0.003
inch (variation). PC+0.03, PC 0.03, +0.03, or
0.03 equals 0.03 mm (variation).
Find the correct thickness of the shim set as fol-
lows:
3. Use a micrometer to measure the total thickness
of the old shim set that was removed from under
the pinion carrier. Make a note of the measure-
ment for later use.
4. Check the pinion cone number for the old pinion.
See Figure 33. If this number is a plus (+) value,
subtract the value from the value in Step 3. If
the pinion cone number is a minus ( ) value, add
the number to the value in Step 3. The number
shown is in 0.00 × inch (+2 = +0.002 inch). The
result is the standard thickness for a shim set.
NOTE: The value calculated in Step 4 is the thickness
of the standard shim set, without a variation.
5. Check the pinion cone number for the new pin-
ion. Add or subtract this number to the standard
thickness value of Step 4. 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 5 is the thickness
of the new shim set that will be installed. See the
examples shown in Specifications, Table 5.
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.
6. Install the pinion carrier assembly using the cor-
rect shim set. See Figure 34. Tighten the cap-
screws to the correct value shown in Specifica-
tions, Table 7.
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
17

20. Differential Repair 1400 SRM 46
Crane No. 2® as a sealant. Tighten the nuts
to the correct value shown in Specifications,
Table 7.
1. PINION AND PINION CARRIER
2. SHIMS
3. DIFFERENTIAL HOUSING
Figure 34. Pinion Carrier Assembly
Installation
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.
7. Install the universal joint yoke, flange for the
brake rotor or brake drum, or the gear for the
speed reducer. See Figure 35.
8. Install the spacer and pinion nut. Tighten the
pinion nut to the correct torque as shown in Spec-
ifications, Table 7.
1. BRAKE DISC
2. BRAKE CALIPER
3. AIR CHAMBER
4. BRACKET
5. YOKE
6. PINION CARRIER
7. SEAL
Figure 35. Units With Air-Operated Disc Brakes
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 32.
CAUTION
Do not install a cold ring gear on the flange
case half. A cold ring gear will damage the
18

21. 1400 SRM 46 Differential Repair
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.
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. 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 capscrews,
washers, and nuts as shown in Figure 36. 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 cap-
screw torque specifications, see Specifications,
Table 7.
NOTE: On S/H6.00-7.00XL (S/H135-155XL, S/H135-
155XL2) (B024, C024, F006, G006) lift truck models,
if rivets were use to hold the ring gear and flange
case half together, replace them with bolts, nuts, and
washers
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, Table 4. The maxi-
mum pressure must be applied for approximately
one minute at the end of the press cycle. Do not
use more than the maximum pressure. Dam-
age 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 37.
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
degrees. The gauge cannot go in more than half
the distance 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 Fig-
ure 38.
8. Install the bearing cones on both of the case
halves. Use a press and a sleeve of the correct
size.
1. FLANGE CASE HALF
2. RING GEAR
3. BOLT HEAD AGAINST GEAR
Figure 36. Installation With Capscrews
1. RING GEAR 2. CASE HALF
Figure 37. Installation With Rivets
19

22. Differential Repair 1400 SRM 46
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 IN FOUR PLACES
WITH 0.08 mm (0.003 in.) GAUGE
Figure 38. Gear and Case Half Installation
Check
11. Install one thrust washer and side gear into the
flange case half.
12. Install the spider (cross), differential pinions and
thrust washers into the flange case half. See Fig-
ure 14.
13. Install the second side gear and thrust washer
over spider and differential pinions.
14. Align the marks and assemble the two halves of
the differential case. See Figure 39.
15. 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.
16. Tighten the fasteners to the correct torque value
in a pattern opposite each other. See Figure 40.
See Specifications, Table 7.
17. Install the other fasteners into the case halves.
Tighten the fasteners to the correct torque value.
1. THRUST WASHER
2. SIDE GEAR
3. SPIDER GEARS
4. CASE HALF
5. ALIGNMENT
MARKS
Figure 39. Differential Pinion and Side Gears
Figure 40. Fasteners Tightening Sequence
18. 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 41.
1. Put the differential and ring gear assembly in a
vise. Install soft metal covers for the jaws of the
vise to protect the ring gear.
2. Install the tool into the differential until the
splines of the tool engage one side of the gear.
20

23. 1400 SRM 46 Differential Repair
1. APPROXIMATELY 305 mm (12 in.)
2. WELD NUT TO END OF SHAFT
Figure 41. Tool to Check Differential Gears
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 42. 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. See the Differential
and Ring Gear Assembly, Disassemble section
for the procedure.
4. Check the case halves, spider, gears, and thrust
washers for cracks, wear, or damage that caused
the incorrect torque value. Repair or replace
parts as necessary. Assemble the parts after
repair and repeat Step 1 through Step 3.
1. TOOL
2. READ TORQUE VALUE
Figure 42. Rotating Torque Check
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 dif-
ferential carrier and bearing caps.
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 diameter
of the bearing cup, and onto bearing bores.
NOTE: Adhesives normally become hard (dry) in ap-
proximately two hours. The assembly process must
be completed 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. See Figure 43.
4. Install the bearing cups over the bearing cones
that are assembled on the case halves. See Fig-
ure 44.
1. ADHESIVE
2. BEARING CAP
3. CARRIER LEG
Figure 43. Adhesive Application
21

24. Differential Repair 1400 SRM 46
1. BEARING CUP
2. CARRIER
3. BEARING BORE
4. PUT ADHESIVE HERE
Figure 44. 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 differential carrier.
The bearing cups must be flat against the bores
between the differential carrier legs. See Fig-
ure 44. Make sure that the ring gear does not
touch the pinion.
6. Install both bearing adjusting rings into position
between the differential carrier legs. Turn each
adjusting ring until hand tight against the bear-
ing cups. See Figure 45.
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.
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.
8. Use a light leather, plastic, or rubber hammer
and seat each bearing cap to move it into posi-
tion. The caps must fit easily against the bear-
ings, adjustment rings, and carrier. Do not force
the bearing caps into position.
9. If the bearing caps do not correctly fit into po-
sition, check the alignment marks between the
caps and the differential carrier. Remove the
caps and repeat Step 5 through Step 9.
NOTE: Do not install the cotter keys, dowel 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.
10. Install the capscrews and washers that hold
bearing caps to the differential carrier. Tighten
the capscrews by hand four to six turns, then
tighten the capscrews to the correct torque value.
See Specifications, Table 7.
1. BEARING CAP
2. BEARING BORE
3. ADJUSTMENT RING
4. ALIGNMENT MARKS
Figure 45. Bearing Caps Installation
22