Structure 1 Ton Class: Front Axle and Reduction Differential
Structure 1 Ton Class: Front Axle and Reduction Differential
Structure 1 Ton Class: Front Axle and Reduction Differential
Structure
1 Ton Class
11 10
12
2 14
13 8
3 4
6
15 5
7 9
210089
The frame support 2 is bolted to the front axle housing The reduction differential is mounted on the front axle
together with the backing plate 15 of wheel brake. housing 4. The input flange 11 carries a drive gear
While the front wheel hub 1 carries a single wheel, a which is in mesh with the driven gear mounted on the
double wheel can be mounted on it with optional rim. reduction pinion 10.
7-1
FRONT AXLE AND REDUCTION DIFFERENTIAL
2 Ton Class
11 10
12
2 14
8
13
3
4
5 6
7
15 9
210090
The frame support 2 is bolted to the front axle housing The reduction differential is mounted on the front axle
together with the backing plate 15 of wheel brake. housing 4. The input flange 11 carries a drive gear
While the front wheel hub 1 carries a single wheel, a which is in mesh with the driven gear mounted on the
double wheel can be mounted on it with optional rim. reduction pinion 10.
7-2
FRONT AXLE AND REDUCTION DIFFERENTIAL
3 Ton Class
11 10
12
14
2 13
8
3 4
5 6
15 7 9
210091
The frame support 2 is bolted to the front axle housing The reduction differential is mounted on the front axle
together with the backing plate 15 of wheel brake. housing 4. The input flange 11 carries a drive gear
While the front wheel hub 1 carries a single wheel, a which is in mesh with the driven gear mounted on the
double wheel can be mounted on it with optional rim. reduction pinion 10.
7-3
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front Wheels
Removal
2
[Single wheel] 1
[Single wheel]
1 Wheel nuts
2 Front wheel
[Double wheels]
1 Extension valve
2 Outer wheel nuts [Double wheels]
5
3 Front wheel (outer)
4
4 Inner wheel nuts
5 Front wheel (inner)
3
1
2
209938
Start by:
(a) Pull the parking brake lever and block the rear wheels.
(b) Loosen the wheel nuts 1 by two turns. Then, raise the
front end of the truck using a hoist or the hydraulic
system.
(1) Hoisting
Using slings and eye-bolts at both ends of the cross
member on top of the outer mast, lift the front end of
the truck with a hoist.
209939
7-4
FRONT AXLE AND REDUCTION DIFFERENTIAL
CAUTION
After raising the front end, place wood blocks
under the frame to prevent the truck from falling.
209940
and outer wheel. Then, remove the inner wheel nuts and Inner wheel
inner wheel. nut
209941
Installation
To install, follow the removal sequence in reverse, paying
attention to the following points.
(1) Tighten the wheel nuts evenly to the specified torque
so that the wheels will not wobble during operation.
7-5
FRONT AXLE AND REDUCTION DIFFERENTIAL
4
11
10
13
12
2 14
7
8
3 1
209942
Sequence
1 Front wheel 8 Mast
2 Nuts 9 Brake pipe
3 Fork, Lift bracket 10 Parking brake cable
4 Return hose for lift cylinder 11 Universal joint
5 High-pressure hose for lift cylinder 12 Bolt, Nut
6 Tilt cylinder socket 13 Bolt, Nut
7 Mast support bearing cap 14 Front axle and reduction differential
7-6
FRONT AXLE AND REDUCTION DIFFERENTIAL
Bolt
209943
(2) Removing parking brake cable
To remove the parking brake cable, remove the parking
brake lever assembly from the dashboard and disconnect
the cable from the lever.
Note: To dismount the reduction differential alone, remove
the front axle as described above. To dismount the
reduction differential after removal of the engine and
transmission, the front axle needs not to be removed
from the truck.
Installation
To install, follow the removal sequence in reverse, paying
attention to the following points.
(1) After connecting the parking brake cable, make sure
that the brake lever operating effort is within the
specification.
245 to 294 N
Parking brake lever operating
(25 to 30 kgf)
effort
[55 to 66 lbf]
(2) Before installing the mast, bleed the brake fluid circuits
of trapped air. For bleeding, refer to “GROUP 9
BRAKE SYSTEM.”
(3) After installing the mast, make sure that tilt angles,
forward and backward, are correct and that the lift
chains, right and left, are equal in tension. Refer to
“GROUP 12 MAST AND FORKS ”
(4) Fill the front axle housing with oil up to the plug hole
level.
7-7
FRONT AXLE AND REDUCTION DIFFERENTIAL
Front Axle
Disassembly
11
12
1
2
5 3
6
9
7
8 10
210092
Sequence
1 Air bleeder 7 Front wheel hub, Brake drum
2 Level plug 8 Oil seal
3 Drain plug 9 Oil seal
4 Axle shaft 10 Tapered roller bearing
5 Lock ring, Lock nut 11 Brake assembly
6 Tapered roller bearing 12 Frame support, Axle housing
Start by:
(a) Remove the mast. For replacement of the front Note: It is not necessary to remove the axle housing
axle housing and disassembly of the differential, nor to drain the oil for removing the axle shaft or
refer to “GROUP 12 MAST AND FORKS.” disassembling the wheel hub.
(b) Jack up the truck.
(c) Support the front end of the truck with blocks or
stands at both sides to keep the truck in the
horizontal position.
(d) Remove the front wheels.
7-8
FRONT AXLE AND REDUCTION DIFFERENTIAL
209945
209947
7-9
FRONT AXLE AND REDUCTION DIFFERENTIAL
(b) Set a dial indicator against the flange of the axle 209949
7-10
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reassembly
To reassemble, follow the disassembly sequence in reverse,
paying attention to the following points.
(1) Front wheel hub
(a) Fill grease (Autolex A or equivalent) in the front
wheel hub as shown.
Stuff grease in the roller holder of the tapered
roller bearing (inner) using the palm.
Apply grease to the lip groove of oil seal.
CAUTION
Use care not to let grease in the brake drum. Grease 209950
209951
7-11
FRONT AXLE AND REDUCTION DIFFERENTIAL
210093
(b) Rotate the hub and tap its periphery with a soft-
head mallet for snug assembling.
(c) Fully tighten the lock nut to obtain hub bearing
preload within the specified limits.
Note: To check the hub bearing preload, hook a spring
scale on the hub bolt, then pull it to measure the
tangential force of the hub bolt.
Unit: N (kgf) [lbf]
Truck Model 1 ton 2, 3 ton
Item class classes
(d) Fit the lock ring into place and tighten the lock
bolt.
(e) Check the preload again.
(3) Drain plug
(a) Tighten the drain plug to the specified torque.
7-12
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reduction Differential
Disassembly
18
20
19 10
17
11
16
14
10
21
13
2 15
4 8
12
5
4
2
7
6
1 3
6 1 3
7
210094
Sequence
1 Lock plate 12 Reduction pinion, Tapered roller bearing
2 Adjusting screw (inner), Shims
3 Bearing cap 13 Carrier cover
Remove parts 4 through 9 as an assembly. 14 Tapered roller bearing
4 Tapered roller bearing 15 Driven gear
5 Pinion shaft 16 Plate
6 Differential pinion 17 Drive gear, Ball bearing
7 Bevel gear, Spacer 18 Input flange
8 Differential case 19 Ball bearing
9 Bevel gear 20 Oil seal
10 Cover, O-ring 21 Differential case
11 Lock nut, Shims
7-13
FRONT AXLE AND REDUCTION DIFFERENTIAL
209955
209956
7-14
FRONT AXLE AND REDUCTION DIFFERENTIAL
❋ 209957
7-15
FRONT AXLE AND REDUCTION DIFFERENTIAL
7-16
FRONT AXLE AND REDUCTION DIFFERENTIAL
Reassembly
10 11 9 18 19 20
12
13
17
14
16
15
22
2 ton class
21
3 2 7
3 ton class
6 1 5 4
23 23 23
210095
7-17
FRONT AXLE AND REDUCTION DIFFERENTIAL
Sequence
1 Differential case 13 Ball bearing
2 Differential gear, Thrust washer 14 Plate
3 Differential gear, Thrust washers 15 Differential carrier
4 Differential pinion, Pinion thrust washer (2, 3 16 Bevel pinion, Shims, Tapered roller bearing
ton classes), Pinion shaft, Spring pin (inner)
5 Bevel gear 17 Driven gear
6 Bolt 18 Tapered roller bearing
7 Tapered roller bearing 19 Shims
8 Carrier cover 20 O-ring, Cover
9 Oil seal 21 Bearing cap
10 Ball bearing 22 Adjusting screw
11 Input flange 23 Lock plate
12 Drive gear
209960
7-18
FRONT AXLE AND REDUCTION DIFFERENTIAL
Shims
209962
7-19
FRONT AXLE AND REDUCTION DIFFERENTIAL
Note: Be sure that the lip of oil seal faces in the right
direction.
209963
209964
7-20
FRONT AXLE AND REDUCTION DIFFERENTIAL
209965
(c) Hook a spring scale onto the bolt hole of the input
flange, and pull it in the tangential direction to
check the preload for the tapered roller bearing (the
force when the flange starts rotating). Adjust the
preload by increasing or decreasing the shims.
34.32 to 49.03 N
Tangential force
(3.5 to 5.0 kgf)
(spring scale reading)
[7.7 to 11.0 lbf]
209966
7-21
FRONT AXLE AND REDUCTION DIFFERENTIAL
209967
Decrease
Increase
Increase
Backlash
Decrease 209968
209969
7-22
FRONT AXLE AND REDUCTION DIFFERENTIAL
Adjustment
Adjusting reduction gear tooth contact
After the reduction gear and pinion have been replaced,
adjust the tooth contact as follows.
(1) Determine the required total shim thickness by
calculating on the basis of machining error marked on
the end face of the reduction pinion as follows. Put on
the determined total thickness of shims and install the
reduction gear and pinion. Shims
7-23
FRONT AXLE AND REDUCTION DIFFERENTIAL
Note: For “Toe” or “Heel” contact, see the contact pattern on the outside (convex) of the reduction gear tooth. In the
case of “Face” or “Flank” contact, repeat the above adjustment until the correct tooth contact is obtained.
7-24
FRONT AXLE AND REDUCTION DIFFERENTIAL
Troubleshooting
Abnormal noise Fit of differential gears in differential case out of Replace worn parts.
comes out when specification due to wear
turning a corner Differential gear teeth broken or seized on spider, Replace defective parts.
or damaged by wear gear or pinions.
7-25
FRONT AXLE AND REDUCTION DIFFERENTIAL
Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Models 1 ton class 2 ton class 3 ton class
Items
A 0.08 (0.0031)
Face runout of axle shaft flange
B 0.5 (0.0197)
A 0.5 (0.0197)
Runout of Axle shaft (1/2 of gauge reading)
B 0.5 (0.0197), maximum
Preload for hub bearing 1
N (kgf) [lbf] A 0.5 to 4.9 (5 to 50) [0.4 to 3.6]
Hub bearing lock nuts
(outer) 2 A 196 ± 20 (20 ± 0.6) [144.6 ± 14.8]
Axle shaft bolts 3 A 98 ± 9.8 (10 ± 1) [72.3 ± 7.2]
146 ± 15 213 ± 21.3
Tightening Backing plate bolts 4 A (14.9 ± 1.5) (21.7 ± 2.2)
torque [107.7 ± 11.1] [157.1 ± 15.7]
N·m (kgf·m) Axle support nuts 5 A 378 ± 38 (38.5 ± 3.9) [278.8 ± 28]
[lbf·ft] 157 ± 16 378 ± 38
Wheel nuts 6 A (16 ± 1.6) (38.5 ± 3.9)
[115.8 ± 11.8] [278.8 ± 28]
86 ± 8.6 202 ± 20
Rim bolts 7 A (8.8 ± 0.9) (20.6 ± 2) —
[63.4 ± 6.3] [149 ± 14.8]
6 6 5
5
1 1
2 2
3 3
4 4
7
210096
7-26
FRONT AXLE AND REDUCTION DIFFERENTIAL
7-27
FRONT AXLE AND REDUCTION DIFFERENTIAL
12
13 8
10
Riduction
differential
1 6 3
7 2
4
11
9
210097
7-28