Propeller Shaft and Axle General Specification ................................................. PA -2 Troubleshooting ............................................ PA -6 Generals ....................................................... PA -10 Adjustment .................................................... PA -11 Propeller Shaft Components ................................................. PA -12 Removal ....................................................... PA -13 Inspection ..................................................... PA -13 Front Propeller Shaft Disassembly ............................................ PA -15 Inspection ................................................ PA -16 Reassembly ............................................ PA -18 Rear Propeller Shaft Disassembly ............................................ PA -20 Inspection ................................................ PA -21 Reassembly ............................................ PA -23 Installation ............................................... PA -24 Front Axle Wheel Hub Disassembly ............................................ PA -25 Inspection ................................................ PA -30 Reassembly ............................................ PA -30 Axle and Knuckle Components ............................................ PA -36 Disassembly ............................................ PA -37 Reassembly ............................................ PA -40 Wheel Alignment Description .............................................. PA -44 Inspection ................................................ PA -44 Rear Axle Wheel Hub Components ............................................ PA -49 Removal .................................................. PA -50 Disassembly ............................................ PA- 52 Inspection ................................................ PA -53 Reassembly ............................................ PA -53 Axle Housing Components ............................................ PA -57 Disassembly ............................................ PA -58 Reassembly ............................................ PA -60 Rear Axle(F302,F320) Adjustment .................................................... PA -63 Inspection ..................................................... PA -65 Specification ................................................. PA -67 Wheel Hub Components ............................................ PA -69 Replacement ........................................... PA -70 Differential Carrier Assembly Components ............................................ PA -72 Removal .................................................. PA -73 Installation ............................................... PA -73 Disassembly ............................................ PA -74 Inspection ................................................ PA -78 Reassembly ............................................ PA -80 Adjustment .............................................. PA -85 Differential Carrier Assembly Components ................................................. PA -88 Removal ....................................................... PA -89 Installation .................................................... PA -90 Disassembly ................................................. PA -91 Reassembly .................................................. PA -93
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Hyundai HD78 Propeller Shaft and Axle (Мост и Редуктор)
Hyundai HD78 Propeller Shaft and Axle (Мост и Редуктор)
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Propeller Shaft andAxle
GeneralSpecification ................................................. PA -2Troubleshooting ............................................ PA -6Generals ....................................................... PA -10Adjustment .................................................... PA -11
Propeller ShaftComponents ................................................. PA -12Removal ....................................................... PA -13Inspection ..................................................... PA -13Front Propeller Shaft
Disassembly ............................................ PA -15Inspection ................................................ PA -16Reassembly ............................................ PA -18
Rear Propeller ShaftDisassembly ............................................ PA -20Inspection ................................................ PA -21Reassembly ............................................ PA -23Installation ............................................... PA -24
Front AxleWheel Hub
Disassembly ............................................ PA -25Inspection ................................................ PA -30Reassembly ............................................ PA -30
Axle and KnuckleComponents ............................................ PA -36Disassembly ............................................ PA -37Reassembly ............................................ PA -40
Wheel AlignmentDescription .............................................. PA -44Inspection ................................................ PA -44
Rear AxleWheel Hub
Components ............................................ PA -49Removal .................................................. PA -50Disassembly ............................................ PA- 52Inspection ................................................ PA -53Reassembly ............................................ PA -53
Axle HousingComponents ............................................ PA -57Disassembly ............................................ PA -58Reassembly ............................................ PA -60
Rear Axle(F302,F320)Adjustment .................................................... PA -63Inspection ..................................................... PA -65Specification ................................................. PA -67Wheel Hub
Components ............................................ PA -69Replacement ........................................... PA -70
Differential Carrier AssemblyComponents ............................................ PA -72Removal .................................................. PA -73Installation ............................................... PA -73Disassembly ............................................ PA -74Inspection ................................................ PA -78Reassembly ............................................ PA -80Adjustment .............................................. PA -85
Differential Carrier AssemblyComponents ................................................. PA -88Removal ....................................................... PA -89Installation .................................................... PA -90Disassembly ................................................. PA -91Reassembly .................................................. PA -93
2nd tightening torqueafter full loosening 58 6 43.3
Loosening angle aftertightening Approximately 45° <1/8 turns>
Rear AxleInstall Position Tightening Torque
Nm Kgf·m Ib.f-ft
Bolt (for install the final drive gear and the differential case) 226~265 23~27 166.3~195.2
Tightening bolt for bearing cap 69~78 7~8 50.6~57.8
Bolt (for install the side bearing lock plate) 20~26 2.0~2.7 14.4~19.5
Tightening Nut for differential carrier assembly 34~44 3.5~4.5 25.3~32.5
Tightening Bolt for rear brake assembly 98~137 10~14 72.3~101.2
Nut (for install the wheel hub and the rear drum brake):Aft-er tightening, lock using a triangular or pyramid punch 304~382 31~39 224.2~282.0
Tighten the wheel bearinglock nut
1st tightening 98~127 10~13 72.3~94
2nd tightening torque after fullloosening 29~39 3~4 21.6~28.9
Tightening Bolt for rear axle shaft 98~117 10~12 72.3~86.7
Filler plug 59~78 6~8 43.3~57.8
Drain plug 59~78 6~8 43.3~57.8
TroubleshootingPropeller Shaft
Symptom Causes Remedy
Vibration at Pr-opeller Shaft
High Speed The yoke direction is wrong. Rearrange the align mark.
The universal joint needle roller bearing is defective. Replace with the spider kit.
The propeller shaft is bent Replace the propeller shaft.
The dynamic balance of the propeller shaft is incorr-ect. Adjust the dynamic balance.
The flange linking bolt is loosened. Tighten with specified torque.
The ball bearing is worn out or adhered. Replace the ball bearing.
Low Speed The transmission is too fast. Move the shift bar of the trans-mission to proper position.
The axial clearance of the universal joint spider is to-o large. Adjust the clearance by Shim.
The clearance of the slip joint spline is too large. Replace the yoke sleeve or pr-opeller shaft.
AbnormalNoiseat Propeller S-haft
At start The flange linking blot is loosened. Tighten with specified torque.
The tightening bolt for center bearing is loosened. Tighten with specified torque.
The center bearing is weakened or deformed. Replace the rubber
The universal joint needle roller bearing is worn. Replace with the spider kit.
The clearance of the slip joint spline is too large. Replace the yoke sleeve or pr-opeller shaft.
Running with R-egular speed
The axial clearance of the universal joint spider is to-o large. Adjust the clearance by Shim.
The universal joint needle roller bearing is worn. Replace with the spider kit.
The ball bearing is worn out or adhered. Replace the ball bearing.
The lubricant between the bearing and the spline isdefective. Lubricate.
Front AxleSymptom Causes Remedy
Vibration at Steering Wheel Kingpin wear. Replace.
The clearance of kingpin and bushing is too large. Replace the kingpin bushing.
The front wheel hub bearing is adhered, worn or d-efective in rotation. Replace.
The wheel alignment is defective. Adjust
The tie rod end ball stud is too worn out. Replace the tie rod end assembly.
The air pressures of the tires are uneven. Adjust.
The tightening castle nuts for the knuckle arm andthe tie rod arm are loosened. Tighten with the specified torque.
The tightening nut for tie rod ball stud is loosened. Tighten with the specified torque.
The tightening nut for suspension U-bolt is loosen-ed. Tighten with the specified torque.
The vertical clearance between the knuckle and t-he front axle is too large. Adjust the kingpin thrust washer.
Hard to control the steeringwheel
The clearance between the kingpin and the kingpi-n bushing is too large. Replace the kingpin bushing.
The strut ball bearing is adhered, worn or defectiv-e in rotation. Replace the thrust ball bearing.
The tire air pressure is too low. Adjust the air pressure.
The wheel alignment is defective. Adjust.
The grease is deficiency in kingpin. Oil the grease.
Steering wheel does not ret-urn properly.
The front axle parts are too tightened. Tighten with the specified torque.
The wheel alignment is defective. Adjust.
Steering wheel can not be t-urned.
The rotating angle adjustment is defective. Adjust the rotating angle.
The tie rod is bent. Replace.
Vehicle is drawn to one side. The sizes of the left and right tires are different. Replace with the same size.
The outer diameters of the left and right tires aredifferent. Replace with the same size.
The air pressures of the tires are different. Apply the same air pressure.
The front axle is bent. Replace.
The front spring is damaged or its tension is defec-tive. Replace.
Front tire is worn irregularlyor too early.
The wheel alignment is defective. Adjust.
The sizes or types of the left and right tires are dif-ferent. Replace with the same size and type.
The tire is not managed properly. Replace the tire position.
Rear Axle
EMTPA5001A-A
General Information
EMTPA5002A-A
Generals
EMTPA5003A
The propeller shaft installing between the transmissionand the rear axle transmits the engine force changed bythe transmission to the final gear of the rear axle. Thepropeller shaft comprises of the front and the rearpropeller shafts. Two or more parts are linked andsupported by wheel base. The propeller shaft having twoor more parts includes a center bearing at the centerportion supported by the frame.
EMTPA5004A
The relative position of the transmission to the rear axleis varying in accordance with the condition of the roadsurface, the vibration during running of the vehicle andthe amount of the load. To compensate the varying of theposition, the propeller shaft includes the universal jointand the slip joint.
EMTPA5005A
AdjustmentUniversal Joint and Boot1. Set the transmission to the neutral position or the N.2. Lift up the vehicle.3. Check that the center bearing moves excessively ormakes an abnormal noise. If there is any problem,replace the propeller shaft.
KMTPA5003A
4. Check that the universal joint boot is torn or shocked.If there is any problem, replace the propeller shaft.
5. Check that the universal joint moves excessively ormakes an abnormal noise. If there is any problem,replace the propeller shaft.
Propeller Shaft Run-out1. Install a dial gauge at the body of the center portionof the front propeller shaft.
2. With rotating the front shaft slowly, check the run-out.And then, check the other side propeller shaft also.
Item Run-out Spec.(mm)
Front Propeller Shaft 0.4 or less
Rear Propeller Shaft 0.4 or less
KMTPA101A
3. If the run-out of the propeller shaft excesses thespecifications, replace the propeller shaft.
Removal1. Making an align mark (C) to the flange yoke (A) of thefront propeller shaft and the parking brake drum (B),remove the tightening nut (D) of the propeller shaft.
KMTPA111A
2. Remove the tightening bolt (A) of the center bearingbracket.
NOTICEFor the short wheel base, the center bearing is one,while for the long wheel base, the center bearingsare two.
KMTPA112A
3. Making an align mark (C) to the rear axle companionflange (A) and the flange yoke (B) of the rearpropeller shaft, remove the tightening bolt (D) of thepropeller shaft.
KMTPA113A
Inspection1. After checking the clearance between the spider andthe needle roller bearing, if it excesses thespecifications, replace the spider kit.
Clearance between the Spider and the Needle Roller:0.01~0.06mm
EMTPA5007A
2. Measuring the bending at the 50mm around thewelding center portion of the propeller shaft, if itexcesses the specification, replace the propellershaft.
7. Holder8. Hanger9. Cushion10. Oil Seal Kit(Housing and Oil Seal)11. Packing⑫. Ball Bearing13. Front Propeller Shaft
* For disassembly for the ○ number, refer to thecorresponding contents.
1. Remove the snap ring
CAUTION• Replace the snap ring with new ones after
removal.
EMTPA5010A
2. Remove the needle roller bearing.
EMTPA5011A
3. Remove the ball bearing
EMTPA5012A
Inspection1. Check the clearance between the spider and theneedle roller bearing.
CAUTION• When replace the spider or needle roller
bearing, replace them with the spider kit.
EMTPA5007A
2. Check the clearance of snap ring along to the axisdirection1. Measure the clearance2. Adjust the clearance
CAUTION• Replace the snap ring with new ones after
removal.• Use the snap rings having the same
thickness at the both sides.
KMTAX5009A
Snap Ring
Thickness Color Code
1.5 No Color
1.55 Yellow
1.6 Blue
1.66 Cyan
EMTPA5013A
3. Measure the bending at the bent center portion of thepropeller shaft.
EMTPA5008A
Reassembly
EMTPA5014A
1. Insert the needle roller bearing by pressing-in.
EMTPA5015A
2. Install the snap ring.
EMTPA5016A
3. Assemble the center bearing.Setting the arrow mark to upward, insert the centerbearing into cushion, and apply adhesion into thegap. Install the housing tightening bolt with setting it'shead to upward.
EMTPA5017A
4. Using a thickness gauge, measure the gap betweenthe snap ring and the groove of the snap ring.
Reference : 0~0.15mmLimit : 0.3mm or less
CAUTION• If the gap excesses the limit value, replace
the snap ring.
EMTPA5030A
5. Apply the grease enough to the grease nipple of theuniversal joint.
For assembly for the ○ number, refer to the corresponding contents.
1. Insert the needle roller bearing by pressing-in.
EMTPA5011A
2. Install the snap ring.
EMTPA5016A
Installation1. Setting the aligning mark (C) of the rear axlecompanion flange (A) to that of the flange yoke (B) ofthe rear propeller shaft, tighten the bolt (D) of thepropeller shaft.
NOTICEFor narrow version, the center bearing is one, whilefor the wide version, the center bearings are two.
3. Setting the aligning mark (C) of the flange yoke (A) ofthe front propeller shaft to that of the parking brakedrum (B), tighten the bolt (D) of the propeller shaft.
1. Place the wooden block (A) at the front and rear sideof the rear wheel.
KMTPA201A
2. Loosen the wheel nut (A). Lift up the axle using agarage jack (B) and support the frame with a safetystand (C).
KMTPA202A
3. After removing the wheel nut (A), remove the wheeland tire (B) from the hub (C).
CAUTIONWhen removing the wheel and tire (B), be carefulthat the hub bolt (D) is not damaged.
KMTPA203A
4. After removing the wheel cap(A), remove the split pin(B) and the lock nut (C).
CAUTIONWhen removing the lock nut (C), be careful thatthe washer and the outer bearing does not falldown to the ground.
KMTPA204A
5. Remove the washer (A), the outer bearing (B) andthe hub assembly (C) from the knuckle (D).
KMTPA205A
6. Tapping evenly the three notch parts on the hub innersurface with a brass bar, removing the oil seal (A),the inner bearing (B) and the inner bearing race (C).
NOTICEWhen using the brass bar, do not tap except thenotch parts (A) located inside of the hub.
KMTPA206A
7. Tapping evenly the three notch parts on the otherside hub inner surface with a brass bar, removing theouter bearing race (A).
KMTPA207A
8. After removing the hub nut (A), remove the drum (C)from the wheel hub (B).
1. Place the wooden block (A) at the front and rearsides of the rear wheel.
KMTPA201A
2. Loosen the wheel nut (A). Lift up the axle using agarage jack (B) and support the frame with a safetystand (C).
KMTPA202A
3. After removing the wheel nut (A), remove the wheeland tire (B) from the hub (C).
CAUTIONWhen removing the wheel and tire, be carefulthat the hub bolt is not damaged.
KMTPA203A
4. After removing the grease cap (A), remove the splitpin (B) and the lock nut (C).
KMTPS5990A
5. Remove the washer (D), the outer bearing (E) andthe hub assembly (F) from the knuckle (G).
6. After taking off the disk tightening bolt, remove thedisk assembly from the wheel hub (B).
7. Remove the hub from the knuckle.
Inspection1. Check the cracks and wear on the hub.2. Check the scratch and damage on the brake disk.3. Check for the cracks.4. Check the assembling state of the bearing.
Reassembly[Drum Brake]1. Installing the drum (C) at the wheel hub (B), tightenthe hub nut (A).
CAUTIONAfter tightening the hub nut (A), at least 4portions of the groove parts of the stud shouldbe calked.
KMTPA208A
2. By tapping evenly, install the inner bearing race (B)and the outer bearing race (C) at the wheel hub (A).
KMTPA209A
3. Install the inner bearing (B) and the oil seal (C) at thewheel hub (A).
CAUTION• The bearing should be a set with the bearing
race.• Use a new oil seal (C) always.
KMTPA210A
4. Fill the recommended grease in the wheel hub (A)with specified amount.
Recommended Grease:MS511-33
5. Install the washer (A), the outer bearing (B) and thehub assembly (C) at the knuckle (D).
CAUTION• The bearing should be a set with the bearing
race.
KMTPA205A
6. Install the lock nut (A).1) With rotating the hub assembly (B), tighten the
lock nut (A) fully with the force of 98~117Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,loosen the nut fully.
2) Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 5~9 Nm (6kgf·m, 43.3 lb-ft) and then loosen the nut at45°(1/8 turns).
KMTPA211A
7. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe moving torque by multiplying the tangential forceto the radius.
8. After installing the split pin (B), install the wheel cap(A).
KMTPA213A
9. After installing the wheel and tire (B) to the hub (C),tighten the wheel nut (A).
KMTPA203A
10.After removing the garage jack (B) supporting theaxle and the safety stand (C) supporting the frame,tighten the wheel nut (A) with the specified torque.
CAUTIONAfter tightening the hub nut, at least 4 portionsof the groove parts of the stud should be calked.
3. By tapping evenly, install the inner bearing race (C)and the outer bearing race (E) at the wheel hub (D).
4. Install the inner bearing (B) and the oil seal (A) at thewheel hub (D).
CAUTION• The bearing should be a set with the bearing
race.• Replace the oil seal(A) with new one after
removal.
KISE210E
5. Fill the recommended grease in the wheel hub (A)with specified amount.
Recommended Grease:MS511-33
6. Install the washer, the outer bearing and the hubassembly at the knuckle.
CAUTION• The bearing should be a set with the bearing
race.7. Install the lock nut (A).
1. With rotating the hub assembly (B), tighten thelock nut (A) fully with the force of 98~117Nm(10~13 kgf·m, 72.3~86.7 lb-ft) After that,loosen the nut fully.
2. Again with rotating the hub assembly (B), tightenthe lock nut (A) with the force of 59 Nm (6 kgf·m,3.31 lb-ft) and then loosen the nut at 45°(1/8turns).
KMTPA5002A
8. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe moving torque by multiplying the tangential forceto the radius.
9. After installing the split pin (A), install the wheel cap.
KMTPS5991A
10.After installing the wheel and tire (B) to the hub (C),tighten the wheel nut (A).
KMTPA5508A
11.After removing the garage jack (B) supporting theaxle and the safety stand (C) supporting the frame,tighten the wheel nut (A) with the specified torque.
9. Install the wheel hub. (Refer to the “Wheel HubAssembly”)
Wheel AlignmentDescriptionWhen wheel alignment and steering angle are measured,check that the vehicle has no load or every parts of thefront axle are properly assembled.
CAUTIONBefore the adjustment, check again followings.1. The front wheel is loosened.2. The knuckle is loosened.3. The linkage between the knuckle flange and
knuckle arm is loosened.4. The bolts, the screws or the nuts are loosened.5. The leaf spring is damaged or weakened.6. The tire air pressure is too high or low.7. The adjusted backlash of the steering gear is
proper.InspectionToe-in1. Set the front wheel along with the straight direction.2. Make a mark at the front end of the front wheel. (Themarking point is the middle position of the width andheight of the wheel)
3. Setting the needle height of the toe-in gauge to themarking point of the left and right tire, measure thetoe-in value. Measure the distance (A) between thetwo wheels.
KMTAX5019A
4. Moving the vehicle to forward so that the markingpoint moves backward. Setting the marking point tothe height of the toe-in gauge (i.e. turn 180°), at therear side, measure the distance (B) between the twowheels.
KMTAX5020A
5. The difference between the measured value of rearside (B) and the measured value of front side (A) isthe toe-in value.
Specified Value (B-A): 1~3mm
KHHA850A
6. If the measured toe-in value excesses the specifiedvalue, adjust it by loosening the clamp bolts (B) of theleft and right tie rods (A) and turning the tie rod (A)with a pipe wrench (C).
Tightening Torque of the Clamp Bolt (B):20~29 Nm (2~3 kgf·m, 14~22 lb-ft)
EMTPA5026A
Camber1. Set the front wheel along with the straight direction.2. Remove the wheel hub cap (A).
KMTPA361A
3. Wipe out the grease at the end of the spindle. Installthe self centering plunger of the camber, the casterand the king pin gauge (A) to the wheel hub bysetting them to the center hole of the spindle.
KMTPA362A
4. Set the gauge (A) in horizontal plane. To do that, setthe bubble (in longitudinal direction) of the levelgauge to the zero point.
5. Measure the camber value(B) of the gauge (A). Thecenter line of the bubble is the camber value.
Specified Value : 1°±30′
KMTPA363A
6. By the same method, measure the camber value ofthe opposite wheel.
Kingpin inclination angle and Caster1. To maintain the vehicle in horizontal position, place aplate (B) having the same height with the turn table(A) under the rear tire (C).
KMTPA371A
2. Positioning the two front tires of the vehicle to thecenter of the turn table, pull (set up) the parkingbrake.
CAUTIONIf it is hard to move the vehicle, lift up thevehicle with a jack and place the turn table andthe plate under the front and rear tire.
3. Set the scales of the both turn table to zero point.
4. Turn the tire to be measured to the outward until thescale of the turn table is positioned 20° (A).
KMTPA363A
5. Remove the wheel hub cap (A).
KMTPA373A
6. Wipe out the grease at the end of the spindle. Installthe self centering plunger of the camber, the casterand the king pin gauge (A) to the wheel hub bysetting them to the center hole of the spindle.
7. Set the gauge (A) in horizontal plane. To do that, setthe bubble (in longitudinal direction) of the levelgauge to the zero point.
8. By turning the zero setting screws of the caster (A)under the gauge and the kingpin tilting angle, set thebubble to 0.
CAUTIONFor left side wheel, use the left scale as thekingpin tilting angle scale. For right side wheel,use the right scale as the kingpin tilting anglescale.
9. Turn the wheel 20° again so as to set the scale of theturn table to 0°. Then the center line of the bubbleindicates the kingpin tilting angle value. Measure thecenter line value of the bubble.
Specified Value : 8°±10′
10.By turning the tire to inward, set the scale of the turntable to 20°.
11.Set the gauge (A) in horizontal plane. To do that, setthe bubble (in longitudinal direction) of the levelgauge to the zero point.
12.From the caster scale, read the each pointing scaleof the casters.
Specified Value: 1°±30′
13.By the same method, measure the caster and thekingpin tilting angle values of the opposite wheel.
Steering AngleBefore inspecting the steering angle, complete theinspection of the wheel alignment.1. To maintain the vehicle in horizontal position, place aplate (B) having the same height with the turn table(A) under the rear tire (C).
KMTPA371A
2. Positioning the two front tires of the vehicle to thecenter of the turn table, pull (set up) the parkingbrake.
CAUTIONIf it is hard to move the vehicle, lift up thevehicle with a jack and place the turn table andthe plate under the front and rear tire.
3. Set the scales of the both turn table to 0°.4. Turn the tire to inward. Measure the scale of the turntable.
Specified Value(°) : 40.8~42.8
5. Turn the tire to outward. Measure the scale of theturn table.
Specified Value(°) : 30.8~32.8
6. If the measured value excesses the specified value,tighten or loosen the knuckle stopper bolt (A) at bothsides (LH/RH) to adjust the steering angle.
KMTPA382A
7. After adjusting the steering angle, tighten the nut (A)of the stopper bolt with specified torque.
Side SlipBefore checking the side slip, complete the inspection ofthe wheel alignment.1. Set the front wheel along with the straight direction.2. Maintaining the position of the front wheel to thestraight direction, drive the vehicle on the slip testerslowly.
CAUTIONWith maintaining the position of the front wheelto the straight direction, pass through the sideslip tester thoroughly. Do not turn the wheel ordo not fall off from the tester.
3. The value indicated on the tester is the side slip. Ifthe side slip excesses the specified value, the wheelalignment should be adjusted.
CAUTION• Be careful that the brake lining and the brake
drum inner surface are not contaminated by theoil or grease.
Removal1. Place the wooden block (A) at the front and rearsides of the front wheel.
KMTPA401A
2. Loosen the wheel nut. Lift up the axle with a garagejack (A) and support the frame with a safety stand(B).
KMTPA402A
3. After taking off the wheel nut (A), remove the wheeland tire (B) from the hub (C).
CAUTIONWhen removing the wheel and tire (B), be carefulthat the hub bolt (D) is not damaged.
KMTPA403A
4. After taking off the hub bolt (A), remove the axle shaft(B).
NOTICEWhen it is hard to remove the axle shaft (B), inserthub bolts (A) into the removing screw holes (C)evenly.
KMTPA404A
5. Remove the oil seal (A).
KMTPA405A
6. Loosening the tightening bolt (A) for the lock nut,remove the lock washer (B).
KMTPA406A
7. Using the special tool (09527-47000), remove thelock nut (A).
KMTPA407A
8. Remove the rear wheel hub (B) with the outerbearing (C) from the axle housing (A).
CAUTIONBe careful that the outer hub bearing (C) do notdrop down to the ground.
KMTPA408A
Disassembly1. Tapping evenly the three notch parts on the hub innersurface with a brass bar, removing the oil seal (A),the inner bearing (B) and the inner bearing race (C).
KMTPA409A
NOTICEWhen using a brass bar, do not tap except the notchparts (A) located inside of the hub.
KMTPA420A
2. Tapping evenly the three notch parts on the otherside hub inner surface with a brass bar, removing theouter bearing race (A).
KMTPA410A
3. After taking off the hub nut (A), remove the drum (C)from the wheel hub (B).
KMTPA411A
Inspection1. Check that the rotation state is proper after installingthe bearing(A) to the bearing race(B). If it has beenadhered, worn or defective in rotation, replace thebearing(A) and the bearing race (B) in a set.
KMTPA409A
2. If the hub bolt is worn or corroded, remove the hubbolt from the wheel hub and replace it.
Reassembly1. Installing the drum (C) to the wheel hub (B), tightenthe hub nut (A).
CAUTIONAfter tightening the hub nut (A), at least 4portions of the groove parts of the stud shouldbe calked.
8. Just before the wheel hub (A) is moving, measure thetangential force using a spring gauge (B). Calculatethe starting torque by multiplying the tangential forceto the radius.
11.After installing the wheel and tire (B) to the hub (C),tighten the wheel nut (A).
KMTPA403A
12.After removing the garage jack (A) supporting theaxle and the safety stand (B) supporting the frame,tighten the wheel nut with the specified torque.
Disassembly1. Place the wooden block (A) at the front and rearsides of the front wheel.
KMTPA401A
2. Loosen the wheel nut. Lift up the axle with a garagejack (A) and support the frame with a safety stand(B).
KMTPA402A
3. After taking off the wheel nut (A), remove the wheeland tire (B) from the hub (C).
CAUTIONWhen removing the wheel and tire (B), be carefulthat the hub bolt (D) is not damaged.
KMTPA403A
4. As the same method with the 2~3 steps, remove theopposite side wheel and tire.
5. Support the both hub with a jack (A).
KMTPA501A
6. Making an align mark (C) to the rear axle companionflange (A) and the flange yoke (B) of the rearpropeller shaft, remove the tightening bolt (D) of thepropeller shaft.
KMTPA113A
7. After removing the brake line (A), remove the brakehose clip (B).
NOTICE• If the brake line is rubber hose, remove it after
biting it with vise pliers.• If the brake line is steel pipe, remove the line
with pressing the brake pedal.
KMTPA502A
8. After taking off the tightening nut(A) of the shockabsorber, remove the shock absorber (B).
KMTPA503A
9. After taking off the tightening nut (A) of the U-bolt,remove the U-bolt (B).
KMTPA504A
10.After getting down the jack (A) supporting the bothhub, remove the axle housing (B).
KMTPA505A
Reassembly1. After positioning the axle housing (B) at the rear sideof the vehicle, lift up the jack (A) supporting the bothhubs slowly.
KMTPA505A
2. Setting the center bolt (A) of the leaf spring to thecenter hole (B) of the axle housing, lift up the axlehousing (C) completely.
KMTPA510A
3. After installing the U-bolt (B), tighten the U-bolttightening nut (A) with the specified torque.
6. Setting the align marks (C) of the rear axlecompanion flange (A) to the flange yoke (B) of therear propeller shaft, install the tightening bolt (D) ofthe propeller shaft.
8. Install the wheel and tire (B) to the hub (C). Tightenthe wheel nut (A).
KMTPA403A
9. After removing the garage jack (A) supporting theaxle and the safety stand (B) supporting the frame,tighten the wheel nut with the specified torque.
10.Remove the wooden block (A) from the front and rearsides of the front wheel.
KMTPA401A
11.Bleed the brake system. (Refer to the "Air Bleeding ofBR Group")
Rear Axle(F302,F320)ADJUSTMENTExchange the lubricating oil1. Recommended lubricating oilThe rear axle gear must be applied with hypoid gearoil SAE 80W-90 or SAE 85W-140 GL-5 Quantity: 5.5Lit.In tropical zone: SAE 85W-140 GL-5 for 5.5 LitIn temperate or cold zone: SAE 80W-90 GL-5 for 5.5Lit
2. Time of Change of Lubricating OilFor every 8000 Km travel,inspect the rear axle oillevel and fill as specified.Oil change period for rear axle:1) On completion of running at beginning of vehicle
(2500 Km of travel)2) Every 24000 Km of travel
3. Specific operation for change of lubricating oilThe rear axle oil filler plug is on the axle housing rearcover.The oil should be filled so that the oil level is flushwith the access hole.
NOTICE• Change of Lubricating oil should be carried out in
warm condition.• Be careful not to be hurt by hot oil.• Clear the foreign matter from the oil drain plug.• Clean the health plug.
Connection of brake line and ABS1. Connection of brake line
1) Position the brake tube onto the axle housingtransition boss. Connect one end of it to the teefitting and the other end to brake hose.
2) Before assembling, the line should be tested bycompressed air for any leakage and the cavityshould be cleaned.
2. Connection of ABS (If installed)1) Range of electric resistance of sensor: 1550-1700
ohm.2) When the wheel speed is greater 30 rpm, the
output induced voltage of sensor is ≥0.2V (AC)and the ratio of its max induced voltage to its mininduced voltage should be ≤2.0.
SUDPAA011L
1. HARD PIPE ASSY-LH2. 3-WAY VALVE TRANSITION BRACKET ASSEMBLY (for ABS)3. HOSE (2 for ABS)4. HARD PIPE ASSY-RH5. BOLTBOLT (transition bracket assembly, for ABS)
NOTICEThe brake tubes 1 and 4 should be mounted asper the steps as given in Fig. which facilitatesassembling and sealing.
SUDPA7038L
On completion of assembling of the completeaxle, oil should be applied as specified.
Test specification for rear axle assemblyFor users having necessary conditions, a rear axle testbed may be used to test the reassembled rear axle. Forusers without those conditions, the rear axle may bemounted onto the vehicle and observed during slowrunning.
WARNINGObserving of the operation state of the rear axlemounted onto the vehicle should be done in a areafar away from the crowd. Pay attention to the safetyof human body and properties of other people andyour own.1. Test scopeDuring the test, check the assembling of the rear axleassembly for complete correctness and check allthreaded connections for correct tightening andlocking. Check the leakage condition of the bondarea and the oil seal. Check the noise of the carrierassembly and braking effect of the wheel brake. Thetest duration is not less than 3 min.
2. The rear axle assembly under test should conform tothe following:1) The gears must be free from any abnormal noise.
When one of the brake drum is applied, knockingor drastic noise is not allowed from thedifferential.
2) No rotating part may come into contact with anystationary part.
3) After the vehicle is stopped, when touching byhand any bearing and oil seal seat, it should becool or slightly warm. The brake drum should notbe subject to overheat.
4) No oil seal, bond area or castings blow hole, etcmay be subject to oil leakage.
3. A defect found in the test may be reconditioned.However, reacceptance is required after thereconditioning.
INSPECTION1. CleaningThe parts may possibly contaminated by dirty oil orsludge. Cleaning of parts is essential. Usual methodsinclude steam cleaning, gasoline cleaning, acid oralkaline solution cleaning, neutral solvent cleaning,trichloroethylene cleaning and magnetic forcecleaning. Some parts may possibly be damagedduring cleaning. Therefore, careful inspection mustbe done during cleaning.1) Metal part
a. GasolineUnlike any other method, gasoline is not ableto penetrate or dissolve sludge. Unless thesurface of part has been precision machined,a metal brush or other tool to remove sludgeand brushing should be done twice.
b. Alkaline treatmentExcellent result can be obtained by usingalkaline treatment to clean steel parts andcastings. Alkaline treatment is not appropriatefor alloy parts.
2) Rubber partsMineral oil cannot be used. Alcohol can be usedfor cleaning or just a piece of clean cloth can beused to wipe off any dirt.
3) Corrosion preventionAfter cleaning all waste oil and grease off the partsurface, a layer of clean oil should be applied onthe surface for corrosion prevention.
2. Inspection1) Before cleaning, the part should be inspected by
using any already prepared measuring apparatusor tool. Decide according to the specifiedmaintenance criteria if the part is suitable forreuse. Any damaged part should be repaired orreplaced as required. If one of paired parts isseriously worn and the assembling clearanceexceeds the specified degree, this part or thepaired parts can be replaced as required. Inprinciple, any paired parts should be replaced in apaired manner.
2) For the view point of preventive maintenance,some parts within repair or wear limit should bereplaced before they exceed the limit.
3) All parts should, as necessary, be carefullyinspected by visual inspection or by means ofNDT such as infrared ray, ultrasonic wave or Xray. The part can be repaired or replaced as
necessary if any abnormality is found duringvisual inspection, such as irregular wear, ironrust, bending, deformation, scratch, crack, partialwear, discoloration, loose fitting , excessive wearof friction liningand etc, deterioration of frictionlining and etc, failure of return spring orattenuation of return force or abnormal noise ofbearing or gear, etc.
4) Any rubber part such as O ring, oil seal or gasket,after disassembled, should be replaced accordingto the situation. All hub oil seals and pinion gearoil seal after disassembled must be replaced.
5) For cleaning of carrier and differential assembly,replace them according to the assembling order.
6) Check the dismounted bearing, gear and anyother parts for any ablation, flaking off, pockmarkor excessive wear. Replacement is necessary ofany such defect.
3. Reconditioning and Replacement
NOTICEIn order to achieve effectively the value of the rearaxle product, it is an effective means to replace anylow-value wear-prone part.For instance, replacement of any worn gasket, bushor oil seal can prevent damage of gear or bearing,etc.Replacement of such parts will not increase the costfor replacement of important parts.1) Steel parts
For paired parts that may not be reconditioned,such as gear, differential and bearing, when anyused or damaged part is rejected, replacement bysuited part is required as well. That is to say, anypaired parts should be replaced in a pairedmanner but not in a single manner.
2) Rubber partsFor rubber parts such as oil seal, replacement isa must once the seal is damaged. In this case,reuse may not be considered.
3) Axle housingAny cracked or bent axle housing should bereplaced at once.
CAUTIONNever try to repair any axle housing bymeans of welding or straightening;otherwise, the axle housing may becomedefective during use of vehicle, possiblycausing serious result.
NOTICENever work under the vehicle when only one jack isused! During repair of the vehicle (inc. axles), makesure the wheels are blocked by using sole timber.Make surethe vehicle will not move even if the brakefails.
REPLACEMENT1. Dismounting of wheel end part
1) Dismounting of axle shaft
WARNINGBefore dismounting the axle shaft, the wheelsshould be blocked by using sole timber andthe parking system should be released.For dismounting, loosen and screw off all theaxle shaft bolt. Use a copper hammer toslightly knock on the center of the tail of theaxle shaft for 2 or 3 times so that the axleshaft flange face is disconnected from thewheel hub joint face. Then pull the axle shaftflange by hand and the axle shaft can bedrawn out.
NOTICEWhen the axle shaft spline part is to passthrough the oil seal, the axle shaft lever partshould be propped by hands and the axle shaftshould be rotated slowly so that they are shift outin parallel and that hub oil seal will not bedamaged and the axle shaft are prevented fromfalling onto the ground and hurting anyone.
2) Dismounting of wheel hubScrew off the bolt 22 and remove the lockingwasher. Screw off the nut 20. Place the palletunder the wheel hub brake drum assembly. Use acopper bar or soft hammer to knock on the outeredge of the brake drum outwards. Remove thewheel hub brake drum assembly.
SUDPA7035L
2. Equipment and adjustment of wheel end part1) Mount the brake assembly onto the flange of axle
housing and tighten the brake backplate bolt to98~137 N.m. Adjust the brake clearance to0.3±0.05mm (Measurement and adjustment canbe done by using a clearance gauge oradjustment can be done on the brake pumpstroke in such a manner that the wheel hub isblocked. Then adjust it in an inverse way forapproximately 4 to 6 turns).
NOTICEMake sure that the inside of the rear axlehousing is clean and free from any iron dust, dirt,cutting edge, burr or any mechanical impurities.
WARNINGBrakes of the same batch should be selected.New brakes, i.e. left and right brakes, must bein consistent color. The old brakes should bethe product on the same axle.
NOTICEDuring assembling, there are marks R (right) andL (left) on the brake backplate. Make sure thatassembling is not done in an inverse way.
2) Assemble the spacing ring 2 onto the axle sleeveso that the inner end face of the spacing ringabuts on the sleeve step.
3) The wheel hub with brake drum assembly mustbe clean inside before mounting. The wheel hubmust be filled with No. 2 lithium grease. Mountthe spacer. Apply small amount of grease at theinternal and external cutting edges of the inner oilseal and press in the wheel hub.
SUDPA7036L
4) Mount the wheel hub with oil seal assembly intothe axle sleeve.Fit over the specing ring. Mount the outer bearinginner race. Screw on the wheel hub nut. At thesame time, adjust the pretightening force of thewheel hub bearing, i.e. tighten the wheel hub nutso that when rotating the wheel hub, thetangential pulling force applied on the wheel hubbolt is 42-52 N. Fit over the lock washer onto theaxle sleeve. Use three cross groove screws tolock the lock washer on the wheel hub nut andtighten it. Mount the wheel hub outer oil seal.
NOTICEAssembling may fail if the thread on the axlesleeve on the axle housing or the thread of theaxle head nut is subject to any damage orcorrosion.
5) Mount the axle shaft. Tighten the axle shaft boltto 180±20 Nm.
NOTICE1. A proper pressing tool should be used for
mounting of the oil seal. An inappropriate toolmay cause damaged oil seal.
2. The oil seal may be prone to damage andshould be placed in the package beforeassembling.
3. When the axle shaft splinepart is to passthrough the oil seal, the axle shaft lever partshould be propped by hands and the axleshaft should be rotated slowly so that theypass through in parallel and that the axleshaft oil seal will not be damaged.
CAUTION1. When assembling the axle assy, the
lubricating oil and grease to lubricatevarious assemblies and parts should be ofthe same grade as for normal service.
2. Never apply any lubricating grease ontothe bearing before assembling. (Thebearing should be lubricated whenassembling.) Dry grease may possiblyprevent normal lubrication of the axleassy., even causing defective oil seal.
Differential Carrier AssemblyCOMPONENTS
SUDPAA013L
1. Nut-flange2. Washer3. O ring4. Flange assy5. Oil seal assypinion6. Outer bearing-pinion7. Bolt8. Bearing cage9. Adjusting shim
10. Inner bearing-pinion11. Split pin12. Pinion13. Pilot bearing14. Adjusting shim15. Bolt16. Bolt17. Diff. carrier18. Adjusting ring
19. Bearing20. Differential case (right)21. Differential side gear shim22. Bolt23. Spring washer24. Lock piece25. Bolt26. Cover27. Differential side gear
28. Differential pinion gear shim29. Differential pinion gear30. Cross shaft31. Ring gear32. Differential case (left)33. Bolt34. Bolt
REMOVALCAUTION
When axle shaft is dismantled, please distinguishleft from right axle shaft, thus mistake will not bemade in re-installation.The carrier is dismantled according to the following steps1. Release and draw out left/right axle shaft.
SUDPA7002L
2. Support the carrier with cart, dismantle 12 boltslinking carrier and rear axle, dismantle the carrierassembly from axle housing.
WARNING1. Don't use hammer to knock on the edge of
axle shaft flange, don't prize axle shaft orscrew by such tools as flat spade!
2. Don't lie under carrier while dismantling orinstalling tightening bolts of carrier. Cartshall be used to transport carrier.
INSTALLATION1. ASSEMBLY OF DIFFERENTIAL CARRIER
CAUTION1. Before carrier is installed, one shall assure
the interior of axle housing has been checkedand cleared utterly
2. On the engagement face between axlehousing and carrier, heavy load sealing gluewill be applied.
SUDPA7003L
1) Install carrier assembly inside axle housing, afterbolt has been tightened, it shall be retightened. Intightening, the torque shall reach the valuerequired in torque table(Table on Bolt Torque isshown in "Tighening torque").
2) Install axle shaft, tighten linking bolt, retightenbolt to the scope required in torque table(Tableon Bolt Torque is shown in "Tighening torque" ).
3) Fill wheel axle with correct lubricating oil.
CAUTIONIf the pinion, ring gear, differential gear andwheel end parts were decomposed, checkedor replaced, before traffic tool is operated,differential gear shall be assured to operatenormally(in addition, wheel on one side canrotate independently and freely).
2. Mounting of pinion assembly1) Place the adjusting shim onto the Diff carrier. The
upper most and bottommost shims should beapplied with sealant on the surface to contact thehousing.
NOTICEIf the gear before disassembly is used, theadjusting shim kept after disassembly of theassembly should be used. If the shims aredamaged, then shims with the same thicknessand quantity should be prepared prior to theassembling. If a new gear is to be mounted, aset of adjusting shims with nominal thicknesscan be mounted first.That not fewer than two shims of 0.1mm and0.2mm should be used. (The nominal thicknessof F320 series adjusting shim is 1.75mm.
2) Mount the pinion assembly onto the carrier.Screw on the attachment bolt to the specifiedtorque. (For the tightening torque see the TorqueTable.)
SUDPA7026L
3. Mounting of differential assembly
NOTICELubricate the differential bearing.1) Mount the differential assembly onto the carrier.
SUDPA7027L
2) Mount the bearing outer races on both sides ofthe differential. Mount the differential bearing capand adjusting ring. Mount but not tighten theattachment bolts of the bearing cap.
3) Use hands to tighten the attachment bolts of thebearing cap. A wrench may be used if it is difficultto tighten the bolts by hands.
NOTICEIt may be difficult to screw on the adjusting ring ifthe ring and the relevant threads are notlubricated.
Up to this point, the preliminary assembling ofthe carrier assembly has been finished. Next, thepretightening load of the differential bearing, thebacklash andcontact pattern of gears should beadjusted.
DISASSEMBLYCAUTION
If pinion and ring gear need to be usedrepetitively,before Diff. Carrier assembly isdecomposed, the contact dent of gear and gear gapshall be checked. Of course, the best result is toacquire good gear contact dent and gear gap byadjustment. If gear is decided to replace at thebeginning, the step can be given up.The steps for replacing pinion and ring gear1. Install Diff. Carrier shell assembly inside repairgauntry, loosen but not dismantle collar nut. BeforeDiff. Carrier assembly is decomposed, mark shall bemade on the left and right bearing cover , so toprevent left and right bearing cover from beingwrongly assembled in reassembling; ditto, theadjusting ring shall also be marked.
SUDPA7004L
2. Dismantle the retainer bolt on the bearing cover ,take down lock piece, loosen the bolt fixing bearingcover, dismantle nut on bearing cover by wrench;dismantle bearing cover and bolt, take out differentialassembly from Diff. Carrier by chain and hoister.
SUDPA7005L
3. Turn over carrier assy, make ring gear assemblyupwardly, dismantle connection bolt between thebearing cage of and carrier, take down pinionassembly by chain and hoister.
SUDPA7006L
CAUTIONBe sure not to damage or lose the adjustmentshim on the bearing cage . If shim cannot surelybe used again, the group number and thicknessof shim shall be made clear, shim shall bereorganized and reassembly.
Dismantle pinion assembly
SUDPA7007L
CAUTIONWhen dismantling flange assembly, don't lay pinionon hard surface.1. Take out flange nut loosened in step 1 of "The stepsfor replacing pinion and ring gear" by special tool,take down flange assembly; then press out pinionand cone & roller assy by special tool. If bearing hasnot be damaged, it is not necessary to dismantle itscup-bearing and cone; if a part will be replaced,corresponding parts shall be replaced. (see Figure 8),the dismantling steps are shown in 2 and 3.
SUDPA7008L
2. Take down the cup-bearing-inner.
SUDPA7009L
3. Take down the cone & roller assy-outer.
SUDPA7010L
4. Dismantle guide bearing of pinion
SUDPA7011L
SUDPA7012L
NOTICEDismantling tools indicated in figure is only asschematic use. Under the premise of not damagingcomponent, a user himself can select tools withsimilar functions for dismantling.
INSPECTIONDETECTION AND MAINTENANCE ON DIFFERENTIAL ASSEMBLY
SUDPA7013L
NOTICE- In the process of dismantling differential assembly,
differential assembly shall be laid on soft surface, soto prevent wheel tooth of ring gear from beingdamaged.
1. Dismantle the linking bolt tightening ring gear anddifferential case, if ring gear doesn’t slide down fromdifferential case, copper bar or soft hammer can beused to slightly knock on the external edge of ringgear, then dismantle ring gear.
SUDPA7014L-1
2. Make assembly mark on the engagement facebetween left and right differential case, dismantle bolttightening and differential case(left and right), takedown the differential case(right).
SUDPA7014L-2
3. Take down side gear shim and side gear.
SUDPA7014L-3
4. Dismantle differential pinion gear and cross shaftassembly, then dismantle shim and differential piniongear from cross shaft.
SUDPA7014L-4
5. Take down side gear shim and side gear.6. Check if bearings on both ends of differential gearhave been damaged or not. If not, it is not necessaryto dismantle bearing; if damaged, the cone & rollerassy and cup-bearing shall all be replaced.
SUDPA7015L
REASSEMBLYASSEMBLY ON DIFFERENTIAL ASSEMBLY
CAUTIONBefore assembling, hyperbolic gear oil shall beapplied on the rotation engagement surface ofdifferential case, side gear, differential pinion gear,support shim and bearing of side gear. (in tropicalzone, applying SAE 85W-140 GL-5; in temperatezone or Frigid zone, applying SAE 80W-90 GL-5 )1. Assemble the cone & roller assy.
SUDPA7016L-1
NOTICEIn order to prevent bearing from being damaged,suitable pressing sleeve shall be applied. Usedcup-bearing is a good option. If the inner diameter ofinner ring is less than the outer diameter of bearingengagement part of differential case, a notch can bemade from bearing shaft upwardly, so to solve thematter.
2. Assemble side gear shim and side gear intodifferential case(left).
SUDPA7016L-2
3. Assemble planetary gear and shim on cross shaft,then assemble them together into differentialcase(left) . Rotate gear, check if gear system may beblocked or not.
SUDPA7016L-3
4. Assemble side gear and side gear shim.5. Assemble differential case(right) according to markon the differential case. Assemble linking bolt ofdifferential case and tighten to correct torque. Rotateside gear to see if gear system may be blocked ornot.
SUDPA7016L-5
6. Assemble ring gear, assemble bolt linking ring gearand differential case, tighten bolt to correct torque.
SUDPA7016L-6
ASSEMBLE AND ADJUST PINION ASSEMBLY
SUDPA7017L
CAUTIONBefore pressing bearing in, a little lubricating oilshall be applied on the out diameter of pinion. (intropical zone, applying SAE 85W-140 GL-5; intemperate zone or Frigid zone, applying SAE 80W-90GL-5 ). Before cone & roller assy of bearing andguide bearing are assembled, suitable pressingsleeve shall be used. (size is basically equivalent tosize of inner ring of bearing, in addition, the innerring of pressing sleeve shall be larger than thediameter of gear axle).1. Assembling components of pinion assembly
1) Before assembling the cup-bearing, check if burrexists on the surface of cup-bearing, if existing,clear away it.Press cup-bearing into bearing cage
SUDPA7018L
2) Pressing pilot bearing into pinion.
SUDPA7019L
2. Adjustment on the pre-tightened force of bearinginside pinion.1) Assemble bearing cage, inside, outside bearing
and pre-tightened shim(not including pinion andoil seal), lay pre-tightened shim between twocone of bearing and along the direction of axis ofbearing.
SUDPA7020L
CAUTIONIf the reassembled bearing of pinion has beenused, new pre-tightened shim shall beapplied. If it is found that pre-tightened shimhas been seriously worn during the period ofdecomposing assembly, the shim shall beabandoned during the period, however, thethickness of the shim shall be measured andrecorded.
2) Assembled system shall be properly oiled andlubricated; 64KN force shall be applied onassembly. Pressing sleeve must be pressed onthe end face of the inner ring of bearing.
3) When 64KN force is applied on assembly, checkrotation torque. Around bearing cage, wind softmetal wire, hang spring balance to pull.Rotationtorque of bearing cage shall be within the scopeof 1.5~3.0 N.m.
CAUTIONAfter having confirmed value of torque, startto rotate bearing cage.
4) If the pre-tightened force of bearing cannot reachthe requirement, adjust the preload of pinionsupport by varying pre-tightened shim. Thickerpre-tightened shim will reduce pre-tightened load,thinner pre-tightened shim will increasepre-tightened load.
SUDPA7021L
NOTICEGenerally, for this kind of adjustment, suitablepreload may not be acquired in one time ofoperation. Preload testing shall be applied ineach assembly and each time of adjustment.After pre-tightened force has reachedrequirement, when pinion assembly isassembled, a pre-tightened shim with size largerthan test value by 0.02~0.03 shall be selected.When shim is assembled on assembly, thesurplus 0.02~0.03 size can just meet thepre-tightened pressure of assembly. Test onpre-tightened force of bearing shall be completedthrough 3~4 times of tests.
3. Final test on pinion bearing for pretightening force1) Assemble the pinion, the bearing and the bearing
cage
SUDPA7022L
2) Fix the bearing cage assembly by means of themethod as given in Fig.1 or 2. Jaw vice method:Use a jaw vice to clamp the bearing saddleassembly (See Fig.1. Use flange nut to fasten theflange. See the tightening toque table for thetightening torque of the flange nut.)Holding down method: By means of continuousforce, use pressing sleeve to hold down the innerrace of outer bearing.
SUDPA7023L
3) Test the pinion bearing for preload.Wind the soft annealed wire around the bearingcage. Hook up the spring balance to pull it. Therotating torque for bearing cageshould bebetween 1.5 and 3.0 N.m.
NOTICEAfter confirming the torque value, start theoperation of turning the bearing cage.
4) If the requirement of bearing pretightening forceis not met, then the pinion assembly should bedisassembled and assembly and commissioningshould be done again as per the procedure asgivenin page 19 in this manual. Adjust thepreload of pinion bearing by changing thepretightening washer. A thicker pretighteningwasher will reduce the pretigthening load while athinner one will increase it.
WARNINGA pretightening washer as supplied by themanufacturer should be used. Never try touse a shim or any washer as made byyourself. Such inappropriate part may causefailure of pretightening load and bearing orgear.
4. Mounting of oil seal and flange1) After adjustment of the pinion bearing cage for
pretightening load, an appropriate tool should beused to press the oil seal onto the pinion bearingcage.
SUDPA7024L
NOTICEAt the point A in the size of the pressing sleeveshould be ensured.
2) Before mounting the flange, make sure that thefitting surface between flange and oil seal is cleanand dry. Mount the flange washer and flange nutand tighten the flange nut to the specified torque.Insert and lock the cotter pin. (See the toquetable for the torque.)
NOTICEAfter tightening and locking the flange nut andcheck the torque of pinion bearing cage, theprocedure to mount the bearing cage assemblyinto the carrier may begin.
5. Requirement and method for reassembly of flange
WARNINGNever use any flange whose fitting surface withthe oil seal is subject to any damage (nick orscratch).The surface fitting with the oil seal, on the flange, isan important interface to prevent foreign dirt fromentering into the axle and to prevent internallubricating oil from leaking outside. The condition ofthe fitting surface with the oil seal, on the flange, is avery important factor for the service life of oil seal. Itis required that oil seal fitting surface on the flangeshould be inspected carefully to check for any sign ofabrasion or damage. This flange should not be usedin case of any visible score or abrasion or any rubbedsurface exceeding the protecting diameter of oil seallip.
SUDPA7025L
NOTICENever use any abrasive paper or abrasive materialto clean the oil seal fitting surface on the flange. Dirtshould be got rid off by using chemical cleaningagent.
6. Replacement of oil sealIt is strongly recommended that mounting should bedone by using an oil seal pressing sleeve. Anappropriate pressing sleeve can allow the oil seal tobe mounted vertically to a proper depth.
NOTICEThe oil seal may be subject to damage before andduring mounting. For mounting of a new oil seal,damage or pollution should be prevented. Beforemounting the new oil seal, the oil seal should beplaced inside the package.A new flange should also be placed in a properprotective device before mounting.
ADJUSTMENT1. Adjustment of pretightening load of differentialbearingAppropriate pretightening load of differential bearingcan ensure proper operation the differential bearingand facilitate correct contact of the pinion and ringgear.
NOTICEBefore the adjustment, check that the adjusting ringscrew thread pair and the driven gear have beencleaned. For adjustment of the pretightening load,the only adjustment item is the differential adjustingring and any other operation has been finished in theabove-mentioned procedures.Tighten the left and right adjusting rings in such away that the axial positions of the adjusting rings onboth sides are approximately the same. Adjust thepretightening load of the differential bearing bymeans of the adjusting rings. The tightening torque torotate the differential assembly should be2.0~4.0Nm.
SUDPA7028L
SUDPA7029L
SUDPA7030L
SUDPA7031L
NOTICEWhen checking the pretightening load of thebearing, the bearing must have been lubricated andchecking must be done after the bearing has rotatedfor several turns.
2. Adjustment of backlash of gearsRotate the left and right adjusting rings to change theaxial position of the ring gear so as to adjust thepinion and ring gear. In order not to change thealready adjusted pretightening load of the differentialbearing, the advance and retreat amount of the leftand right adjusting rings must be equal. Measure thebacklash of the ring gear at the approximatelytrisection point. Backlash should be between 0.15and 0.30 and the backlash variation should not begreater than 0.08.
SUDPA7032L
SUDPA7033L
NOTICEIn order to reduce the backlash of the gear, theadjusting ring of the ring gear on the side with toothshould be loosened for several pitches. Theadjusting ring on the other side should be tightenedfor the same pitches. Reverse operation can becarried in order to increase the backlash.
3. Adjustment of contact pattern of pinion and ring gear
Adjustment of contact pattern of pinion and ring gearContact pattern of ring gear
Adjusting methedConvex side Concave side
Move the ring gear towardsthe pinion.If the backlash is too smallat the moment, move the pi-nion away.
Move the ring gear away fro-m the pinion.If the backlash is too large atthe moment, move the pinio-n towards the ring gear.
Move the pinion towards thering gear.If the backlash is too smallat the moment, move the rin-g gear away.
Move the pinion away from t-he ring gear.If the backlash is too large atthe moment, move the ringgear towards the pinion.
13. A/B Shim14. Bolt15. Spring Washer16. Pin17. Bolt18. Spring Washer19. Differential Collar20. Adjust Screw21. Side Bearing22. Bolt23. Differential Case, LH24. Drive Gear
25. Differential Case RH26. Differential Case Bolt27. Differential Gear28. Differential Gear Washer29. Differential Pinion Washer30. Differential Pinion31. Differential Spider32. Side Bearing Cap33. Lock Plate34. Bolt35. Spring Washer36. Bearing Cap Bolt
CAUTION• The bearing cap and the differential carrier
should be replaced as a set.
Removal1. After removing the drain plug(A), drain out the gearoil.
KMTPA610A
2. After taking off the hub bolt (A), remove the axle shaft(B).
NOTICEWhen it is hard to remove the axle shaft (B), inserthub bolts (A) into the removing screw holes evenly.
KMTPA611A
3. Remove the axle shaft at the opposite side also.4. Making an align mark (C) to the rear axle companionflange (A) and the flange yoke (B) of the rearpropeller shaft, remove the tightening bolt (D) of thepropeller shaft.
KMTPA113A
5. Disassemble the contacting surface between the rearaxle companion flange (A) and the flange yoke (B) ofthe rear propeller shaft.
CAUTIONAs this part is very heavy, be careful theprecautions. Before the working, be sure that itis supported by jack.
KMTPA613A
6. After taking off the differential carrier tightening boltand nut (A), remove the differential carrier assembly(B) from the axle housing (C).
KMTPA614A
Installation1. After installing the differential carrier assembly (B) tothe axle housing (C), tighten the differential carriertightening bolt (A) with the specified torque.
2. Setting the aligning mark (C) of the rear axlecompanion flange (A) to that of the flange yoke (B) ofthe rear propeller shaft, tighten the bolt (D) of thepropeller shaft.
4. Install the rear axle shaft of the opposite side.5. Fill in the recommended oil.
Recommended Oil: API GL-5, SAE 80W/90Oil Amount: 4.5±0.25ℓ
KMTPA661A
Disassembly1. Fix the differential carrier (A) at the vise or theworking base.
KMTPA701A
2. Remove the differential carrier bearing cap bolt (A).
KMTPA702A
3. After removing the bearing cap(A), remove the sidebearing nut (B).
KMTPA703A
4. Remove the differential carrier assembly (A) and theside bearing race (B) from the differential carriercollar (C).
KMTPA704A
5. After removing the side bearing (A), remove thedifferential case bolts (B).
KMTPA705A
6. After removing the differential case, remove thedifferential pinion, the differential pinion washer, thedifferential gear, the differential gear washer and thedifferential spider, sequentially.
7. After taking off the tightening bolt of the drive gear,disassemble the differential case and the driver gear.
8. Remove the self locking nut (A) and the companionflange (B).
KMTPA708A
9. Remove the pinion drive (A), the inner bearing (B),the space (C) and the shim (D).
KMTPA709A
10.Remove the oil seal (A) and the outer bearing (B).
KMTPA710A
11.Remove the bearing race (A), the oil stopper (B) andthe outer bearing race (C) from the differential collar.
KMTPA711A
Reassembly1. Install the outer bearing race (C), the oil stopper (B)and the bearing race (A) into the differential collar.
KMTPA711A
2. Install the outer bearing (B) and a new oil seal (A).
KMTPA710A
3. Install the shim (D), the space (C), the inner bearing(B) and the pinion drive (A).
KMTPA709A
4. Install the companion flange and the self locking nut(A).
6. After installing the differential pinion, the differentialpinion washer, the differential gear, the differentialgear washer and the differential spider, install thedifferential case.
7. After installing the differential case bolt (B), install theside bearing.
KMTPA705A
8. Install the differential carrier assembly (A) and theside bearing race (B) at the differential carrier collar(C).
KMTPA704A
9. After installing the side bearing nuts (B), install thebearing cap (A).