DRIVE AXLE REPAIR -

DRY BRAKE
S2.0-3.5FT (S40-70FT, S55FTS) [H187];
H2.0-3.5FT (H40-70FT) [P177]

PART NO. 4120526 1400 SRM 1758

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

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General .....................................................................................................................................................................1
Drive Axle Repair .................................................................................................................................................... 1
Remove and Disassemble ....................................................................................................................................1
Clean and Inspect ................................................................................................................................................4
Assemble and Install ...........................................................................................................................................4
Differential Repair .................................................................................................................................................. 7
Remove .................................................................................................................................................................7
Differential Assembly From Center Section .................................................................................................. 7
Drive Pinion, Pinion Gear, and Bearings From Center Section ................................................................. 12
Disassemble ....................................................................................................................................................... 18
Differential Assembly ....................................................................................................................................18
Drop Box Housing ..........................................................................................................................................20
Center Section ................................................................................................................................................21
Clean and Inspect ..............................................................................................................................................23
Assemble ............................................................................................................................................................ 24
Center Section ................................................................................................................................................24
Drop Box Housing ..........................................................................................................................................27
Differential Assembly ....................................................................................................................................28
Install ................................................................................................................................................................. 32
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) ...................................................................... 32
Drive Pinion, Pinion Gear, and Bearings Into Center Section ................................................................... 34
Differential Assembly Into Center Section .................................................................................................. 39
Ring Gear Backlash, Adjust ..........................................................................................................................44
Ring Gear, Runout Check ............................................................................................................................. 45
Gear Set, Tooth Contact Pattern Check .......................................................................................................46
Torque Specifications ............................................................................................................................................ 48

This section is for the following models:

S2.0-3.5FT (S40-70FT, S55FTS) [H187];

H2.0-3.5FT (H40-70FT) [P177]

©2018 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
1400 SRM 1758 General

General
This section has the repair procedures for the drive
axle and differential assembly.

Drive Axle Repair

REMOVE AND DISASSEMBLE on top of the assembly. See Figure 2 and
Figure 3.

WARNING 8. Remove the parking brake cable. Refer to the

When putting the lift truck on blocks, make sure section Brake System 1800SRM1743.
the surface is solid, even, and level. Any blocks
used to support the lift truck must be solid, one- 9. Place blocks under the axle assembly and
piece units. connect slings and lifting device.

1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift
truck.
2. Raise the lift truck and put blocks under the
frame so that the drive wheels do not touch the
floor. Put blocks under the counterweight for
stability.
10. Place blocks under the transmission to support
the transmission while removing the drive axle.
11. Remove the capscrews retaining the drive shaft
and remove the drive shaft.
12. Remove the transmission isolator mounting
bolt located on top of the assembly.

3. Remove the mast assembly as described in the 13. Remove the four mounting capscrews from the
section Mast Repair (S/N F507, F508, F562, drive axle assembly. See Figure 2 and Figure 3.
F563) 4000SRM1669.

4. Drain the oil from the drive axle.

5. Remove the drain plug and drain the oil from

the drive axle into a suitable container. See
Figure 1.

WARNING
On lift trucks with pneumatic tires, completely
remove air from tires before removing them from
lift truck. Air pressure in tires can cause tire and
rim parts to explode, which can cause serious
injury or death. Never loosen nuts that hold
together inner and outer wheel halves when there
is air pressure in tire.
1. CENTER SECTION
6. Remove the wheels. 2. DRAIN PLUG

7. Disconnect the brake line connecting the Figure 1. Drain Plug

master cylinder to the brake manifold located

1
Drive Axle Repair 1400 SRM 1758

1. UNIVERSAL JOINT 15. LOCK PLATE

2. INPUT SHAFT (YOKE) 16. LOCK NUT
3. DUST COVER 17. AXLE SHAFT
4. BRAKE MANIFOLD 18. CAPSCREW
5. BRAKE LINE, LEFT SIDE 19. PIN
6. HANGER ASSEMBLY 20. WHEEL NUT
7. BRAKE ASSEMBLY 21. HUB BOLT
8. HUB/BRAKE DRUM ASSEMBLY 22. INNER SEAL
9. CENTER SECTION HOUSING 23. ROLLER BEARING
10. O-RING 24. OUTER SEAL
11. WASHER 25. CAPSCREW
12. CAPSCREW 26. BRAKE LINE, RIGHT SIDE
13. ROLLER BEARING 27. WASHER
14. WHEEL BEARING WASHER 28. CAPSCREW

Figure 2. Drive Axle for Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (H187)

2
1400 SRM 1758 Drive Axle Repair

Figure 3. Drive Axle for Lift Truck Models H2.0-3.5FT (H40-70FT) (P177)

3
Drive Axle Repair 1400 SRM 1758

Legend for Figure 3.

1. UNIVERSAL JOINT 13. AXLE SHAFT

2. INPUT SHAFT (YOKE) 14. CAPSCREW
3. DUST COVER 15. HUB/BRAKE DRUM ASSEMBLY
4. BRAKE MANIFOLD 16. INNER SEAL
5. CENTER SECTION HOUSING 17. ROLLER BEARING
6. O-RING 18. OUTER SEAL
7. WASHER 19. CAPSCREW
8. CAPSCREW 20. BRAKE ASSEMBLY
9. ROLLER BEARING 21. BRAKE LINE
10. WHEEL BEARING WASHER 22. HANGER ASSEMBLY
11. LOCK PLATE 23. WASHER
12. LOCK NUT 24. CAPSCREW

NOTE: The drive line yoke is a slip joint and should
slide out from the differential easily.
14. Remove blocks and lower the drive axle
assembly and disengage the drive axle
assembly from the transmission.
15. Place blocks under the differential assembly.
16. Remove the axle shafts, hub/brake drum
assemblies, and back plates. Refer to the
section Brake System 1800SRM1743.
2. Place the hanger assembly in position on the
center section housing. Apply Loctite® 242 to
the capscrews and install capscrews to retain
hanger assembly. Tighten capscrews in
sequence shown in Figure 5 and Figure 6 to
90 to 99 N•m (66 to 73 lbf ft)225 to 248 N•m
(166 to 183 lbf ft). Repeat this step on the
opposite side.

17. Remove the capscrews that hold the hanger

assembly to the center section housing. Remove
the hanger assembly. Repeat this step on the
opposite side.

CLEAN AND INSPECT

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer's
recommended safety precautions.

1. Clean all the parts of the drive axle with

solvent.

2. Inspect the bearings and seals for damage.

3. 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. The splines for the axle shafts must not
1. O-RING
be damaged. 2. HANGER ASSEMBLY

ASSEMBLE AND INSTALL Figure 4. Hanger Assembly

1. Apply grease to new O-rings and install O-rings
on the hanger assemblies. See Figure 4.

4
1400 SRM 1758
Figure 5. Hanger Assembly Tightening Sequence
for Lift Truck Models S2.0-3.5FT (S40-70FT,
S55FTS) (H187)
Figure 6. Hanger Assembly Tightening Sequence
for Lift Truck Models H2.0-3.5FT (H40-70FT) (P177)
NOTE: Apply Loctite® 515 or High Performance
RTV Silicone Gasket Maker on the axle shaft flange
when installing.
3. Install the back plates, hub/brake drum
assemblies, and axle shafts. Refer to the section
Brake System 1800SRM1743.
Drive Axle Repair
4. Connect slings and lifting device to drive axle.
NOTE: When installing the drive axle, ensure the
drive axle is held with the upper surface of the drive
axle against the frame. This will prevent any gap
between the frame and the drive axle mount, and
will ensure even weight bearing distribution.
5. Position the drive axle in the lift truck. When
positioning the drive axle, slide the drive shaft
(yoke) into the drive axle assembly.
NOTE: It is recommended to use a torque multiplier
to achieve the torque specification in Step 6.
6. Install the four mounting capscrews and
washers. Tighten the capscrews to
820 to 902 N•m (605 to 665 lbf ft).
7. Place the drive shaft in position and install the
retaining capscrews. Tighten the drive shaft
capscrews to 30 to 37 N•m (22 to 27 lbf ft).
NOTE: When installing the transmission isolator,
make sure to place one washer above and below the
isolators.
8. Install the transmission isolator mounting bolt
located on top of the assembly. Tighten the bolt
to 225 to 250 N•m (166 to 184 lbf ft). See
Figure 7 and Figure 8.
9. Remove blocks from under the transmission.
10. Install the parking brake cable. Make sure the
brake cable is routed properly and has no
interference. Verify that the parking brake
operates properly. Refer to the section Brake
System 1800SRM1743.
11. Connect the brake line connecting the master
cylinder to the brake manifold located on top of
the assembly.
NOTE: Perform this step for Lift Truck Models
S2.0-3.5FT (S40-70FT, S55FTS) (H187) .
12. Install the wheels and nuts and tighten the
nuts to 340 to 380 N•m (251 to 280 lbf ft).
5
Drive Axle Repair 1400 SRM 1758

NOTE: Perform this step for Lift Truck Models

H2.0-3.5FT (H40-70FT) (P177) .
15. Remove the fill plug and fill the drive axle to
the proper level as shown in Figure 9, with
6.3 to 6.8 liter (6.6 to 7.1 qt) of SAE 80W-90
gear oil through the fill hole. Install the fill
plug.

16. Remove the air from the brake system as

described in the section Brake System
1800SRM1743.

17. Install the mast assembly as described in the

section Mast Repair (S/N F507, F508, F562,
F563) 4000SRM1669.

18. Raise the lift truck and remove blocks from

under the frame and from under the
counterweight. Lower the lift truck.

1. TRANSMISSION
2. CENTER SECTION HOUSING
3. ISOLATOR, TRANSMISSION
4. WASHER
5. LOCKWASHER
6. MOUNTING BOLT

Figure 7. Transmission to Center Section Housing

Mounting Bolt for Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (H187)

WARNING
Add air to the tires only in a safety cage. Inspect
safety cage for damage before use. When adding
air, use a clip-on chuck with enough hose to let the
operator stand clear of the cage.

NOTE: Perform this step for Lift Truck Models

H2.0-3.5FT (H40-70FT) (P177) .
NOTE: When tightening the wheel nuts, DO NOT
use any lubricant on the studs or nuts. 1. TRANSMISSION
2. CENTER SECTION HOUSING
13. Inflate the tires using a safety cage. Install the 3. ISOLATOR, TRANSMISSION
wheels and nuts and tighten the nuts to 4. WASHER
340 to 380 N•m (251 to 280 lbf ft). 5. LOCKWASHER
6. MOUNTING BOLT
14. Install the drain plug and tighten to
50 to 55 N•m (37 to 41 lbf ft). See Figure 1. Figure 8. Transmission to Center Section Housing
Mounting Bolt for Lift Truck Models H2.0-3.5FT
(H40-70FT) (P177)

6
1400 SRM 1758 Differential Repair

Legend for Figure 9.

1. OIL FILL PLUG

2. OIL FILL LEVEL

19. Remove the blocks on each side (front and

back) of the steering tires.

20. Operate the lift truck and check for proper

operation and leaks.

Figure 9. Oil Fill Level

Differential Repair
REMOVE
For the following repair procedures, the drive axle
must be removed and disassembled. Refer to the
section Drive Axle Repair.

Differential Assembly From Center Section

STEP 1.
Remove the capscrews retaining the center
section cover and remove cover.

1. CENTER SECTION COVER

2. CAPSCREW
3. CENTER SECTION

7
Differential Repair 1400 SRM 1758

NOTE: Before working on the differential assembly, inspect the hypoid gear set for damage. If inspection
shows no damage, the same gear set can be used again. Using a dial indicator, measure the backlash of the
gear set and make a record of the dimension. See the procedure Gear Set, Tooth Contact Pattern Check.
During differential reassembly, adjust the backlash to the original recorded dimension when the gear set is
installed into the center section.

STEP 2.
Remove differential assembly retainer ring
cotter pins. Using a retainer ring special tool,
Hyster Part No. 1663599 , loosen the retainer
rings. If necessary, loosen the bearing cap
capscrews to allow the retainer rings to turn
freely.

1. COTTER PIN
2. RETAINER RING

1. RETAINER RING SPECIAL TOOL

8
1400 SRM 1758 Differential Repair

STEP 3.
Mark one differential carrier leg and bearing
cap to correctly match the parts when
assembling differential assembly. Mark the
parts using a center punch and hammer.
Remove the capscrews and washers retaining
the bearing caps. Remove the bearing caps.

1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. BEARING CAP

STEP 4.
Remove the retainer rings.

1. CENTER SECTION
2. RETAINER RING

9
Differential Repair 1400 SRM 1758

STEP 5.
Loosen locknut, and remove thrust screw from
center section.

1. CENTER SECTION
2. THRUST SCREW
3. LOCKING NUT

10
1400 SRM 1758 Differential Repair

STEP 6.
Remove the differential assembly.

1. CENTER SECTION
2. DIFFERENTIAL ASSEMBLY
3. TAPERED ROLLER BEARING AND CUP

1. CENTER SECTION
2. DIFFERENTIAL ASSEMBLY
3. TAPERED ROLLER BEARING AND CUP

11
Differential Repair 1400 SRM 1758

Drive Pinion, Pinion Gear, and Bearings From Center Section

STEP 1.
Remove the snap ring from the pinion head.

1. CENTER SECTION
2. SNAP RING
3. PINION

STEP 2.
Using a press, press the bearing out of the
pinion support bracket.

1. PINION SUPPORT BRACKET

2. BEARING

12
1400 SRM 1758 Differential Repair

STEP 3.
Remove the capscrews and washers retaining
the pinion cover and remove cover.

1. CAPSCREW
2. WASHER
3. PINION NUT
4. CENTER SECTION

CAUTION
When removing the pinion nut, make sure the staked areas do not touch the pinion threads. The staked
areas can cause damage to the pinion threads, making the pinion unserviceable.

STEP 4.
Using a small and flat chisel, unstake the
pinion nut.
Remove the pinion nut and washer.

1. CENTER SECTION
2. WASHER
3. PINION NUT

13
Differential Repair 1400 SRM 1758

STEP 5.
Remove the capscrews and washers retaining
the drop box housing.

1. CENTER SECTION
2. DROP BOX
3. CAPSCREW
4. BRACKET

STEP 6.
Using two of the M8 × 1.25 × 50 capscrews
removed from the drop box housing, push the
drop box housing from the center section and
outer bearing from the pinion. If the capscrews
do not have enough threaded length, use a pry
bar to finish removing the housing.

1. INSERT M8 × 1.25 × 50 CAPSCREWS

14
1400 SRM 1758 Differential Repair

NOTE: When removing the pinion, be sure to retain the shims.

STEP 7.
Carefully remove pinion assembly from the
center section. Using a press and a bearing
puller, remove the shims and inner bearing
from the pinion.

1. CENTER SECTION
2. BEARING
3. SHIMS
4. PINION

1. PINION
2. SHIMS
3. BEARING
4. CENTER SECTION

15
Differential Repair 1400 SRM 1758

STEP 8.
Remove the driven gear.

1. DRIVEN GEAR
2. CENTER SECTION

NOTE: When removing the outer bearing, be sure to retain the shims.

STEP 9.
Remove the outer bearing and shims. Using a
press or suitable soft drift, remove the bearing
cup.

1. DROP BOX
2. BEARING CUP
3. BEARING
4. SHIMS

16
1400 SRM 1758 Differential Repair

STEP 10.
Using a suitable soft drift, remove the bearing
cup.

1. DROP BOX
2. BEARING CUP

STEP 11.
Using a suitable soft drift, remove the pinion
inner bearing cup.

1. CENTER SECTION
2. INNER BEARING CUP

17
Differential Repair 1400 SRM 1758

DISASSEMBLE
Differential Assembly
STEP 1.
Remove the bearing cups. Using a suitable
bearing puller, remove the bearings from the
differential assembly.

1. BEARING CUP
2. TAPERED ROLLER BEARING
3. DIFFERENTIAL ASSEMBLY

STEP 2.
Remove the capscrews retaining the ring gear
to the differential assembly. Using a soft
hammer, remove the ring gear.

1. RING GEAR
2. DIFFERENTIAL ASSEMBLY
3. CAPSCREW

18
1400 SRM 1758 Differential Repair

NOTE: Mark each side of the case halves before separating to ensure alignment at reassembly.

STEP 3.
Remove the capscrews retaining the case halves
together and separate the case halves.
Inspect the case halves for wear or damage. If
wear or damage is present, the entire
differential assembly must be replaced.

1. CAPSCREW
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF

STEP 4.
Remove the side gears and thrust washers from
the differential halves.

1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF

19
Differential Repair 1400 SRM 1758

STEP 5.
Remove the pinions and thrust washers from
the spider.
Inspect the spider for wear or damage. Replace
as needed.

1. THRUST WASHER
2. PINION
3. SPIDER

Drop Box Housing

STEP 1.
Remove the input shaft oil seal.

1. DROP BOX
2. OIL SEAL

20
1400 SRM 1758 Differential Repair

STEP 2.
Remove the drive gear outer bearing.

1. BEARING
2. DROP BOX

Center Section
NOTE: Only remove the breather cap and elbow fitting if they are damaged.

STEP 1.
Remove the breather cap and elbow fitting.

1. BREATHER CAP
2. ELBOW FITTING
3. CENTER SECTION

21
Differential Repair 1400 SRM 1758

NOTE: Only remove the brake manifold and bracket if they are damaged.

STEP 2.
Remove the capscrew and washer retaining the
brake manifold and bracket. Remove the brake
manifold and bracket.

1. CAPSCREW
2. WASHER
3. BRAKE MANIFOLD AND BRACKET
4. CENTER SECTION

STEP 3.
Remove the drive gear.

1. DRIVE GEAR
2. CENTER SECTION

22
1400 SRM 1758
STEP 4.
Remove the drive gear inner bearing.
1. BEARING
2. CENTER SECTION
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
Clean and inspect the following parts of the
differential:
Differential Repair
• Drive axle
- Clean the parts of the axle with solvent and
dry with compressed air. Inspect all machined
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 damaged
must be replaced.
Main differential assembly
•
- Inspect all parts of the main differential
assembly for wear or damage. Parts that are
damaged must be replaced.
23
Differential Repair 1400 SRM 1758

ASSEMBLE

Center Section
STEP 1.
Using a press on the outer race of the bearing,
press the drive gear inner bearing into the
center section until it is contacting the bottom
of the bore.

1. BEARING
2. CENTER SECTION

24
1400 SRM 1758 Differential Repair

STEP 2.
Install the drive gear. Check the orientation to
make sure the yoke will slip into the drive gear.

1. DRIVE GEAR
2. CENTER SECTION

A. TOWARD YOKE
B. TOWARD CENTER SECTION

25
Differential Repair 1400 SRM 1758

STEP 3.
Place the brake manifold and bracket in
position on the differential assembly. Install
the capscrew and washer. Tighten the capscrew
to 19 to 21 N•m (14 to 15.5 lbf ft)

1. CAPSCREW
2. WASHER
3. BRAKE MANIFOLD AND BRACKET
4. CENTER SECTION

STEP 4.
Wrap the breather cap and elbow fitting
threads with approximately 1.5 turns of Teflon
tape. Install the breather cap and elbow fitting.

1. BREATHER CAP
2. ELBOW FITTING
3. CENTER SECTION

26
1400 SRM 1758 Differential Repair

Drop Box Housing

STEP 1.
Using a press on the outer race of the bearing,
press the drive gear outer bearing into the drop
box until it is contacting the bottom of the bore.

1. BEARING
2. DROP BOX

STEP 2.
Using a press on the outer diameter of the
input shaft oil seal, press the input shaft oil
seal into the drop box until the seal is flush
with the housing.
After installing the seal, apply grease to the lip
of the seal.

1. DROP BOX
2. OIL SEAL

27
Differential Repair 1400 SRM 1758

Differential Assembly
STEP 1.
Lubricate both sides of the thrust washers with
80W - 90W gear lube. Install the pinions and
thrust washers onto the spider.

1. THRUST WASHER
2. PINION
3. SPIDER

STEP 2.
Lubricate both sides of the thrust washers with
80W - 90W gear lube. Install the side gears and
thrust washers into the differential halves.

1. CASE HALF
2. THRUST WASHER
3. SIDE GEAR
4. SPIDER ASSEMBLY
5. CASE HALF

28
1400 SRM 1758 Differential Repair

STEP 3.
Place the spider assembly into the case halves
and assemble the case halves. Apply Loctite®
242 to the threads of the capscrews and install
the capscrews. Tighten the capscrews in the
sequence shown to
125 to 145 N•m (92 to 107 lbf ft).
Make sure the backlash between the side and
pinion gears is
0.15 to 0.25 mm (0.0059 to 0.0098 in.).

1. CAPSCREW
2. CASE HALF
3. SPIDER ASSEMBLY
4. CASE HALF

29
Differential Repair 1400 SRM 1758

STEP 4.
Place the ring gear in position on the
differential assembly and install capscrews.
Tighten the capscrews in a cross/diagonal
pattern to 152 to 167 N•m (112 to 123 lbf ft).

1. RING GEAR
2. DIFFERENTIAL ASSEMBLY
3. CAPSCREW

30
1400 SRM 1758 Differential Repair

CAUTION
Do not damage the bearing rollers or cage when pressing the bearing cones onto the differential
assembly. Press on the inner raceway of the cone.

STEP 5.
Press the bearing cones onto the onto the
differential assembly. Install the bearing cups
onto the bearing cones.

1. BEARING CUP
2. TAPERED ROLLER BEARING
3. DIFFERENTIAL ASSEMBLY

31
Differential Repair 1400 SRM 1758

INSTALL
Pinion Inner Shim Set, Adjust Thickness
(Depth of Pinion)
NOTE: Use this procedure if a new ring gear and
pinion set is installed, or if the depth of the pinion
has to be adjusted.
NOTE: If replacing the center section, use a new
standard shim set with nominal thickness of 1 mm
for adjusting the depth of the pinion and a new
standard shim set with nominal thickness of 1 mm
for adjusting the preload. Perform the following
procedure until the correct backlash and gear tooth
contact pattern is achieved.
The pinion is adjusted using shims. If the same
bearings, ring gear, and pinion are used, use the
original shim set. See Figure 10. If a new bearings,
ring gear, and pinion are used, adjust the pinion as 1. PINION NUT
described below. 2. WASHER
3. BEARING
The correct shim set thickness can be found by 4. OUTER SHIM SET (CONTROLS BEARING
using the original and new parts. Use the original PRELOAD)
shim set thickness and the pinion variation number 5. GEAR
on the original and new pinion. For the location and 6. BEARING
7. INNER SHIM SET (CONTROLS DEPTH OF
identification of the number, see Figure 11. PINION)

Figure 10. Shim Set Location

1. PINION VARIATION NUMBER

Figure 11. Pinion Variation Number

32
1400 SRM 1758 Differential Repair

Find the correct thickness of the mounting distance
(inner) shim set as follows:
1. Use a micrometer to measure the total
thickness of the original shim set that was
removed from under the pinion carrier. Make a
note of the measurement for later use.
2. Check the pinion variation number for the
original pinion. See Figure 11. If this number is
a plus (+) value, subtract the value from the
value in Step 1. If the pinion variation number
is a minus (−) value, add the number to the
value in Step 1. The number shown is in 0.00 ×
inch (+2 = +0.002 in.). The result is the
standard thickness for a shim set.
NOTE: The value calculated in Step 2 is the
thickness of the standard shim set, without a
variation.
3. Check the pinion variation number for the new
pinion. Add or subtract this number to the
standard thickness value of Step 2. 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 in Table 1.
NOTE: The value calculated in Step 3 is the
thickness of the new shim set that will be installed.
See the examples shown in Table 1.

Table 1. Pinion Variation Numbers Examples

Examples in. mm
NOTE: The Pinion Variation Number is on the end of the pinion. See Figure 11.
1. Original Shim Set Thickness Original Pinion Variation 0.030 −0.002 0.76 −0.05
Number = +2 in. (+0.05 mm)
Standard Shim Set Thickness New Pinion Variation 0.028 +0.005 0.71 +0.13
Number = +5 in. (+0.13 mm)
New Shim Set Thickness = 0.033 0.84
2. Original Shim Set Thickness Original Pinion Variation 0.030 +0.002 0.76 +0.05
Number =−2 in. (−0.05 mm)
Standard Shim Set Thickness New Pinion Variation 0.032 +0.005 0.81 +0.13
Number = +5 in. (+0.13 mm)
New Shim Set Thickness = 0.037 0.94
3. Original Shim Set Thickness Original Pinion Variation 0.030 −0.002 0.76 −0.05
Number = +2 in. (+0.05 mm)
Standard Shim Set Thickness New Pinion Variation 0.028 −0.005 0.71 −0.13
Number =−5 in. (−0.13 mm)
New Shim Set Thickness = 0.023 0.58
4. Original Shim Set Thickness Original Pinion Variation 0.030 +0.002 0.76 +0.05
Number =−2 in. (−0.05 mm)
Standard Shim Set Thickness New Pinion Variation 0.032 −0.005 0.81 −0.13
Number =−5 in. (−0.13 mm)
New Shim Set Thickness = 0.027 0.68

33
Differential Repair 1400 SRM 1758

Drive Pinion, Pinion Gear, and Bearings Into Center Section

STEP 1.
Press the pinion inner bearing cup into the
center section.

1. CENTER SECTION
2. INNER BEARING CUP

STEP 2.
Press the outer bearing cup into the drop box
housing.

1. DROP BOX
2. BEARING CUP

34
1400 SRM 1758 Differential Repair

NOTE: Install the thickest shim first, next to the

pinion head.
STEP 3.
Install mounting distance (inner) shims,
determined in
Pinion Inner Shim Set, Adjust Thickness
(Depth of Pinion), and press pinion head
bearing on pinion.

1. PINION
2. SHIMS
3. BEARING

STEP 4.
Install the pinion assembly into the center
section housing.

1. CENTER SECTION
2. PINION ASSEMBLY

35
Differential Repair 1400 SRM 1758

STEP 5.
Install the driven gear onto the pinion.

1. DRIVEN GEAR
2. PINION
3. CENTER SECTION

STEP 6.
Apply sealant, Hyster Part No. 264159 or
equivalent, to the mating surface of the drop
box housing.
Place the drop box housing in position on the
center section. Install the capscrews and
washers and tighten to
19 to 23 N•m (14 to 17 lbf ft).

1. CENTER SECTION
2. DROP BOX
3. CAPSCREW
4. BRACKET

36
1400 SRM 1758 Differential Repair

NOTE: Install the thickest shim first, next to the

driven gear.
STEP 7.
Install the preload (outer) shims and outer
bearing. Install the washer and new pinion nut.
Use the pinion nut to press the outer bearing
onto the pinion.
Tighten the pinion nut to
530 to 645 N•m (391 to 476 lbf ft) to seat the
bearings. Rotate the pinion two revolutions in
both directions. Loosen the pinion nut and
retighten to 370 to 410 N•m (273 to 302 lbf ft)
for the pre-load. Rotate the pinion two
revolutions in both directions. Verify pinion
shaft rotating torque is
4.0 to 6.0 N•m (35.4 to 53.1 lbf in). Add or
remove preload (outer) shims as necessary to 1. CENTER SECTION
obtain the correct rotating torque. 2. SHIMS
3. BEARING
4. WASHER
5. PINION NUT

STEP 8.
Using a press, press on the outer race of the
bearing and press the bearing into the pinion
support bracket.

1. PINION SUPPORT BRACKET

2. BEARING

37
Differential Repair 1400 SRM 1758

STEP 9.
Place the pinion support bracket in position
and install capscrews. Tighten capscrews to
90 to 108 N•m (66 to 80 lbf ft).

1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. PINION SUPPORT BRACKET

STEP 10.
Install the snap ring on the pinion head.

1. CENTER SECTION
2. SNAP RING
3. PINION

38
1400 SRM 1758 Differential Repair

Differential Assembly Into Center Section

STEP 1.
Place the differential assembly into the center
section.

1. CENTER SECTION
2. DIFFERENTIAL ASSEMBLY
3. TAPERED ROLLER BEARING AND CUP

STEP 2.
Install the bearing caps in the same location as
removed. Install capscrews and washers.
Tighten the capscrews finger tight only.

1. CENTER SECTION
2. WASHER
3. CAPSCREW
4. BEARING CAP

39
Differential Repair 1400 SRM 1758

STEP 3.
Install the retainer rings.

1. CENTER SECTION
2. RETAINER RING

40
1400 SRM 1758 Differential Repair

STEP 4.
Using a retainer ring special tool, Hyster Part
No. 1663599 , adjust the retainer rings in equal
rotations so the backlash of the ring gear is
0.20 to 0.28 mm (0.008 to 0.011 in.). See
Ring Gear Backlash, Adjust.
Tighten each retainer ring one to two notches
past the point where the retainer makes
contact with the bearing cup.
Tighten the bearing cap capscrews to
225 to 270 N•m (166 to 199 lbf ft). Recheck the
backlash.
Check the ring gear runout. See
Ring Gear, Runout Check.
Verify that the rotating torque at the pinion
shaft has increased
0.5 to 0.7 N•m (4.4 to 6.2 lbf in). Check the
pinion and ring gear tooth contact pattern. See
Gear Set, Tooth Contact Pattern Check.
1. COTTER PIN
Install differential assembly retainer ring 2. RETAINER RING
cotter pins.

1. RETAINER RING SPECIAL TOOL

41
Differential Repair 1400 SRM 1758

STEP 5.
Stake the pinion nut with 8 mm spherical
punch until a 1 to 2 mm (0.039 to 0.079 in.) gap
is between the nut and pinion shaft at two
places. Retighten the drop box capscrews to
19 to 23 N•m (14 to 17 lbf ft).
Apply sealant, Hyster Part No. 264159 or
equivalent, to the mating surface of the pinion
cover.
Place the pinion cover in position on the drop
box and install the washers and capscrews.
Tighten the capscrews to
19 to 23 N•m (14 to 17 lbf ft).

1. CAPSCREW
2. WASHER
3. PINION NUT
4. CENTER SECTION

STEP 6.
Set the clearance between the thrust screw and
the ring gear to
0.25 to 0.38 mm (0.010 to 0.015 in.). This can be
done by setting the thrust screw so it just
contacts the ring gear and then backing the
thrust screw out 1/4 of a turn. After the
clearance is set, tighten the locking nut to
68 to 95 N•m (50 to 70 lbf ft). Verify the
clearance is still between
0.25 to 0.38 mm (0.010 to 0.015 in.).

1. CENTER SECTION
2. THRUST SCREW
3. LOCKING NUT

42
1400 SRM 1758 Differential Repair

STEP 7.
Apply sealant, Hyster Part No. 264159 or
equivalent, to the mating surface of the center
section for the center section cover.
Place the center section cover in position and
install capscrews. Tighten capscrews to
19 to 23 N•m (14 to 17 lbf ft) in the torque
sequence shown.

1. CENTER SECTION COVER

2. CAPSCREW
3. CENTER SECTION

43
Differential Repair 1400 SRM 1758

Ring Gear Backlash, Adjust 7. If the backlash reading is not within

specifications, adjust backlash as needed.
If the old gear set is installed, adjust the backlash to Continue onto Step 8 through Step 11.
the setting that was measured before the
differential assembly was disassembled. 8. Verify that the bearing cap capscrews are only
If a new gear set will be installed, adjust the finger tight.
backlash to 0.20 to 0.28 mm (0.008 to 0.011 in.).
To adjust/check the backlash, follow the steps
outlined below:

1. Install a dial indicator on the mounting flange

of the differential as shown in Figure 12.

2. Adjust the dial indicator so that the plunger or

pointer is against the tooth surface. See
Figure 12.

3. Adjust the indicator to zero.

4. Hold the drive pinion in position.

5. After reading the dial indicator, rotate the

differential and ring gear a small amount in
both directions, against the drive pinion teeth.

6. If the backlash reading is within specifications,

0.20 to 0.28 mm (0.008 to 0.011 in.), continue Figure 12. Gear Clearance Check
checking tooth contact patterns.

44
1400 SRM 1758
NOTE: To increase backlash, move ring gear away
from drive pinion. To decrease backlash, move ring
gear toward drive pinion.
NOTE: When adjusting backlash, move the ring
gear only. Do not move the drive pinion.
9. Loosen one bearing adjusting ring one notch,
then tighten the opposite ring the same
amount. See Figure 13 and Figure 14.
1. TIGHTEN RETAINER RING THIS SIDE
2. INCREASE BACKLASH
3. LOOSEN RETAINER RING THIS SIDE
Figure 13. Backlash Increase
1. LOOSEN RETAINER RING THIS SIDE
2. DECREASE BACKLASH
3. TIGHTEN RETAINER RING THIS SIDE
Figure 14. Backlash Decrease
Differential Repair
10. Tighten the bearing cap capscrews to
225 to 270 N•m (166 to 199 lbf ft). Recheck the
backlash.
11. Repeat Step 2 through Step 10 until backlash is
within 0.20 to 0.28 mm (0.008 to 0.011 in.).
12. Check the tooth contact pattern. See
Gear Set, Tooth Contact Pattern Check.
13. Check the ring gear runout. See
Ring Gear, Runout Check.
Ring Gear, Runout Check
1. Attach a dial indicator to the mounting flange
of the differential assembly as shown in
Figure 15.
1. DIAL INDICATOR
Figure 15. Ring Gear Runout Check
2. Adjust the dial indicator so that the plunger or
pointer is against the back surface of the ring
gear.
3. Set the indicator to zero.
4. Rotate the ring gear and check the dial
indicator for the maximum needle movement.
The maximum movement permitted is
0.20 mm (0.008 in.).
5. If the movement exceeds the maximum limit,
remove the differential and ring gear assembly
from the differential assembly and find the
reason for the movement.
6. Install the differential and ring gear into the
differential assembly after the parts are
repaired or replaced.
45
Differential Repair 1400 SRM 1758

Gear Set, Tooth Contact Pattern Check
NOTE: The gear clearance can be changed within
the limits of 0.20 to 0.28 mm (0.008 to 0.011 in.).
NOTE: If the original gear set is installed, adjust
the clearance to the original value recorded in
Differential Assembly From Center Section. If a new
gear set is installed, adjust the retainer rings for
0.20 to 0.28 mm (0.008 to 0.011 in.) clearance. Refer
to Table 2.

Table 2. Ring and Pinion Tooth Contact Adjustment

1. Apply a colored dye or grease to approximately
12 of the ring gear teeth.
2. Rotate ring gear forward and backward so that
the 12 gear teeth go past the drive six times to
get to the contact patterns. Repeat if needed to
get a clearer pattern.
3. Check the tooth contact pattern on the ring
gear. See Table 3 and Table 4. Make sure that
the pattern is checked on the side of the tooth
where the pinion applies the force in the for-
ward direction.

Table 3. Correct Tooth Contact

The contact area is the center between the top and NOTE: Normal pattern during adjustment shown.
bottom of the tooth. The contact area is toward the
inner circumference of the ring gear.

46
1400 SRM 1758 Differential Repair

Table 3. Correct Tooth Contact (Continued)

The contact area is the center between the top and NOTE: Wear pattern from operation shown.
the bottom of the tooth. The contact area will be al-
most the full length of the tooth.

Table 4. Incorrect Tooth Contact

The pinion is too far away from the center of the
gear. Add shims to move pinion toward ring gear.
Check that the clearance is correct. Some movement
of ring gear away from pinion may be necessary.

47
Torque Specifications 1400 SRM 1758

Table 4. Incorrect Tooth Contact (Continued)

The pinion is too close to the center of the ring gear.
Remove shims to move pinion away from the ring
gear. Check that the clearance is correct. Some move-
ment of the ring gear toward the pinion may be nec-
essary.

Assemble and install the drive axle. Refer to the

section Drive Axle Repair.

Torque Specifications
Axle Shaft Capscrews Hanger Assembly to Center Section Housing
90 to 108 N•m (66 to 80 lbf ft) 225 to 248 N•m (166 to 183 lbf ft)

Bearing Cap Capscrews Hanger Assembly to Frame

225 to 270 N•m (166 to 199 lbf ft) 820 to 902 N•m (605 to 665 lbf ft)

Brake Assembly to Axle Mount Capscrews Pinion Cover Capscrews

255 to 306 N•m (188 to 226 lbf ft) 19 to 23 N•m (14 to 17 lbf ft)

Brake Manifold to Center Section Housing Pinion Nut, for Pre-Load

Capscrews
19 to 21 N•m (14 to 15.5 lbf ft)
Differential Carrier Halves Capscrews
125 to 145 N•m (92 to 107 lbf ft)
Differential Cover Capscrews
19 to 23 N•m (14 to 17 lbf ft)
Drain Plug
50 to 55 N•m (37 to 41 lbf ft)
Drive Shaft Capscrews
30 to 37 N•m (22 to 27 lbf ft)
Drop Box Housing Capscrews
19 to 23 N•m (14 to 17 lbf ft)
370 to 410 N•m (273 to 302 lbf ft)
Pinion Nut, to Seat Bearings
530 to 645 N•m (391 to 476 lbf ft)
Pinion Support Bracket Capscrews
90 to 108 N•m (66 to 80 lbf ft)
Ring Gear Capscrews
152 to 167 N•m (112 to 123 lbf ft)
Thrust Screw Locking Nut
68 to 95 N•m (50 to 70 lbf ft)
Transmission Mount Bolt to Center Section
Housing
225 to 250 N•m (166 to 184 lbf ft)

48
1400 SRM 1758 Torque Specifications

Wheel Nuts
450 to 500 N•m (332 to 369 lbf ft)

49
 NOTES

50
 TECHNICAL PUBLICATIONS

1400 SRM 1758 2/18 (12/14)