Eixo Diferecial

DRIVE AXLE AND
DIFFERENTIAL
ASSEMBLY REPAIR
(WET BRAKE)
H6.0FT, H7.0FT (H135FT, H155FT)
[H006, J006, K006, L006];
H8.0FT, H8.0FT9, H9.0FT
(H170FT, H175FT36, H190FT)
[A299, B299, C299]
PART NO. 1661537 1400 SRM 1344

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
Identification Plate ..............................................................................................................................................1
Drive Axle Removal .................................................................................................................................................1
Planetary Reduction Gear Repair ........................................................................................................................ 12
Remove and Disassemble ..................................................................................................................................12
Clean and Inspect ..............................................................................................................................................21
Assemble and Install .........................................................................................................................................21
Brake Repair ..........................................................................................................................................................29
Wet Brake Noise Reduction .............................................................................................................................. 53
General ...........................................................................................................................................................53
Adding Additive To Transmission ................................................................................................................ 54
Differential Repair ................................................................................................................................................ 54
Remove ...............................................................................................................................................................55
Disassemble ....................................................................................................................................................... 60
Assemble ............................................................................................................................................................ 67
Install ................................................................................................................................................................. 74
Bevel Pinion ...........................................................................................................................................................78
Drive Axle Installation ..........................................................................................................................................92
Special Tools ........................................................................................................................................................ 102
Torque Specifications .......................................................................................................................................... 103
This section is for the following models:
H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006, L006];

H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) [A299, B299, C299]
©2018 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
1400 SRM 1344 General
General
This manual covers the repair of the drive axle,
differential, and the wet disc brakes.
IDENTIFICATION PLATE
See Figure 1.
1. DANA PART NUMBER

2. DANA SERIAL NUMBER
3. HYSTER PART NUMBER
4. AXLE OVERALL RATIO
Figure 1. Identification Plate
Drive Axle Removal

Mast Repair (S/N A513, A514, A613, A614,
WARNING A643, A644, A683, A684) 4000SRM1406 for
When putting the lift truck on blocks, make sure lift truck models.
the surface is solid, even, and level. Any blocks • H8.0FT, H8.0FT9, H9.0FT (H170FT,
used to support the lift truck must be solid, one- H175FT36, H190FT) (A299, B299)
piece units. Mast Repair (S/N A613, A614, A643, A644,
A683, A684) 4000SRM1956for lift truck models
1. Put blocks on each side (front and back) of the
steering tires to prevent movement of the lift • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
truck. Mast Repair (S/N A613, A614, A643, A644,
A683, A684) 4000SRM1956 for lift truck
2. Raise the lift truck and put blocks under the
models
frame so that the drive wheels do not touch the
floor. Put blocks under the counterweight for • H8.0FT, H8.0FT9, H9.0FT (H170FT,
stability. H175FT36, H190FT) (C299)
3. Remove the mast assembly as described in the

section WARNING
Mast Repairs, 2- and 3-Stage Masts (S/N Completely remove air from tires before removing
A513, A514, A613, A614, A702, A703, A704, them from lift truck. Air pressure in tires can cause
A705, A706, A707, A751, A752, B513, B514, tire and rim parts to explode, which can cause
B586, B587, B588, B589, B590, B591, B749, serious injury or death. Never loosen nuts that
B750, B751, B752, B753, B754) hold together inner and outer wheel halves when
4000SRM1250 for lift truck models there is air pressure in tire.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006, 4. Remove the air from the tires and remove the
J006, K006) wheels.
1
Drive Axle Removal 1400 SRM 1344
NOTE: Perform Step 5 through Step 23 for lift 13. Disconnect the drive axle to transmission
truck models H6.0FT, H7.0FT (H135FT, H155FT) cooling return hose from the manifold on the
(H006, J006, K006, L006) . drive axle. See Figure 3.
5. Remove the drive axle main housing center fill/
14. Disconnect the transmission to drive axle
level plug and O-ring. See Figure 2.
cooling supply hose from the manifold on the
drive axle. See Figure 3.
6. Remove the oil fill plugs and O-rings on both
sides of the drive axle. See Figure 2.
15. Place blocks under the axle assembly and
connect slings and lifting device.
7. Remove the oil drain plugs on both sides of the
drive axle. Drain the oil into a suitable
16. Remove the capscrews retaining the drive
container. See Figure 2.
shaft. Remove the drive shaft.
8. Remove the drive axle main housing center
17. Remove the four mounting capscrews and
drain plug. Drain the oil into a suitable
washers from the drive axle. See Figure 4.
18. Remove blocks and lower the drive axle
9. Remove the parking brake cables. Refer to the
assembly. Pull axle forward and away from
section
frame.
Brake System - DANA 1800SRM1247 for lift
truck models 19. Place blocks under the differential assembly.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
20. Disconnect the cooling hoses from the manifold
J006, K006)
and drive axle. Remove the cooling hoses. See
Wet Brake System 1800SRM1977 for lift Figure 5.
truck models
• H6.0FT, H7.0FT (H135FT, H155FT) (L006) 21. Disconnect the brake cooling lines from the
manifold and the drive axle. Remove the brake
10. Disconnect the brake supply line from the cooling lines. See Figure 5.
brake line cross fitting on the drive axle. See
Figure 3. 22. Remove the socket head screws retaining the
brake manifold to the drive axle. Remove the
11. Disconnect the accumulator/brake booster manifold. See Figure 5.
supply line from the manifold on the drive axle.
See Figure 3. 23. Disconnect the brake lines from the drive axle.
Remove the brake lines with cross fitting, as an
12. Disconnect the brake booster return line from assembly, from the drive axle. See Figure 5.
the manifold on the drive axle. See Figure 3.
NOTE: Note placement of hose clamps prior to

removal of hoses to aid in installation.
2
1400 SRM 1344 Drive Axle Removal
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE
Figure 2. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models, H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006)
3
Figure 3. Drive Axle and Brake Cooling Lines and Brake Lines for Lift Truck Models, H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006, L006)
4
Legend for Figure 3.
1. ACCUMULATOR 6. BRAKE LINE, LEFT SIDE

2. TRANSMISSION TO DRIVE AXLE COOLING 7. ACCUMULATOR/BRAKE BOOSTER SUPPLY LINE
SUPPLY HOSE 8. BRAKE BOOSTER RETURN LINE
3. DRIVE AXLE TO TRANSMISSION COOLING 9. BRAKE SUPPLY LINE
RETURN HOSE 10. BRAKE COOLING LINE, RIGHT SIDE
4. DRIVE AXLE COOLING RETURN HOSE, LEFT 11. BRAKE LINE, RIGHT SIDE
SIDE 12. DRIVE AXLE COOLING RETURN HOSE, RIGHT
5. BRAKE COOLING LINE, LEFT SIDE SIDE
1. CAPSCREW 3. DRIVE AXLE

2. WASHER
Figure 4. Drive Axle Mounting Capscrews
5
Figure 5. Manifold and Cooling Hoses Removal for Lift Truck Models, H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006)
6
1. MANIFOLD 6. CROSS FITTING

2. DRIVE AXLE COOLING RETURN HOSE, LEFT 7. BRAKE COOLING LINE, RIGHT SIDE
SIDE 8. BRAKE LINE, RIGHT SIDE
3. BRAKE COOLING LINE, LEFT SIDE 9. DRIVE AXLE COOLING RETURN HOSE, RIGHT
4. BRAKE LINE, LEFT SIDE SIDE
5. SOCKET HEAD SCREWS
NOTE: Perform Step 24 through Step 43 for lift 26. Remove drive axle main housing center drain
truck model H8.0FT, H8.0FT9, H9.0FT (H170FT, plug from main housing, Drain oil into suitable
H175FT36, H190FT) (A299, B299, C299) . container. See Figure 6.
24. Remove drive axle main housing center fill plug
from main housing. See Figure 6.
25. Remove right side and left side drain plugs

from drive axle. Drain oil into suitable
7
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 3. RIGHT SIDE DRAIN PLUG
PLUG 4. LEFT SIDE DRAIN PLUG
2. DRIVE AXLE MAIN HOUSING CENTER FILL 5. RIGHT SIDE FILL PLUG
PLUG 6. LEFT SIDE FILL PLUG
Figure 6. Drive Axle Drain and Fill Plugs for Lift Truck Models, H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299, C299)
8
27. Remove the parking brake cables. Refer to the 28. Disconnect load sense in and load sense out
section hose assemblies from accumulator charge
valve. See Figure 7.
Brake System - DANA 1800SRM1247 for lift
truck models
29. Disconnect brake line from modulating brake
• H8.0FT, H8.0FT9, H9.0FT (H170FT, valve. See Figure 7.
H175FT36, H190FT) (A299, B299)
Wet Brake System 1800SRM1977 for lift 30. Disconnect hydraulic pressure supply hose
truck models from accumulator charge valve. See Figure 7.
• H8.0FT, H8.0FT9, H9.0FT (H170FT, 31. Disconnect hydraulic return hose from
H175FT36, H190FT) (C299) accumulator charge valve and modulating
brake valve. See Figure 7.
NOTE: Note placement of hose clamps prior to
removal of hoses to aid in installation.
9
Figure 7. Drive Axle, Manifold, Cooling Hoses, and Brake Lines for Lift Truck Models, H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299, C299)
10
A. REAR VIEW B. FRONT VIEW
1. MODULATING BRAKE VALVE 9. MANIFOLD

2. BRAKE LINE 10. DRIVE AXLE
3. LOAD SENSE IN HOSE ASSEMBLY 11. COOLING RETURN TO TRANSMISSION HOSE
4. LOAD SENSE OUT HOSE ASSEMBLY 12. COOLING SUPPLY FROM TRANSMISSION HOSE
5. ACCUMULATOR CHARGE VALVE 13. AXLE VENT LINE
6. HYDRAULIC PRESSURE SUPPLY HOSE 14. COOLING SUPPLY LINES
7. HYDRAULIC RETURN HOSE 15. SOCKET HEAD SCREW
8. COOLING RETURN HOSE 16. BRAKE LINE
32. Place blocks under the axle assembly. Connect 38. Disconnect cooling return to transmission hose
slings and lifting device to axle assembly. from manifold. See Figure 7.
33. Remove the capscrews and the drive shaft from 39. Disconnect cooling supply from transmission
the drive axle. hose from manifold. See Figure 7.
34. Remove the four mounting capscrews and 40. Disconnect axle vent line from drive axle. See
washers from the drive axle. See Figure 8. Figure 7.
35. Remove blocks and lower the drive axle 41. Remove cooling supply lines from manifold and
assembly. Pull axle forward and away from drive axle. See Figure 7.
frame.
42. Remove two socket head screws and manifold
36. Place blocks under the differential assembly. from drive axle. See Figure 7.
37. Remove cooling return hoses from manifold and 43. Disconnect brake lines from drive axle. Remove
drive axle. See Figure 7. brake lines with cross fitting, as an assembly,
from drive axle. See Figure 7.

2. WASHER
11
Planetary Reduction Gear Repair 1400 SRM 1344
Planetary Reduction Gear Repair
REMOVE AND DISASSEMBLE

Refer to Figure 9 and Figure 10 for the following repair procedures.
1. CAPSCREW 14. INNER BEARING

2. OUTER AXLE SHAFT 15. SEAL
3. O-RING 16. HALF SHAFT - SHORT OR LONG
4. PLANETARY GEAR CARRIER 17. CAPSCREW
5. BEARING 18. SHOULDER RING
6. CENTERING RING 19. SOCKET HEAD SCREW
7. RETAINING SCREW 20. WHEEL HUB SUPPORT
8. PLANETARY GEAR 21. RING CASE
9. RETAINING RING 22. RIGHT AXLE CASE
10. SUN GEAR 23. PLUG
11. OUTER BEARING 24. HEXAGON BOLT
12. WHEEL HUB 25. MAGNET PLUG
13. WHEEL STUD 26. LEFT AXLE CASE
Figure 9. Planetary Reduction Gear Assembly for Lift Truck Models, H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299, C299)
12
1400 SRM 1344 Planetary Reduction Gear Repair
1. O-RING 14. WHEEL HUB

2. OIL LEVEL PLUG 15. BEARING
3. DRIVE AXLE HOUSING ARM 16. SEAL
4. CAPSCREW 17. CAPSCREW
5. O-RING 18. OUTER AXLE SHAFT
6. RING GEAR 19. O-RING
7. WHEEL HUB SUPPORT 20. PLANETARY GEAR CARRIER
8. AXLE SHAFT 21. CENTERING RING
9. SOCKET HEAD SCREW 22. RETAINING SCREW
10. SHOULDER RING 23. SUN GEAR
11. CAPSCREW 24. DRAIN PLUG
12. WHEEL STUD 25. RETAINING RING
13. BEARING 26. PLANETARY GEAR
Figure 10. Planetary Reduction Gear Assembly for Lift Truck Models, H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006)
13
STEP 1.
Connect an overhead lifting device to the
planetary reduction gear assembly.
NOTE: Make an alignment mark on the axle housing and planetary carrier cover before removing the
planetary carrier cover.
STEP 2.
Remove the socket head screws retaining the
planetary carrier cover to the axle housing.
1. SOCKET HEAD SCREW
NOTE: Planetary gear images shown in Step 3 through Step 9 are for lift truck models H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006, L006) . Lift truck models H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (A299, B299, C299) , have four planetary gears.
14
STEP 3.
Remove complete planetary carrier assembly
from axle housing.
1. AXLE HOUSING
2. PLANETARY CARRIER ASSEMBLY
STEP 4.
Remove and discard the O-ring from the
planetary carrier assembly.
1. O-RING
STEP 5.
Remove the retaining rings retaining the
planetary gears.
1. RETAINING RING
2. PLANETARY GEAR
15
STEP 6.
Remove the planetary gear and bearing
assemblies.
1. PLANETARY GEAR AND BEARING ASSEMBLY
STEP 7.
Remove the ring gear.
1. RING GEAR
STEP 8.
Remove the retaining screw and centering ring.
1. RETAINING SCREW
2. CENTERING RING
16
STEP 9.
Remove the planetary gear carrier.
1. PLANETARY GEAR CARRIER
STEP 10.
Place the reduction gear assembly upside down.
Remove the capscrews retaining the outer axle
shaft to the wheel hub.
1. CAPSCREW
STEP 11.
Using a plastic hammer, tap the outer axle
shaft out of the wheel hub support and wheel
hub.
1. OUTER AXLE SHAFT
17
STEP 12.
Remove and discard the O-ring from the outer
axle shaft.
1. O-RING
STEP 13.
Remove the capscrews retaining the shoulder
ring.
1. CAPSCREW
STEP 14.
Remove the shoulder ring.
1. SHOULDER RING
NOTE: Use a cylindrical block, with a minimum outside diameter of 99 mm (3.90 in.) and maximum outside
diameter of 118 mm (4.65 in.), for the puller to push against the end of the wheel hub support.
18
STEP 15.
Using a suitable puller and cylindrical block,
disengage the wheel hub support from the
wheel hub.
1. WHEEL HUB
2. WHEEL HUB SUPPORT
STEP 16.
Remove the outer bearing cone.
1. OUTER BEARING CONE
STEP 17.
Remove the seal from the hub.
19
STEP 18.
Remove the inner bearing cone.
1. INNER BEARING CONE
STEP 19.
Remove the inner and outer bearing cups from
the wheel hub.
1. BEARING CUP
STEP 20.
Remove the intermediate disc.
NOTE: Make a note of the order of the brake discs and friction plates to ensure proper assembly.
20
STEP 21.
Remove the sun gear, brake discs, and friction
plates.
CLEAN AND INSPECT 2. Inspect the bearings and bearing cups for
damage. If either bearing or bearing cup is
damaged, replace both bearings and bearing
WARNING cups.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 3. Inspect the all parts for wear and damage.
solvents, always follow the solvent manufacturer's Replace parts as needed.
recommended safety precautions.
4. Inspect the brake discs and friction plates as
1. Clean all the parts with solvent. described in the section Brake Repair. Replace
as needed.
ASSEMBLE AND INSTALL

Refer to Figure 9 and Figure 10 for the following repair procedures.
STEP 1.
Install the sun gear.
21
NOTE: Install brake discs and friction plates in sequence noted during disassembly.
STEP 2.
Lightly lubricate the brake discs and friction
plates with John Deere JDM J20C.
Install the first friction plate.
1. FRICTION PLATE
STEP 3.
Install the first brake disc.
1. BRAKE DISC
STEP 4.
Before installing the last friction plate and the
intermediate disc, apply a thin coat of grease on
the contact surfaces to hold them in position
when mounting the planetary reduction gear
assembly.
22
STEP 5.
Position the wheel hub under a press. Lubricate
the inner and outer bearing cups with John
Deere JDM J20C. Using the press and special
tool T9, press the bearing cups into the wheel
hub.
1. INNER BEARING CUP

2. WHEEL HUB
3. SPECIAL TOOL T9
STEP 6.
Lubricate the inner bearing cone with John
Deere JDM J20C.
Position the inner bearing cone into the bearing
cup.
NOTE: Verify that the seal is correctly oriented.
STEP 7.
Position the seal in the special tool T10.
1. SEAL
2. SPECIAL TOOL T10
23
STEP 8.
Position special tool T10 and seal on the wheel
hub. Using the press, press the seal into its
seat.
1. SEAL
2. SPECIAL TOOL T10
STEP 9.
Place the wheel hub in position on the wheel
hub support.
Using a plastic hammer, lightly hammer all
around the edge of the wheel hub until the
bearing cone is seated in the bearing cup.
1. WHEEL HUB
STEP 10.
Lubricate the outer bearing cone with John
Deere JDM J20C and install the outer bearing
cone.
around the inner edge of the bearing cone until
the bearing cone is seated in the bearing cup.
24
STEP 11.
Install the shoulder ring.
STEP 12.
Apply Loctite® 242 to the threads of the
capscrews and install the capscrews. Tighten
the capscrews in two stages in a crisscross
pattern to a final torque of
68 to 75 N•m (50 to 55 lbf ft).
STEP 13.
Lubricate a new O-ring with a lithium based
grease. Install the O-ring on the outer axle
shaft.
1. O-RING
25
STEP 14.
Install the outer axle shaft while aligning the
holes in the outer axle shaft with the holes in
the wheel hub.
STEP 15.
Apply Loctite® 242 to the threads of all the
capscrews. Install the capscrews.
Tighten the capscrews in two stages using a
crisscross pattern to a final torque of
182 to 202 N•m (134 to 149 lbf ft).
1. CAPSCREW
NOTE: Planetary gear images shown in Step 16 through Step 22 are for lift truck models H6.0FT, H7.0FT
STEP 16.
Install the planetary gear carrier onto the outer
axle shaft.
26
STEP 17.
retaining screw. Install the retaining screw and
centering ring. Tighten the retaining screw to
116 to 128 N•m (86 to 94 lbf ft).
1. RETAINING SCREW
2. CENTERING RING
CAUTION
The jointed portion of the internal ring of the bearing must face the bottom of the pin.
STEP 18.
Fit the planetary gears onto the pins of the
planetary gear carrier.
1. PLANETARY GEAR
27
STEP 19.
Install the retaining rings to lock the planetary
gears in position.
1. PLANETARY GEAR
2. RETAINING RING
STEP 20.
grease. Install the O-ring on the ring gear.
1. O-RING
STEP 21.
Install the ring gear onto the planetary gears
and wheel hub.
around the ring gear until ring gear is seated
onto the planetary gears.
1. RING GEAR
28
STEP 22.
1. O-RING
STEP 23.
planetary reduction gear assembly. Attach the
planetary reduction gear assembly to the axle
housing.
STEP 24.
Apply Loctite® 242 to the threads of the socket
head screws. Install the socket head screws to
retain the planetary reduction gear assembly to
the axle housing.
Tighten the socket head screws in two stages
using a crisscross pattern to a final torque of
129 to 143 N•m (95 to 105 lbf ft).
29
Brake Repair 1400 SRM 1344
Brake Repair

Refer to Figure 11 and Figure 12 for the following procedures.
Figure 11. Brake Assembly for Lift Truck Models, H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006,
L006)
30
1400 SRM 1344 Brake Repair
1. SOCKET HEAD SCREW 15. DRIVE AXLE MAIN HOUSING

2. WASHER 16. DISC (PART OF PISTON ASSEMBLY)
3. PARKING BRAKE LEVER 17. TUBE (PART OF PISTON ASSEMBLY)
4. NUT 18. O-RING
5. ADJUSTING SCREW 19. O-RING
6. SOCKET HEAD SCREW 20. PISTON
7. THRUST BUSHING 21. RETURN SPRING
8. CAP 22. SOCKET HEAD SCREW
9. BLEEDER VALVE 23. FRICTION PLATES
10. O-RING 24. INTERMEDIATE DISC
11. BEARING 25. BRAKE DISCS
12. THRUST LEVER 26. SOCKET HEAD/PIN SCREW
13. BEARING 27. AUTOMATIC REGULATION SPRING
14. OIL BREATHER 28. DOWEL PIN
31
Figure 12. Brake Assembly for Lift Truck Models, H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT)
(A299, B299, C299)
32
1. PARKING BRAKE LEVER 15. O-RING

2. WASHER 16. O-RING
3. SOCKET HEAD SCREW 17. SOCKET HEAD SCREW
4. THRUST BUSHING 18. FRICTION PLATES
5. BEARING 19. PLUG
6. DISC 20. BLEEDING BOLT
7. PISTON 21. THRUST LEVER
8. SOCKET HEAD SCREW 22. SPACER
9. GRUB BOLT 23. SPRING
10. NUT 24. BRAKE DISC
11. O-RING 25. INTERMEDIATE DISC
12. PLUG 26. MAIN HOUSING
13. RETURN SPRING 27. SOCKET HEAD/PIN SCREW
14. DOWEL
STEP 1.
planetary reduction gear assembly.
STEP 2.
planetary carrier cover to the axle housing.
33
NOTE: Planetary gear images shown in Step 3 and Step 4 are for lift truck models H6.0FT, H7.0FT
STEP 3.
Remove the complete planetary carrier
assembly from the axle housing.
1. AXLE HOUSING
2. PLANETARY CARRIER ASSEMBLY
STEP 4.
Remove and discard the O-ring from the
planetary carrier assembly.
1. O-RING
STEP 5.
Remove the intermediate disc.
34
NOTE: Make a note of the order of the brake discs and friction plates to ensure proper assembly.
STEP 6.
Remove the sun gear, brake discs, and friction
plates.
STEP 7.
Verify that no brake discs or friction plates
remain in the axle housing.
1. FRICTION PLATE
STEP 8.
Remove the axle shaft.
35
STEP 9.
Remove the socket head screws and return
springs from the piston.
1. PISTON
2. RETURN SPRING AND SOCKET HEAD SCREW
STEP 10.
Remove the socket head/pin screws that guide
the piston.
1. PISTON
2. SOCKET HEAD/PIN SCREW
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.
CAUTION
Hold onto the piston as it may be suddenly ejected and damaged.
36
STEP 11.
Slowly apply compressed air through the brake
fluid port to extract the entire piston.
1. PISTON
NOTE: The O-rings must be replaced each time the unit is disassembled.
STEP 12.
Remove and discard the O-rings from the
piston.
1. O-RING
2. O-RING
NOTE: If replacing the brake discs and/or piston seals only, go to Clean and Inspect and then
Assemble and Install, Step 5.
37
STEP 13.
Remove the socket head screw and washer
retaining the parking brake lever to the thrust
lever.

2. WASHER
3. PARKING BRAKE LEVER
38
STEP 14.
Mark the position of the parking brake lever in
relation to the thrust lever.
Remove the parking brake lever.

2. ALIGNMENT MARK
39
NOTE: Prior to removing thrust bushing, clean

area around thrust bushing to prevent dirt from
entering area containing the thrust lever when
thrust bushing is removed.
STEP 15.
thrust bushing to the axle housing.

2. THRUST BUSHING
40
STEP 16.
Remove the thrust bushing.
1. THRUST BUSHING
STEP 17.
Remove and discard O-rings from the thrust
bushing.
1. O-RING
2. O-RING
41
STEP 18.
Mark the position of the thrust lever.
1. THRUST LEVER
STEP 19.
Remove the thrust lever and bearings.
1. BEARING
2. THRUST LEVER
3. BEARING
STEP 20.
Using a press, remove the bearings from the
thrust lever.
1. THRUST LEVER
2. BEARING
3. BEARING
42
CLEAN AND INSPECT 3. Inspect the all parts for wear, damage, and
rust. Replace parts as needed.
WARNING 4. Inspect the brake disc(s). Replace discs when

Cleaning solvents can be flammable and toxic and the groove depth thickness is less than
can cause skin irritation. When using cleaning 0.1 mm (0.0039 in.).
solvents, always follow the solvent manufacturer's The groove depth thickness for a new disc is
recommended safety precautions. 0.3 to 0.5 mm (0.0118 to 0.0197 in.).
1. Clean all the parts with solvent.
2. Inspect the bearings for wear or damage.

Replace as needed.

NOTE: If replacing the brake discs and/or piston seals only, go to Step 5.
WARNING
Hot parts. Wear protective clothing and gloves to prevent burns.
STEP 1.
Heat the bearings to approximately
100°C (212°F). Install the bearings on the
thrust lever.
1. BEARING
STEP 2.
Lubricate the thrust lever and bearings with
John Deere JDM J20C. Install the thrust lever
in position previously marked during removal.
43
STEP 3.
Lubricate new O-rings with a lithium based
grease. Install the O-rings on the thrust
bushing.
For lift truck models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006, L006) pack the
area above O-ring with multipurpose grease
with 2% to 4% molybdenum disulfide prior to
installing thrust bushing onto thrust lever.
1. O-RING
2. O-RING
3. APPLY MULTIPURPOSE GREASE HERE
STEP 4.
Install the thrust bushing.
Apply Loctite® 242 to the socket head screws.
Install the socket head screws. Tighten socket
head screws to
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft).

2. THRUST BUSHING
NOTE: Make sure the stroke automatic springs are installed flush in the piston.
44
STEP 5.
Install the stroke automatic regulation springs
flush in the piston.
1. PISTON
2. STROKE AUTOMATIC REGULATION SPRING
NOTE: The oil passage must face downwards when installed.
STEP 6.
Lubricate new O-rings with a lithium based
grease. Install new O-rings onto the piston.
1. O-RING
2. O-RING
STEP 7.
Lubricate the piston seating surface with
Dexron III oil.
NOTE: The oil passage must face downwards when installed.
45
STEP 8.
Install the piston into the axle housing. Verify
that the oil passage is towards the bottom.
1. OIL PASSAGE
CAUTION
When installing the piston, ensure that all components are free of moisture and that no water enters the
brake oil circuit.
STEP 9.
Lightly tap around the edge of the piston with a
plastic hammer until the piston is seated.
1. PISTON
NOTE: The threaded holes must be free of oil.
46
STEP 10.
head/pin screws.
Install the socket head/pin screws. Tighten
socket head/pin screws to
5 to 7 N•m (44 to 62 lbf in).
1. SOCKET HEAD/PIN SCREW
NOTE: The threaded holes must be free of oil.
STEP 11.
Apply Loctite® 270 to the threads of the return
spring socket head screws.
Install the socket head screws and return
springs. Tighten socket head screws to
5 to 7 N•m (44 to 62 lbf in).
1. SOCKET HEAD SCREW AND RETURN SPRING
STEP 12.
Install the axle shaft.
47
STEP 13.
Install the sun gear.
1. SUN GEAR
NOTE: Install brake discs and friction plates as noted during disassembly.
STEP 14.
Lightly lubricate the brake discs and friction
plates with John Deere JDM J20C.
Install the first friction plate.
1. FRICTION PLATE
STEP 15.
Install the first brake disc.
1. BRAKE DISC
48
STEP 16.
Before installing the last friction plate and the
intermediate disc, apply a thin coat of grease on
the contact surfaces to hold them in position
when mounting the planetary reduction gear
assembly.
NOTE: Planetary gear images shown in Step 17 are for lift truck models H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006, L006) . Lift truck models H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299, C299) , have four planetary gears.
STEP 17.
1. O-RING
STEP 18.
planetary reduction gear assembly. Attach the
planetary reduction gear assembly to the axle
housing.
49
STEP 19.
head screws. Install the socket head screws to
retain the planetary reduction gear assembly to
the axle housing.
Tighten the socket head screws in two stages
using a crisscross pattern to a final torque of
129 to 143 N•m (95 to 105 lbf ft).
STEP 20.
Install the parking brake lever by aligning the
marks made during Step 14,
Remove and Disassemble.

2. ALIGNMENT MARK
50
STEP 21.
Turn the parking brake lever until the
adjusting springs correctly regulate the piston
stroke.
STEP 22.
Position the parking brake levers as shown.
51
STEP 23.
Install the socket head screw and washer to
retain the parking brake lever to the thrust
lever. Tighten the socket head screw to
23.8 to 26.2 N•m (17.6 to 19.3 lbf in).

2. WASHER
STEP 24.
Apply light pressure to the parking brake lever
to bring the thrust lever to rest with the piston,
without pre-loading the inside band.
Adjust the adjusting screw to draw near to the
parking brake lever, leaving a
0.05 to 0.15 mm (0.00197 to 0.00591 in.) gap.
52
CAUTION
The idle stroke should be eliminated without pre-loading the parking brake levers.
CAUTION
After the drive axle is installed and the parking brake cables are connected and the brakes are released,
verify that the parking brake levers lean against the adjusting screws.
STEP 25.
Lock the adjusting screw in position by
tightening the nut to
20 to 25 N•m (14.75 to 18.44 lbf ft).
1. ADJUSTING SCREW
2. NUT
WET BRAKE NOISE REDUCTION of the following manuals to determine the capacity
of each drive axle housing arm.
General
Capacities and Specifications 8000SRM1320 for
Brake noise may occur during the first 50 hours of lift truck models
operation on new lift trucks equipped with a wet
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
brake axle, or on lift trucks where a new wet brake
J006)
axle is installed. This noise may appear in various
forms as either a squeal, grunt/groan, or a Capacities and Specifications 8000SRM1584 for
shuddering noise as brakes are applied. lift truck models
An additive oil (Hyster Part No. 1614088) is • H6.0FT, H7.0FT (H135FT, H155FT) (K006)
available to help reduce excessive braking noise. Capacities and Specifications 8000SRM1958 for
The amount of additive oil to use is proportional to lift truck models
the volume of the system used to cool the brakes.
For the lift trucks covered in this manual, the drive • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
axle system is used to cool the brakes. Refer to one
53
Capacities and Specifications 8000SRM1408 for For example, if fluid capacity of one drive axle
lift truck models housing arm is 9.0 liter (9.5 qt), 5.5 percent of that
H8.0FT, H8.0FT9, H9.0FT (H170FT, is 0.50 liter (0.52 qt), and is the most additive that
•
H175FT36, H190FT) (A299) can be added to each drive axle housing arm (left
and right) to reduce brake noise. See Figure 13.
Capacities and Specifications 8000SRM1587 for
lift truck models NOTE: Additive has very high viscosity and must
• H8.0FT, H8.0FT9, H9.0FT (H170FT, be warmed to 15.5°C (60°F) before adding it to
H175FT36, H190FT) (B299) transmission.
Capacities and Specifications 8000SRM1960 for NOTE: Do Not add additive to center section.
lift truck models 1. Add 2 percent by volume initially, to right and
• H8.0FT, H8.0FT9, H9.0FT (H170FT, left drive axle housing sections. See Figure 13.
H175FT36, H190FT) (C299) Drive lift truck for at least 40 hours or one
week.
Adding Additive To Transmission
2. If brake noise continues, add another 1 percent
by volume, to right and left drive axle housing
WARNING sections. Drive lift truck for another 40 hours
Do not add more than 5.5 percent by volume of or one week.
additive. Adding more additive will cause brake
system on lift truck to not operate properly and 3. If brake noise continues, repeat Step 2 until
safely stop lift truck. maximum quantity of 5.5 percent by volume
has been added to drive axle.
NOTE: DO NOT ADD ADDITIVE TO CENTER SECTION.
A. RIGHT DRIVE AXLE HOUSING ARM C. LEFT DRIVE AXLE HOUSING ARM
B. CENTER SECTION
1. RIGHT DRIVE AXLE HOUSING ARM FILL PLUG 3. LEFT DRIVE AXLE HOUSING ARM FILL PLUG
2. CENTER SECTION
Figure 13. Adding Additive To Stop Braking Noise
54
1400 SRM 1344 Differential Repair
Differential Repair
REMOVE
1. SOCKET HEAD SCREW 15. DIFFERENTIAL CARRIER HALF

2. RING NUT 16. SOCKET HEAD SCREW
3. SEAL 17. NUT
4. SNAP RING 18. O-RING
5. O-RING 19. FLANGE (YOKE)
6. ROLLER BEARING 20. PLATE
7. CAPSCREW 21. SEAL
8. DIFFERENTIAL CARRIER HALF 22. BEARING
9. BEVEL GEAR 23. SPACER
10. THRUST WASHER 24. SHIM
11. SIDE GEAR 25. SHIM
12. SPHERICAL THRUST WASHER 26. BEARING
13. PINION GEARS 27. BEVEL PINION
14. PINION SHAFTS
Figure 14. Differential Assembly for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006, L006)
55
Differential Repair 1400 SRM 1344
1. DIFFERENTIAL CARRIER HALF 12. THRUST WASHER

2. BEVEL PINION 13. DIFFERENTIAL SIDE GEAR
3. PINION SHAFT 14. SHIMS KIT
4. SPHERICAL THRUST WASHER 15. SHIM
5. PINION GEAR 16. SPACER
6. SOCKET HEAD SCREW 17. PLATE
7. RING NUT 18. FLANGE
8. SEAL 19. NUT
9. SNAP RING 20. CAPSCREW
10. O-RING 21. DIFFERENTIAL CARRIER HALF
11. BEARING
Figure 15. Differential Assembly for Lift Truck Models H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299, C299)
56
STEP 1.
Remove the complete planetary reduction gear
assemblies, brake discs, friction plates, axle
shafts, pistons, parking brake levers, and
thrust levers. See the section Brake Repair.
CAUTION
Check and make note of the static torque before
disassembly.
STEP 2.
Measure the static torque of the bevel pinion
and bearings.
STEP 3.
Sling the axle housing arm to be removed and
connect the sling to an overhead lift.
Remove the capscrews retaining the axle
housing arm to the main axle housing.
STEP 4.
Separate the axle housings. Place the axle
housing arm on a bench.
57
STEP 5.
If the differential carrier bearing cones need
replaced, remove the bearing cup from the axle
housing arm.
1. BEARING CUP
NOTE: Perform Step 6 through Step 8 only if the ring nut needs to be removed or adjusted.
STEP 6.
Measure the installation position of ring nut to
facilitate in adjustment during installation.
STEP 7.
Remove the socket head screw.
58
NOTE: After removing the ring nuts, make sure to thoroughly clean the threaded portions of the ring nuts.
STEP 8.
Using special tool T3, remove the ring nut.
1. SPECIAL TOOL T3
2. RING NUT
STEP 9.
Remove the differential assembly.
59
DISASSEMBLE
STEP 1.
Using an appropriate puller, remove the
bearing cone.
1. BEARING CONE
STEP 2.
Remove the bearing cone from the bevel gear
side of the differential carrier.
1. BEARING CONE
2. DIFFERENTIAL CARRIER
60
STEP 3.
Remove the capscrews retaining the bevel gear
to the differential carrier.
1. CAPSCREW
2. BEVEL GEAR
STEP 4.
Remove the bevel gear from the differential
carrier.
1. DIFFERENTIAL CARRIER
2. BEVEL GEAR
STEP 5.
differential halves together.
NOTE: Make alignment marks on the two differential carrier halves to ensure proper assembly.
61
STEP 6.
Using a plastic hammer, separate the
differential carrier halves.
1. DIFFERENTIAL CARRIER HALF
STEP 7.
Remove the thrust washer and first planetary
gear.
1. THRUST WASHER
2. PLANETARY GEAR
STEP 8.
Remove pinion shafts, pinion gears, and
spherical thrust washers.
1. PINION SHAFT
2. SPHERICAL THRUST WASHER
3. PINION GEAR
62
STEP 9.
Remove the second planetary gear and thrust
washer.
1. PLANETARY GEAR
2. THRUST WASHER
STEP 10.
Remove the snap ring and plug.
STEP 11.
If the bearing cone needs replaced, remove the
bearing cup from the axle housing.
1. BEARING CUP
63
NOTE: Perform Step 12 through Step 14 only if the ring nut needs removed or adjusted.
STEP 12.
Measure the installation position of ring nut to
facilitate in adjustment during installation.
STEP 13.
Remove the socket head screw.
NOTE: After removing the ring nuts, make sure to thoroughly clean the threaded portions of the ring nuts.
STEP 14.
Using special tool T3, remove the ring nut.
1. SPECIAL TOOL T3
2. RING NUT
64
NOTE: Perform Step 15 and Step 16 on both ring nuts.
STEP 15.
Remove the snap ring from the ring nut.
1. SNAP RING
STEP 16.
Remove the seal from the ring nut.
1. SEAL
65
CLEAN AND INSPECT • Tapered roller bearings - Inspect the cup,

cone, rollers, and cage of all tapered roller
bearings in the assembly. If bearings show
WARNING signs of wear, cracks, or damage, replace with
new bearing.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning • Bevel Pinion and bevel gear - Inspect the
solvents, always follow the recommendations of bevel pinion and bevel gear for wear or
damage. If the bevel pinion or bevel gear is
the manufacturer.
damaged, they must be replaced as a set.
• Pinions and side gears - Inspect the
pinions and side gears for wear or damage.
WARNING Pinions and side gears that are worn or
Compressed air can move particles so that they damaged must be replaced.
cause injury to the user or to other personnel. • Main differential assembly - Inspect all
Make sure that the path of the compressed air is parts of the main differential assembly for
away from all personnel. Wear protective goggles wear or damage. Parts that are damaged
or a face shield to prevent injury to the eyes. must be replaced.
Clean and inspect the following parts of the

differential:
• 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.
66
ASSEMBLE
NOTE: Perform Step 1 through Step 3 on both ring nuts.
STEP 1.
Lubricate the outer surface of the new seal with
a lithium based grease. Install the new seal
into the ring nut with special tool T4 to a
predetermined depth of
10.85 to 11.15 mm (0.43 to 0.44 in.).
1. SEAL
2. SPECIAL TOOL T4
STEP 2.
Install the snap ring.
Rotate the snap ring to verify that it is properly
set in the groove.
1. SNAP RING
67
STEP 3.
Lubricate a new O-ring and install the O-ring
onto the ring nut.
1. O-RING
STEP 4.
Apply Loctite® 242 to the threads of the ring
nut. Install the ring nut but do not tighten.
1. SPECIAL TOOL T3
2. RING NUT
STEP 5.
If the bearing cones and cups are being
replaced, tighten the ring nut to the previously
measured position.
68
STEP 6.
If the axle housing arms are replaced, apply
Loctite® 510 to two new setscrews. Install the
setscrews in the holes on the opposite side of
the ring nut socket head screws. Tighten
setscrews until they are flush with the axle
housing.
1. SETSCREWS
STEP 7.
replaced, install the bearing cup.
1. BEARING CUP
STEP 8.
Lubricate the thrust washer and planetary gear
with John Deere JDM J20C.
Install the thrust washer and planetary gear
into the differential carrier half.
1. PLANETARY GEAR
2. THRUST WASHER
69
STEP 9.
Lubricate the pinion gears, spherical thrust
washers, and pinion shafts with John Deere
JDM J20C.
Install the pinion gears and spherical thrust
washers onto the pinion shafts. Install the
assemblies into the differential carrier half.
1. PINION SHAFT
2. SPHERICAL THRUST WASHER
3. PINION GEAR
STEP 10.
Lubricate the second planetary gear and thrust
washer with John Deere JDM J20C.
Install the second planetary gear and thrust
washer.
1. THRUST WASHER
2. PLANETARY GEAR
STEP 11.
Verify that the thrust washers are correctly
positioned in the relative recesses.
70
CAUTION
Only use new socket head screws to reassemble
the differential carrier halves.
STEP 12.
Assemble the two differential carrier halves by
matching the marks made during disassembly.
Apply Loctite® 270 to the threads of new socket
head screws. Install socket head screws.
STEP 13.
Tighten the socket head screws in a crisscross
pattern to 78 to 86 N•m (57.5 to 63.4 lbf ft).
CAUTION
Only use new capscrews to reassemble the bevel
gear to the differential carrier.
STEP 14.
Place the bevel gear in position on the
differential carrier. Install new capscrews.
1. CAPSCREW
2. BEVEL GEAR
71
STEP 15.
Tighten the capscrews in a crisscross pattern to
128 to 142 N•m (94.4 to 104.7 lbf ft).
1. CAPSCREW
CAUTION
When installing the bearing cone, verify that the
shim is not contacting the outer cage of the
bearing cone.
STEP 16.
Lubricate the bearing cone with John Deere
JDM J20C.
Position the bearing cone on the bevel gear side
of the differential carrier. Position a shim with
adequate diameter on the internal ring of the
bearing cone. Using an appropriate driver,
install the bearing cone.
1. BEARING CONE
CAUTION
When installing the bearing cone, verify that the
shim is not contacting the outer cage of the
bearing cone.
STEP 17.
Lubricate the second bearing cone with John
Deere JDM J20C.
Position the second bearing cone on the
opposite side of the bevel gear side of the
differential carrier. Position a shim with
adequate diameter on the internal ring of the
bearing cone. Using an appropriate driver,
install the second bearing cone. 1. BEARING CONE
72
STEP 18.
remaining ring nut. Install the ring nut but do
not tighten.
1. SPECIAL TOOL T3
2. RING NUT
STEP 19.
replaced, tighten the ring nut to the previously
measured position.
STEP 20.
replaced, install the remaining bearing cup.
1. BEARING CUP
73
INSTALL
NOTE: The rolling torque of the pinion must be measured without the pinion seal installed. Refer to the
section Bevel Pinion for the procedures on removing and installing the seal.
STEP 1.
Before installing the differential assembly,
measure the rolling torque of the pinion. The
rolling torque should be
1.2 to 1.8 N•m (10.6 to 15.9 lbf ft).
STEP 2.
Install the differential assembly into the main
axle housing.
STEP 3.
grease. Install the new O-ring on the axle
housing.
1. O-RING
74
STEP 4.
Apply Loctite® 242 to the capscrews used to
retain the axle housing together. Assemble the
axle housings. Install the capscrews. Tighten
the capscrews to
283 to 312 N•m (209 to 230 lbf ft).
STEP 5.
Using special tool T3, tighten the ring nut on
the bevel gear side until the clearance between
the bevel pinion and the bevel gear is
0 mm (0 in.). Lock the bevel gear, then loosen
the ring nut 1/4 to ½ turn.
1. SPECIAL TOOL T3
CAUTION
If the bearings are not new, check the static
torque and verify the static torque did not change
from the measurement recorded during removal.
If the bearings are new, check the continuous
torque.
STEP 6.
Preset the bearings by tightening the ring nut
on the opposite side of the bevel gear,
increasing pinion torque up to
1.2 to 1.8 N•m (10.6 to 15.9 lbf in).
75
STEP 7.
Position a dial indicator with a long tip through
the hole for the plug.
Position the tip on the side of a tooth of the
bevel gear, approximately 5 mm (0.197 in.)
from the outer rim. Preload by approximately
1 mm (0.039 in.) and zero the dial indicator.
1. DIAL INDICATOR TIP
STEP 8.
Hold the bevel pinion in position and move the
bevel gear in both directions to check the
clearance between the bevel pinion and bevel
gear. See Table 1.
Table 1. Bevel Set Specifications

Drive Axle Part No. Axle Overall Bevel Set Ratio Clearance
Ratio Minimum Maximum
2078968 14.8 32/13 0.20 mm 0.28 mm
(0.0079 in.) (0.0110 in.)
2078969 15.4 36/14 0.18 mm 0.23 mm
(0.0071 in.) (0.0091 in.)
2089938 16.9 31/11 0.20 mm 0.28 mm
(0.0079 in.) (0.0110 in.)
76
STEP 9.
Adjust the backlash between the bevel pinion
and the bevel gear by loosening one of the ring
nuts and tightening the opposite ring nut.
See Table 1 for specifications for your drive
axle.
1. SPECIAL TOOL T3
STEP 10.
head screw. Install the socket head screw into
one of the two holes to lock the ring nut in
position. Tighten the socket head screw to
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft). Repeat on
opposite side.
STEP 11.
Apply RTV silicone to the plug. Install the plug
and snap ring.
STEP 12.
Install the complete planetary reduction gear
assemblies, brake discs, friction plates, axle
shafts, pistons, parking brake levers, and
thrust levers. See the section Brake Repair.
77
Bevel Pinion 1400 SRM 1344
Bevel Pinion

Refer to Figure 16 for the following procedures.
1. NUT 7. SPACER
2. O-RING 8. SHIM
3. FLANGE (YOKE) 9. SHIM
4. PLATE 10. BEARING
5. SEAL 11. BEVEL PINION
6. BEARING
Figure 16. Bevel Pinion Assembly
STEP 1.
Remove the differential assembly. See the
section Differential Repair.
78
1400 SRM 1344 Bevel Pinion
STEP 2.
Position special tool T5 to lock the bevel pinion
and flange in position.
Remove the nut and O-ring.
1. SPECIAL TOOL T5
2. O-RING
3. NUT
STEP 3.
Remove the flange with plate.
1. FLANGE
2. PLATE
STEP 4.
Remove the seal.
1. SEAL
79
STEP 5.
Remove the bevel pinion, inner bearing cone,
spacer, and shims as an assembly.
Remove the outer bearing cone.
1. BEVEL PINION
STEP 6.
Note the order of the spacer and shim. Remove
spacer and shim from the bevel pinion.
1. SPACER
2. SHIM
STEP 7.
Using a puller and a press, remove the inner
bearing cone from the bevel pinion.
1. BEVEL PINION
2. BEARING CONE
80
STEP 8.
Using an appropriate puller, remove the outer
bearing cup.
STEP 9.
Insert a brass drift into the appropriate holes
and remove the inner bearing cup and shims.
1. SHIMS
2. BEARING CUP
81
CLEAN AND INSPECT Clean and inspect the following parts:

• Bearings - Inspect the cup, cone, rollers, and
cage of all tapered roller bearings in the
WARNING assembly. If bearings show signs of wear,
Cleaning solvents can be flammable and toxic and cracks, or damage, replace with new bearing
can cause skin irritation. When using cleaning cone and cup.
solvents, always follow the recommendations of • Bevel Pinion - Inspect the bevel pinion for
the manufacturer. wear or damage. Replace as needed. If the
bevel pinion is replaced, the bevel gear must
also be replaced.
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.
82

Figure 17. Determining Bevel Pinion Shim Thickness
83
STEP 1.
Reset a depth gauge on a 6 mm (0.236 in.)
calibrated block.
1. CALIBRATED BLOCK
STEP 2.
With the calibrated block on a faceplate, allow
the bearing to set by rotating them in both
directions and applying a vertical thrust to
position the calibrated block on the outer
bearing cups. Check the overall thickness of the
bearing (D).
Example:
D = 42.25 mm
STEP 3.
Check the nominal dimension INT as marked
on the pinion. Add or subtract from the INT the
variation indicated as Y to obtain the actual
bevel pinion mounting distance I. See
Figure 17.
Example:
I = INT − Y
• 130 − 0.15 = 129.85 mm
1. Y MEASUREMENT
2. INT MEASUREMENT
84
STEP 4.
Calculate the shims S for insertion under the
bearing cup of the inner bearing cone using the
following formula:
S = 172.8 (I + D)
172.8 = fixed value
I = actual pinion center distance
D = total bearing thickness
Example:
S = 172.8 − (129.85 + 42.25) = 0.70 mm
1. SHIMS "S"
STEP 5.
Partially insert the shims and the inner
bearing cup into the axle housing. Then
partially insert the outer bearing cup into the
axle housing.
Install special tool T6 through the bearing cups
and shims in the axle housing.
NOTE: Special tool T6 and the bearing cups are

shown out of the axle housing to show the proper
setup of special tool T6.
1. OUTER BEARING CUP

2. INNER BEARING CUP
3. SPECIAL TOOL T6
85
STEP 6.
Connect tension rod of special tool T6 (see
Special Tools) through the hydraulic press.
Energize the press to pull the bearing cups into
the seats of the axle housing. Release hydraulic
press.
1. SPECIAL TOOL T6
2. HYDRAULIC PRESS
STEP 7.
Assemble the special tool T7 with bearings into
the bevel pinion housing as shown. Hand
tighten until the axial gap is eliminated.
1. OUTER BEARING
2. SPECIAL TOOL T7
3. INNER BEARING
STEP 8.
Insert the tip of the depth gauge into the side
hole of the special tool T7.
Reset the depth gauge with a preload of
approximately 3 mm (0.12 in.).
1. SPECIAL TOOL T7
86
STEP 9.
Remove special tool T7 and the bearings from
the axle housing.
Reassemble special tool T7 with a spacer
between the bearings as shown in Step 10.
1. SPECIAL TOOL T7
2. INNER BEARING
3. SHIM
4. SPACER
5. OUTER BEARING
STEP 10.
Insert the tip of the depth gauge into the side
hole and measure the deviation H from the
previous reset in Step 8.
Example:
H = A − B = 1.4 mm
1. SPECIAL TOOL T7
2. DEPTH GAUGE
NOTE: Refer to Figure 16.
87
STEP 11.
The deviation H measured must be added to
the fixed value X to define the pack S1,
installed between the bearings and the spacer.
The value S1 must be rounded to the upper
5/100.
Example:
S1 = H + X
H = A − B = 1.4 mm
X = 0.10 to 0.12 mm (fixed value)
S1 = 1.4 + (0.10 to 0.12) = 1.50 to 1.52 mm
1. SHIMS S1
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
STEP 12.
Heat the inner bearing cone to approximately
100°C (212°F) and install the bearing onto the
bevel pinion.
Once the bearing has cooled down, lightly
lubricate the bearing with John Deere JDM
J20C.
STEP 13.
Install the shims S1 and the spacer as shown.
1. SPACER
2. SHIMS S1
88
STEP 14.
Install the bevel pinion, inner bearing cone,
shims S1, and spacer as an assembly into the
axle housing.
1. BEVEL PINION ASSEMBLY
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
STEP 15.
Heat the outer bearing cone to approximately
100°C (212°F) and install the bearing cone onto
the bevel pinion.
Once the bearing cone has cooled down, lightly
lubricate the bearing with John Deere JDM
J20C.
1. BEVEL PINION
STEP 16.
Install the flange onto the bevel pinion without
the seal.
1. BEVEL PINION
2. FLANGE
89
STEP 17.
Install the nut onto the bevel pinion. Using the
special tool T5 to lock the bevel pinion in place.
Tighten the bevel pinion nut to
700 to 750 N•m (516 to 553 lbf ft).
1. SPECIAL TOOL T5
CAUTION
If the rolling torque exceeds the maximum value,
then the size of the shim S1 between the bearing
and spacer needs to be increased. See Figure 16.
If the rolling torque does not reach the set value,
increase the torque setting of the ring nut in
different stages to obtain a maximum value of
700 to 750 N•m (516 to 553 lbf ft).
CAUTION
If the rolling torque does not reach the minimum
value, then the size of the shims S1 between the
bearing and spacer needs to be decreased. See
Figure 16.
CAUTION
When calculating the increase or decrease of
shims S1, keep in mind that a variation of a shim
of 0.01 mm corresponds to a variation of
6 N•m (53 lbf in) in the torque of the bevel pinon.
STEP 18.
Measure the rolling torque of the bevel pinion.
The rolling torque should be
1.2 to 1.8 N•m (10.6 to 15.9 lbf in).
90
STEP 19.
Remove the nut and flange from the bevel
pinion.
1. BEVEL PINION
2. FLANGE
STEP 20.
Apply gasket cement or equivalent to the outer
surface of the new seal.
Using the special tool T8, install the seal.
1. SEAL
2. SPECIAL TOOL T8
NOTE: Only apply oil to the lip of the seal using John Deere JDM J20C.
STEP 21.
Lubricate the lip of the seal with John Deere
JDM J20C. Install the flange.
Install a new O-ring onto the bevel pinion.
Apply Loctite® 242 to the threads of the bevel
pinion and install the nut.
1. NUT
2. O-RING
3. FLANGE
91
Drive Axle Installation 1400 SRM 1344
STEP 22.
Using the special tool T5 to lock the bevel
pinion in place. Tighten the bevel pinion nut to
700 to 750 N•m (516 to 553 lbf ft).
1. SPECIAL TOOL T5
STEP 23.
Install the differential assembly. See the
section Differential Repair.
Drive Axle Installation

NOTE: Perform Step 1 through Step 19, and 3. Connect the brake cooling lines to the manifold
Step 40 through Step 45 for lift truck models and the drive axle. See Figure 18.
H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006,
K006, L006) . 4. Connect the cooling hoses to the manifold and
1. Position the brake lines with cross fitting, as an
assembly, on the drive axle. Connect the brake 5. Connect slings and lifting device to drive axle.
lines to the drive axle. See Figure 18.
2. Position the manifold on the drive axle. Install

the socket head screws to the manifold and the
drive axle. Tighten the socket head screws to
26 to 29 N•m (19 to 21 lbf ft). See Figure 18.
92
1400 SRM 1344 Drive Axle Installation
Figure 18. Manifold and Cooling Hoses Connections for Lift Truck Models, H6.0FT, H7.0FT (H135FT,
H155FT) (H006, J006, K006, L006)
93
1. MANIFOLD 6. CROSS FITTING

2. DRIVE AXLE COOLING RETURN HOSE, LEFT 7. BRAKE COOLING LINE, RIGHT SIDE
SIDE 8. BRAKE LINE, RIGHT SIDE
3. BRAKE COOLING LINE, LEFT SIDE 9. DRIVE AXLE COOLING RETURN HOSE, RIGHT
4. BRAKE LINE, LEFT SIDE SIDE
5. SOCKET HEAD SCREWS
NOTE: When installing the drive axle, ensure the NOTE: Ensure hose clamps are installed onto hoses
drive axle is held with the upper surface of the drive as noted during removal.
axle against the frame. This will prevent any gap
9. Connect the transmission to drive axle cooling
between the frame and the drive axle mount, and
supply hose to the manifold. See Figure 19.
will ensure even weight distribution.
6. Position the drive axle in the lift truck. 10. Connect the drive axle to transmission cooling
return hose to the manifold. See Figure 19.
NOTE: It is recommended to use a torque multiplier
to achieve the torque specification in Step 7. 11. Connect the brake booster return line to the
manifold. See Figure 19.
7. Install the four mounting capscrews and
washers. Tighten the mounting capscrews to 12. Connect the accumulator/brake booster supply
820 to 902 N•m (605 to 665 lbf ft). See line to the manifold. See Figure 19.
Figure 21.
13. Connect the brake supply line to the brake line
8. Install the drive shaft and capscrews to the cross fitting on the drive axle. See Figure 19.
drive axle. Tighten the capscrews to
55 to 63 N•m (41 to 46 lbf ft).
94
Figure 19. Drive Axle and Brake Cooling Lines and Brake Lines for Lift Truck Models, H6.0FT, H7.0FT
(H135FT, H155FT) (H006, J006, K006, L006)
95
1. ACCUMULATOR 7. ACCUMULATOR/BRAKE BOOSTER SUPPLY LINE

2. TRANSMISSION TO DRIVE AXLE COOLING 8. BRAKE BOOSTER RETURN LINE
SUPPLY HOSE 9. BRAKE SUPPLY LINE
3. DRIVE AXLE TO TRANSMISSION COOLING 10. BRAKE COOLING LINE, RIGHT SIDE
RETURN HOSE 11. BRAKE LINE, RIGHT SIDE
4. DRIVE AXLE COOLING RETURN HOSE, LEFT 12. DRIVE AXLE COOLING RETURN HOSE, RIGHT
SIDE SIDE
5. BRAKE COOLING LINE, LEFT SIDE
6. BRAKE LINE, LEFT SIDE
14. Install the parking brake cables. Refer to Periodic Maintenance 8000SRM1322 for lift
section truck models
Brake System - DANA 1800SRM1247 • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006)
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) Periodic Maintenance 8000SRM1583 for lift
truck models
Wet Brake System 1800SRM1977
• H6.0FT, H7.0FT (H135FT, H155FT) (K006)
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
Periodic Maintenance 8000SRM1957 for lift
15. Install the drive axle main housing center truck models
drain plug. Tighten plug to
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
18. Install the oil fill plugs with new O-rings on
16. Install the oil drain plugs on both sides of the
both sides of the drive axle. Tighten plugs to
drive axle. Tighten plugs to
19. Install the drive axle main housing center fill/
17. Fill the drive axle sections with the proper
level plug with new O-ring. Tighten plug to
fluid. For the correct fluid, quantity, and fill
procedure see
96
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE
Figure 20. Drive Axle Drain and Fill/Level Plugs for Lift Truck Models, H6.0FT, H7.0FT (H135FT, H155FT)
(H006, J006, K006, L006)
97
NOTE: Perform Step 20 through Step 45 for lift 25. Install drive shaft and capscrews. Tighten drive
truck model H8.0FT, H8.0FT9, H9.0FT (H170FT, shaft capscrews to
H175FT36, H190FT) (A299, B299, C299) . 55 to 63 N•m (41 to 46 lbf ft).
20. Position brake lines with cross fitting, as an
NOTE: Ensure hose clamps are installed onto hoses
assembly, on the drive axle. Connect brake
as noted during removal.
lines to drive axle. See Figure 22.
26. Connect cooling supply lines to manifold and
21. Position manifold on drive axle. Install socket drive axle. See Figure 22.
head screws to manifold and drive axle.
Tighten socket head screws to 27. Connect axle vent line to drive axle. See
26 to 29 N•m (19 to 21 lbf ft). See Figure 22. Figure 22.
22. Connect slings and lifting device to drive axle. 28. Connect cooling supply from transmission hose
to manifold. See Figure 22.
NOTE: When installing drive axle, ensure drive
axle is held with the upper surface of drive axle 29. Connect cooling return to transmission hose to
against frame. This will prevent any gap between manifold. See Figure 22.
frame and drive axle mount, and will ensure even
weight distribution. 30. Connect cooling return hoses to manifold and
23. Position drive axle in lift truck.
31. Connect hydraulic return hose to modulating
NOTE: It is recommended to use a torque multiplier brake valve and accumulator charge valve. See
to achieve the torque specified in Step 24. Figure 22.
24. Install four washers and capscrews into drive
axle and frame. See Figure 21. Tighten 32. Connect hydraulic pressure supply hose to
capscrews to 820 to 902 N•m (605 to 665 lbf ft). accumulator charge valve. See Figure 22.

2. WASHER
98
Figure 22. Drive Axle, Manifold, Cooling Hoses, and Brake Lines for Lift Truck Model H8.0FT, H8.0FT9,
H9.0FT (H170FT, H175FT36, H190FT) (A299, B299, C299)
99
A. REAR VIEW B. FRONT VIEW
1. MODULATING BRAKE VALVE 9. MANIFOLD

2. BRAKE LINE 10. DRIVE AXLE
3. LOAD SENSE IN HOSE ASSEMBLY 11. COOLING RETURN TO TRANSMISSION HOSE
4. LOAD SENSE OUT HOSE ASSEMBLY 12. COOLING SUPPLY FROM TRANSMISSION HOSE
5. ACCUMULATOR CHARGE VALVE 13. AXLE VENT LINE
6. HYDRAULIC PRESSURE SUPPLY HOSE 14. COOLING SUPPLY LINES
7. HYDRAULIC RETURN HOSE 15. SOCKET HEAD SCREW
8. COOLING RETURN HOSE 16. BRAKE LINE
33. Connect brake line to modulating brake valve. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
See Figure 22. H175FT36, H190FT) (A299)
Periodic Maintenance 8000SRM1586 for lift
34. Connect load sense out and load sense in hose truck model
assemblies to accumulator charge valve. See
Figure 22. • H8.0FT, H8.0FT9, H9.0FT (H170FT,
H175FT36, H190FT) (B299)
35. Install the parking brake cables. Refer to the Periodic Maintenance 8000SRM1959for lift
section truck model
Brake System - DANA 1800SRM1247 for lift • H8.0FT, H8.0FT9, H9.0FT (H170FT,
truck models H175FT36, H190FT) (C299)
• H8.0FT, H8.0FT9, H9.0FT (H170FT,
39. Install drive axle main housing center fill plug.
H175FT36, H190FT) (A299, B299)
See Figure 23.
Wet Brake System 1800SRM1977 for lift
truck models 40. Remove the air from the brake system as
• H8.0FT, H8.0FT9, H9.0FT (H170FT, described in the section
H175FT36, H190FT) (C299) Brake System - DANA 1800SRM1247 for lift
truck models.
36. Install drive axle main housing center drain
plug into drive axle. See Figure 23. • H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006)
37. Install right side oil drain plug and left side oil • H8.0FT, H8.0FT9, H9.0FT (H170FT,
drain plug into drive axle. See Figure 23. H175FT36, H190FT) (A299, B299)
Wet Brake System 1800SRM1977 for lift
38. Fill the drive axle sections with the proper truck models.
fluid. For the correct fluid, quantity, and fill
procedure see • H6.0FT, H7.0FT (H135FT, H155FT) (L006)
Periodic Maintenance 8000SRM1407 for lift • H8.0FT, H8.0FT9, H9.0FT (H170FT,

H175FT36, H190FT) (C299)
truck model
100
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 3. RIGHT SIDE OIL DRAIN PLUG
PLUG 4. LEFT SIDE OIL DRAIN PLUG
2. DRIVE AXLE MAIN HOUSING CENTER FILL
PLUG
Figure 23. Drive Axle Fill/Drain Plugs for Lift Truck Model H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36,
H190FT) (A299, B299, C299)
101
Special Tools 1400 SRM 1344
Mast Repair (S/N A513, A514, A613, A614,

WARNING A643, A644, A683, A684) 4000SRM1406 for
Add air to the tires only in a safety cage. Inspect lift truck models
safety cage for damage before use. When adding • H8.0FT, H8.0FT9, H9.0FT (H170FT,
air, use a clip-on chuck with enough hose to let the H175FT36, H190FT) (A299, B299) ,
operator stand clear of the cage. Mast Repair (S/N A613, A614, A643, A644,
A683, A684) 4000SRM1956 for lift truck
NOTE: When tightening the wheel nuts, use
models
lubricant on the studs or nuts.
• H6.0FT, H7.0FT (H135FT, H155FT) (L006)
41. Inflate the tires using a safety cage. Install the
wheels and nuts and tighten the nuts to • H8.0FT, H8.0FT9, H9.0FT (H170FT,
610 to 680 N•m (450 to 502 lbf ft). H175FT36, H190FT) (C299)
42. Install the mast assembly as described in the 43. Raise the lift truck and remove blocks from
section under frame and from under the
counterweight. Lower the lift truck.
Mast Repairs, 2- and 3-Stage Masts (S/N
A513, A514, A613, A614, A702, A703, A704, 44. Remove the blocks on each side (front and
A705, A706, A707, A751, A752, B513, B514, back) of the steering tires.
B586, B587, B588, B589, B590, B591, B749,
B750, B751, B752, B753, B754) 45. Operate the lift truck and check for proper
4000SRM1250 for lift truck models operation and leaks.
• H6.0FT, H7.0FT (H135FT, H155FT) (H006,
J006, K006) ,
Special Tools
Description Part Number Description Part Number

Service Tool T3 1660302 Service Tool T8 1660307
Differential Nut Pinion Seal
Service Tool T4 1660303 Service Tool T9 1660308
Differential Seal Pneumatic Hub Bearing
Service Tool T5 1660304 Cup
Pinion Wrench Service Tool T10 1660309
Service Tool T6 1660305 Pneumatic Hub Seal
Pinion Bearing Cup Service Tool - Handle 1660310
Service Tool T7 1660306
Pinion Bearing
Inspection
102
1400 SRM 1344 Torque Specifications
Torque Specifications
Bevel Pinion Nut Oil Drain Plug, Left and Right Side
700 to 750 N•m (516 to 553 lbf ft) 30 to 50 N•m (22 to 37 lbf ft)
Bevel Gear Capscrews Oil Fill Plug, Left and Right Side
128 to 142 N•m (94.4 to 104.7 lbf ft) 30 to 50 N•m (22 to 37 lbf ft)
Differential Adjustment Ring Nut Socket Head Outer Axle Shaft to Wheel Hub Capscrews
Screw 182 to 202 N•m (134 to 149 lbf ft)
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft)
Parking Brake Lever Adjustment Screw Nut
Differential Carrier Halves Socket Head 20 to 25 N•m (14.75 to 18.44 lbf ft)
Screws
78 to 86 N•m (57.5 to 63.4 lbf ft) Parking Brake Lever Socket Head Screw
23.8 to 26.2 N•m (17.6 to 19.3 lbf in)
Drive Axle Housing Arm to Drive Axle Main
Housing Capscrews Piston Guide Socket Head/Pin Screws
283 to 312 N•m (209 to 230 lbf ft) 5 to 7 N•m (44 to 62 lbf in)
Drive Axle Main Housing Center Drain Plug Planetary Gear Carrier to Outer Axle Shaft
30 to 50 N•m (22 to 37 lbf ft) Retaining Screw
116 to 128 N•m (86 to 94 lbf ft)
Drive Axle Main Housing Center Fill/Level
Plug Planetary Reduction Gear Assembly to Axle
30 to 50 N•m (22 to 37 lbf ft) Housing Socket Head Screws
129 to 143 N•m (95 to 105 lbf ft)
Drive Axle to Frame Mounting Capscrews
820 to 902 N•m (605 to 665 lbf ft) Return Spring Socket Head Screws
5 to 7 N•m (44 to 62 lbf in)
Drive Axle to Transmission Mounting Bracket
Capscrews Shoulder Ring to Wheel Hub Support
225 to 250 N•m (166 to 184 lbf ft) Capscrews
68 to 75 N•m (50 to 55 lbf ft)
Drive Shaft Capscrews
55 to 63 N•m (41 to 46 lbf ft) Thrust Bushing Socket Head Screws
23.8 to 26.2 N•m (17.6 to 19.3 lbf ft)
Manifold to Drive Axle Housing Socket Head
Screws Wheel Nuts (Lubed)
26 to 29 N•m (19 to 21 lbf ft) 610 to 680 N•m (450 to 502 lbf ft)
103
NOTES
104
TECHNICAL PUBLICATIONS
1400 SRM 1344 2/18 (2/17)(10/15)(12/13)(7/12)(6/10)

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DRIVE AXLE AND

PART NO. 1661537 1400 SRM 1344

This section is for the following models:

H6.0FT, H7.0FT (H135FT, H155FT) [H006, J006, K006, L006];

©2018 HYSTER COMPANY i

1. DANA PART NUMBER

Figure 1. Identification Plate

Drive Axle Removal

3. Remove the mast assembly as described in the

NOTE: Note placement of hose clamps prior to

Legend for Figure 3.

1. ACCUMULATOR 6. BRAKE LINE, LEFT SIDE

1. CAPSCREW 3. DRIVE AXLE

Figure 4. Drive Axle Mounting Capscrews

Legend for Figure 5.

1. MANIFOLD 6. CROSS FITTING

25. Remove right side and left side drain plugs

Legend for Figure 7.

A. REAR VIEW B. FRONT VIEW

1. MODULATING BRAKE VALVE 9. MANIFOLD

1. CAPSCREW 3. DRIVE AXLE

Figure 8. Drive Axle Mounting Capscrews

Planetary Reduction Gear Repair

REMOVE AND DISASSEMBLE

1. CAPSCREW 14. INNER BEARING

1. O-RING 14. WHEEL HUB

1. SOCKET HEAD SCREW

1. PLANETARY GEAR AND BEARING ASSEMBLY

1. PLANETARY GEAR CARRIER

1. OUTER AXLE SHAFT

1. OUTER BEARING CONE

1. INNER BEARING CONE

ASSEMBLE AND INSTALL

1. INNER BEARING CUP

1. INNER BEARING CONE

NOTE: Verify that the seal is correctly oriented.

1. OUTER BEARING CONE

1. PLANETARY GEAR CARRIER

1. SOCKET HEAD SCREW

REMOVE AND DISASSEMBLE

Legend for Figure 11.

1. SOCKET HEAD SCREW 15. DRIVE AXLE MAIN HOUSING

Legend for Figure 12.

1. PARKING BRAKE LEVER 15. O-RING

1. SOCKET HEAD SCREW

1. SOCKET HEAD SCREW

1. PARKING BRAKE LEVER

NOTE: Prior to removing thrust bushing, clean

1. SOCKET HEAD SCREW

WARNING 4. Inspect the brake disc(s). Replace discs when

2. Inspect the bearings for wear or damage.

ASSEMBLE AND INSTALL

1. SOCKET HEAD SCREW

NOTE: The oil passage must face downwards when installed.

NOTE: The oil passage must face downwards when installed.

NOTE: The threaded holes must be free of oil.

1. SOCKET HEAD/PIN SCREW

NOTE: The threaded holes must be free of oil.

1. SOCKET HEAD SCREW AND RETURN SPRING

1. PARKING BRAKE LEVER

1. SOCKET HEAD SCREW

NOTE: DO NOT ADD ADDITIVE TO CENTER SECTION.

Figure 13. Adding Additive To Stop Braking Noise

1. SOCKET HEAD SCREW 15. DIFFERENTIAL CARRIER HALF