DIFFERENTIAL CARRIER

SECTION DF
CONTENTS
SERVICE DATA AND SPECIFICATIONS .......... DF-2
General Specifications ................................... DF-2
Tightening Torque .......................................... DF-2
TROUBLE DIAGNOSES AND
CORRECTIONS .................................................. DF-3
List of Diagnoses ............................................ DF-3
PRECAUTIONS AND PREPARATION .............. DF-4
Precautions .................................................... DF-4
Special Service Tools ..................................... DF-4
DIFFERENTIAL CARRIER ................................. DF-5
Construction ................................................... DF-5
Removal ......................................................... DF-7
Disassembly ................................................... DF-8
Inspection ..................................................... DF-11
Assembly ...................................................... DF-12
Installation .................................................... DF-23
 SERVICE DATA AND SPECIFICATIONS

General Specifications
SERVICE DATA AND SPECIFICATIONS

Differential gear 4-pinion type

Gear train Constant-mesh, 1-stage reduction type
Input pinion 23
2nd gear assembly 74 - 27
Number of gear train teeth
3rd gear 59
Final drive gear 15
Number of ring gear teeth/Number of final drive gear 66/15
Differential gear oil classification and capacity
SAE80W - 90/API GL-5 Approx. 6.5 (6-7/8, 5-3/4)
L (US qt, Imp qt)

Tightening Torque
Unit N•m kg-m ft-lb

Gear train gear cover securing bolt 22 - 24 2.2 - 2.4 16 - 18

Ring gear securing bolt 132 - 146 13.5 - 14.9 98 - 108
Traction motor securing bolt 110 - 150 11 -15 81 - 111
Drive axle housing RH/LH securing bolt 62 - 68 6.3 - 6.9 46 - 50

DF-2
 TROUBLE DIAGNOSES AND CORRECTIONS
Condition
Oil leakage or oil seepage
(Locate the part experiencing oil loss and
determine whether the problem is with oil
seepage or oil leakage.)
Failure of differential carrier to rotate
Abnormal noise during vehicle starts
(Positively determine noise source is in
differential carrier.)
Abnormal noise during turns
(Positively determine noise source is in
differential carrier.)
Gear squeaks
(To check for gear squeaks, proceed as
follows: Raise front wheels using a jack and
run the traction motor. Determine when gear
squeaking occurs—during acceleration,
deceleration or constant-speed driving.)
List of Diagnoses
TROUBLE DIAGNOSES AND CORRECTIONS
CAUTION:
The following table lists only typical examples. To perform an
accurate diagnosis, carefully listen to the user’s complaints
and check the actual vehicle to fully understand under what
conditions the symptoms occur.
Probable cause Corrective action
• Deteriorated or improper type of gasket • Replace.
and/or O-ring
• Loose drive axle housing RH to LH • Tighten or replace gasket.
• Loose drain plug • Tighten.
• Seized or damaged bearing • Replace.
• Excessive bearing preload • Disassemble and adjust.
• Insufficient gear backlash • Disassemble and adjust.
• Insufficient or improper grade/type of gear • Refill or replace with proper grade/type of
oil gear oil.
• Improperly adjusted input pinion - to 2nd • Adjust: final drive gear, ring gear
gear, 2nd gear - to 3rd gear, 3rd gear - to Replace: input pinion, 2nd gear assembly
final drive gear or final drive gear - to ring or 3rd gear
gear ion backlash
• Improperly adjusted differential gear • Adjust.
backlash
• Insufficient final drive gear or differential • Adjust.
assembly supporting bearing preload
• Worn or damaged gear teeth faces • Replace.
• Loose drive axle housing securing bolts • Tighten.
• Insufficient or improper grade/type of gear • Refill or replace with proper grade/type of
oil gear oil.
• Excessively worn or damaged differential • Replace.
gear
• Seized, damaged or excessively worn • Replace.
thrust washer
• Worn or damaged pinion mate cross shaft • Replace.
• Seized or damaged side bearing • Replace.
• Insufficient or improper grade/type of gear • Refill or replace with proper grade/type of
oil gear oil.
• Improperly adjusted differential gear • Adjust or replace gears.
contact
• Abnormal each gear contact pattern • Adjust or replace gears.
• Cracked or damaged each gears on the • Replace gears as a set.
drive train gear teeth faces
• Improperly adjusted final drive or differential • Adjust.
assembly supporting bearing preload
• Seized or damaged side bearing • Replace.
• Excessive gear runout • Replace.
• Loose nuts and bolts • Tighten.
DF-3
 PRECAUTIONS AND PREPARATION

Precautions
PRECAUTIONS AND PREPARATION

CAUTION:
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• Always clean working area to prevent foreign matter from
getting into parts being assembled or serviced.
• Use a paper rag rather than a cloth when wiping clean
parts. Use of a cloth rag may leave lint or other foreign
matter on parts being wiped.
NOTE:
• It is good practice to remove or install differential carrier
together with front axle assembly. This procedure makes it
easier to work on the differential carrier.
• Before removing differential carrier, it is advisable to clean front
axle assembly and differential carrier.
• Removal and installation of some differential carrier parts
requires use of special service tools as indicated in the table
below.

Special Service Tools

Tool name Description

Bearing replacer Press-fitting left and right side bearing

inner races into differential case

Bearing replacer Press-fitting input pinion, 2nd gear,

final drive gear supporting or side
bearing into drive axle housing

Bearing φ D mm (in)
Input pinion 44.5 (1.75)
2nd gear 54.5 (2.15)
39.5 (1.15)
Final drive gear
54.5 (2.15)
Side 54.5 (2.15)

DF-4
DIFFERENTIAL CARRIER

Construction
DIFFERENTIAL CARRIER

COMPONENT PARTS

DF-5
DIFFERENTIAL CARRIER

Construction (Cont’d)
ADJUSTMENT OF COMPONENT PARTS

DF-6
 DIFFERENTIAL CARRIER

Removal
CAUTION:
For additional information, not covered in this DF section, refer
to the applicable section, as required, to familiarize yourself
with work being performed.
1. Raise front of vehicle using a jack. Place wooden blocks under
left and right frames to support vehicle. Refer to GI section for
details.
2. Remove mast assembly from vehicle. Refer to LM section.
• Before removing lift hose, release pressure in hydraulic line.
• A small amount of hydraulic line oil will escape when lift hose is
removed. Immediately plug the opening following removal.
Placing a cloth on the upper surface of differential carrier
enables easier cleaning.
3. Remove left and right front wheels, then remove drive axle
shaft. Refer to FA section for details.
4. Remove differential carrier drain plug to drain gear oil. Refer to
MA section.

CAUTION:
The drain plug is magnetized and collects metal particle.
Remove metal particle and check the type of metal.
5. Remove flare nuts from left and right wheel cylinders, then
remove brake tubes. Refer to BR section.

CAUTION:
Plug the opening of brake tube to prevent brake fluid from
flowing out.
6. Remove floor mat and floor board. Refer to BF section.
7. Remove brake pedal bracket assembly. Refer to BR section.
8. Remove parking brake cable from parking brake lever.
9. Disconnect cables and harness connected to traction motor.
10. Attach eyebolt (M10 x 1.5) to traction motor and attach a lifting
wire/nylon sling to front axle assembly. Then support front axle
assembly using a hoist, keeping the wire/nylon sling stretched
tight.

CAUTION:
Only authorized technicians are allowed to perform the lifting
operation.
11. Support differential carrier by placing a jack under it.

12. Remove axle mounting bracket securing bolts and nuts.

DFM0084

DF-7
 DIFFERENTIAL CARRIER

Removal (Cont’d)
13. Draw final drive assembly together with traction motor out from
the front of vehicle.

CAUTION:
Before removing differential carrier, make sure drive axle
shafts have been removed in advance.

DFM0083

14. Attach eyebolt (M10 x 1.5) to traction motor and attach a lifting
wire/nylon sling to the bolt. Then support traction motor using a
hoist or crane, keeping the wire/nylon sling stretched tight.

CAUTION:
Place wooden block under differential case to securely hold.
15. Remove traction motor-to-final drive assembly securing bolts.
16. Draw out traction motor shaft from input pinion, then remove
traction motor.

CAUTION:
Be careful not to damage traction motor shaft and O-ring.
17. Place differential carrier on worktable.

Disassembly
WARNING:
• Drive axle is very heavy. Fix it in position firmly.
• During disassembling work the unit must be hanged by
hoisting equipment. Be careful not to damage the two
speed sensors while working.
NOTE:
Before disassembling drive axle unit, clean its entire surface using a
cloth and white kerosene.
1. Remove right drive axle mounting bracket.
2. Remove input pinion cover by unscrewing the bolts.
3. Remove the input pinion and 2nd gear assembly.
4. Remove snap ring of 3rd gear.

DF-8
DIFFERENTIAL CARRIER

Disassembly (Cont'd)
5. Place drive axle unit on work table.

CAUTION:
• When the axle is positioned vertically, the 3rd gear will fall
down. To avoid this place a wood chock or waste cloth
under the gear.
• Drive axle is very heavy and must be lifted slowly.

6. Remove the bolts of drive axle housing RH and LH and the right
hand housing is lifted slowly.

DF-9
DIFFERENTIAL CARRIER

Disassembly (Cont'd)
7. Remove final gear and differential ring gear assembly from
drive axle housing LH.
8. Remove 3rd gear from the bottom.
9. Remove the ball bearings and outer race of taper bearing.

10. Using a pressing tool, press the bearings out of final gear.

DF-10
DIFFERENTIAL CARRIER

Disassembly (Cont'd)
11. Using a bearing puller, remove left and right side bearing from
differential case.

CAUTION:
• Side bearings do not need to be removed unless
necessary.
• Attach an identification tag to removed side bearings and
place them in order for easier and proper reassembly.

12. If final ring gear needs to be removed, remove final ring gear
bolts, then drive ring gear out using a plastic hammer.

13. Remove differential case securing bolts and remove differential

case. Then remove pinion mate shaft, pinion mate gear, side
gears and thrust washers.

Inspection
GENERAL
Clean all removed parts in cleaning solvent. Carefully check for
cracks or damage. If necessary, repair or replace faulty parts with
new ones.

FINAL DRIVE GEAR AND RING GEAR (GEAR SET)

• Check gears for wear or improper tooth contact. Adjust tooth
contact when reassembling as necessary. If gears are
excessively worn or adjusting tooth contact is impossible,
replace with new ones.
• Check for cracks, seizing or damage on teeth faces. If
necessary replace with new ones.

CAUTION:
When replacing final drive gear or ring gear, always replace
both gears as a set.

INPUT PINION, 2ND AND 3RD GEARS

Check for cracks or damage on teeth faces. If necessary, replace
with new ones.

DF-11
DIFFERENTIAL CARRIER

Inspection (Cont’d)
PINION MATE GEAR
• Check for cracks or damage on teeth faces. If necessary,
replace with a new one.
• Check for seizing or excessive wear on contacting surface to
thrust washer. If necessary, replace with a new one.
SIDE GEARS
• Check for cracks or damage on teeth faces. If necessary,
replace with new ones.
• Check for seizing or excessive wear on contacting surfaces to
thrust washers. If necessary, replace with new ones.
SIDE GEAR THRUST WASHERS AND PINION MATE
GEAR THRUST WASHER
Check for seizing, damage or excessive wear. If necessary, replace
with new ones.
BEARINGS
Check for seizing, flaking, wear, rust formation, improper spinning or
noise. If necessary, replace with new ones.
GASKETS
Always replace after every disassembly.

CAUTION:
Old liquid seal needs to be removed completely. Otherwise
leakage of the oil is expected.

DIFFERENTIAL CASE AND DRIVE AXLE HOUSINGS

• Check bearing-fixed areas for wear or damage. If necessary,
replace with a new differential case and differential carrier.
• Check sliding surfaces for wear or damage. If necessary,
replace with new ones.

Assembly
CAUTION:
• Adjust various parts while reassembling differential case
and drive axle housings assemblies.
• Apply a coat of gear oil (differential gear oil) before
installing gears, bearings, etc.
• Differential oil needs to be applied on the shaft of side
gears, pinion mates and thrust washers.
1. Install side gear, pinion mate shaft and pinion mate gear into
each of differential cases together with their corresponding
thrust washers.
2. Install left and right differential cases, then tighten with securing
bolts in a criss-cross fashion (apply Loctite 242 or similar to
bolts).
Securing bolts:
: 67 - 74 N•m (6.8 - 7.5 kg-m, 50 - 55 ft-Ib)

DF-12
DIFFERENTIAL CARRIER

Assembly (Cont’d)
3. Install ring gear (if previously removed) to differential case.
• Lightly tighten ring gear securing bolts in a criss-cross fashion.
• Tap bolt heads with a copper hammer to properly seat.
• Then tighten bolts to specified torque (apply Loctite 242 or
similar to bolts).
Securing bolts:
: 132 - 146 N•m (13.5 - 14.9 kg-m, 98 - 108 ft-Ib)

4. Using pressing tools, press-fit left and right side bearing inner
races into their corresponding bores in differential case.

5. Press fit the bearing inner race into the final drive gear.

DF-13
DIFFERENTIAL CARRIER

Assembly (Cont’d)
6. Install the final drive gear into the housing and adjust the end
play by using shims.
End play:
Standard: 0.02 - 0.07 mm (0.001 - 0.003 in)
Shim: (12 kinds)
1.95 - 2.50 mm, every 0.05 mm
(0.077 - 0.098 in, every 0.002 in)

How to use shims:

1) Read figures punched on the location of A and B.
A indicates dimension a.
B indicates dimension b.

DF-14
DIFFERENTIAL CARRIER

Assembly (Cont’d)
2) Put the bearing outer race. Apply a load of at least 50 kg (110
lb) and take measurement of span “C”.
3) A+B-C=T
Suitable thickness of shim
T - 0.05 mm (0.002 in) (T ~ Pin)
4) Select shim from 12 kinds of thickness.

7. Put the shim in the drive axle housing RH and install bearing
outer race of final drive gear.
8. Put bearing out race of final drive gear in the drive axle housing
LH.
9. When the drive axle housing is assembled with differential gear
assembly, the preload should be adjusted by shim.
Type of shim: (24 kinds)
1.50 - 2.65 mm, every 0.05 in
(0.059 - 0.104 mm, every 0.002 in)

DF-15
DIFFERENTIAL CARRIER

Assembly (Cont’d)

How to choose shim:

1) Read figures punched on drive axle housing D and E.
2) Put bearing outer race to differential gear, apply a load of at
least 50 kg (110 lb) and take measurement of span “G”.
3) D + E - G = Shim thickness
4) Select shim from 24 kinds.

DF-16
DIFFERENTIAL CARRIER

Assembly (Cont’d)

10. Put the shim and bearing outer race to drive axle housing RH.
11. Press fit bearing outer race to drive axle housing LH.
12. Install final drive gear and differential ring gear assembly into
drive axle housing LH.
1) Put final drive gear 3rd gear in the housing then the spline of
final drive gear is installed into 3rd gear.
2) Put differential ring gear assembly into the housing.

CAUTION:
• The ring gear securing bolts should be left side.
• Final drive gear and differential gear (ring gear) need to be
meshed slowly.

DF-17
DIFFERENTIAL CARRIER

Assembly (Cont’d)
13. Put sufficient Loctite 510 (liquid sealant) or similar, on the
mounting surface of drive axle housing LH.

CAUTION:
If Loctite 510 or similar is not used sufficiently, oil leakage is
expected.

14. Lift up the drive axle housing RH and put it down onto the drive
axle housing LH.
NOTE:
Use dowel pin of the drive axle housing LH.

DF-18
DIFFERENTIAL CARRIER

Assembly (Cont’d)
15. Tighten the bolts to install drive axle housing RH to the drive
axle housing LH (apply Loctite 242 or similar to bolts).
Securing bolts:
: 62 - 68 N•m (6.3 - 6.9 kg-m, 46 - 50 ft-lb)

CAUTION:
Tighten bolts in numerical order two or three times.

16. Lift drive axle unit from work bench.

DF-19
DIFFERENTIAL CARRIER

Assembly (Cont’d)
17. Set drive axle unit in horizontal position.

18. After making sure that correct bearing preload is obtained,

reassemble snap ring fixing 3rd gear to final drive gear shaft
spline.

WARNING:
Check if the snap ring is positioned in the groove of the final
drive gear shaft.

19. Check the end float of the 3rd gear.

Standard: 0.05 - 0.31 mm (0.002 - 0.012 in)

WARNING:
If the clearance is not correct when driving, the snap ring may
fall out by the 3rd gear.

DF-20
DIFFERENTIAL CARRIER

Assembly (Cont’d)
20. Put 2nd gear assembly; next, input pinion into drive axle
housing LH.

CAUTION:
• 3rd gear and 2nd gear assembly, 2nd gear and input pinion
need to be meshed slowly.
• When the input pinion is installed, the spline should be at
the right side of it.

21. Loctite 510 (liquid sealer) or similar is used on the mounting

surface of drive axle housing LH.

CAUTION:
If Loctite 510 or similar is not used enough, differential gear oil
leakage is expected.

DF-21
DIFFERENTIAL CARRIER

22. Replace gear train cover.

NOTE:
Use dowel pin.
Bolts for gear train cover:
: 22 - 24 N•m (2.2 - 2.4 kg-m, 16 - 18 ft-lb)

CAUTION:
Tighten bolts in numerical order two or three times.

DF-22
 DIFFERENTIAL CARRIER

Installation
1. Install drain plug on differential carrier, then tighten to specified
torque.

CAUTION:
Before installing drain plug, apply a coat of liquid packing to
plug threads.
2. Attach eyebolt (M10 x 1.5) to traction motor and attach a lifting
wire/nylon sling to the bolt. Then support traction motor using a
hoist or crane, keeping the wire/nylon sling stretched tight.

CAUTION:
• Place wooden block under differential case to securely
hold.
• Only authorized technicians are allowed to perform the
lifting operation.
3. While aligning traction motor shaft with input pinion of
differential carrier, insert the motor shaft into the input pinion.

CAUTION:
• Do not apply an undue force to traction motor shaft during
installation.
• Apply a coat of chassis grease to traction motor shaft
beforehand.
• Apply a coat of chassis grease to O-ring beforehand.
• Be careful not to damage O-ring.
4. Put on parking brake cable bracket in figure place, then tighten
differential carrier-to-traction motor securing nuts and bolts to
specified torque.
Securing nuts and bolts:
: 110 - 150 N•m (11 - 15 kg-m, 81 - 111 ft-lb)
NOTE:
Place of parking brake cable bracket is tightened with a long bolt
compared with other bolts.

5. While supporting final drive assembly using a jack, lift final drive
assembly using a lifting wire/nylon sling and hoist, install final
drive assembly to truck.

DFM0083

DF-23
 DIFFERENTIAL CARRIER

Installation (Cont’d)
6. Install axle mounting bracket to frame, then tighten securing
nuts and bolts to specified torque.
Securing nuts and bolts:
: 324 - 373 N•m (33 - 38 kg-m, 240 - 276 ft-lb)
NOTE:
To facilitate installation of axle mounting bracket, insert a bar rod
into the hole at frame, then pry as required to align the frame with
the bolt holes in drive mounting bracket.
7. Connect motor cables and harness to traction motor.
DFM0084 8. Connect parking brake cable to parking brake lever.
9. Install brake pedal bracket assembly. Refer to BR section for
details.
10. Connect brake tube to brake cylinder, then bleed air from brake
line. Refer to MA section for details.
11. Install front wheels and axle shaft. Refer to FA section.
12. Refill specified amount of gear oil. Refer to MA section.
13. Install mast assembly to vehicle. Refer to LM section.
14. Remove wooden blocks used to support vehicle, then lower the
vehicle to the floor. Refer to GI section for details.
15. Remove the filler plug and add differential oil until the oil spills
out of the filler hole.
Differential gear oil capacity:
Approx. 6.5 L (6-7/8 US qt, 5-3/4 Imp qt)
16. Replace the filler plug.
17. Clean off the oil from truck and floor.

DF-24