13 Rear Axle

46
Reduction gear Reduction Pinion

Differential case
Spider
Differential pinion Differential gear
Reduction gear
Tapered roller
bearing Differential
gear
Axle shaft (LH) Axle shaft (RH)

Differential
Housing Differential case
pinion
E1237D
The rear axle is the final reduction consisting of the final To cope with this, the differential pinion, while turning on
reduction gear installed as a single unit. The final reduction its spider revolves round the inner wheel differential gear
gear changes the torque transmitted from the engine to that has larger resistance, thereby driving the outer wheel
deliver a larger torque to the wheels whereas the differential gear to perform differential action. In this
differential adjusts the difference in distance the outer and manner, tire drag and resultant wear is prevented.
inner wheels are made to travel when the vehicle rounds a
corner.
The reduction gear changes the direction of transmission
axial output rotation (drive force) by 90 degrees and
distributes it to the drive wheels.
While the vehicle is running straight , the differential
pinions do not turn on the spider but revolve with
differential case.
When the vehicle makes a turn, the outer wheel turns
faster than the inner wheel and as a result, the inner wheel
is decelerated and the outer wheel is accelerated.
46-01
46
DIFFERENTIAL LOCK - PNEUMATIC
Vaccum - Diff. lock rear

axle assy-305DH
Lever
actuation
Differential lock
mechanism
In operation, it positively locks the wheel differential, to

provide improved traction under adverse road conditions.
• When the differential carrier operates in the locked
Conventional differentials transmit all ring gear torque only position, there is no differential action between the
through the differential gears to the axle shafts; there is a wheel.
loss of torque to the wheels if just one wheel begins to slip.
• When the differential carrier is operated in the unlocked
With full differential lock, direct power flow is available position, there is normal differential action between the
from the differential case to each axle shaft through a wheels all the time.
combination of fixed & sliding clutch arrangement, which
creates better vehicle control under adverse driving Differential Lock Engagement Indicator
conditions. The Differential Lock also includes a switch (electric) in the
lever actuation, differential lock which senses clutch
This control is most useful in wheel spin situations, such as
engagement and sends an electrical signal to a cab
when a wheel leaves the ground, crosses the patch of ice,
mounted room lamp
or is on an unusually bumpy road. In situations of unequal
traction where both wheels slip, the differential lock Operation - Differential Lock Engaged:
utilizes all traction available at both the wheels. • Pneumatic pressure applied to the slave cylinder moves
The differential lock is Direct Driver controlled system the piston, push rod, shift fork and sliding tooth clutch as
through a mechanical actuation lever device mounted in an assembly. The sliding tooth clutch engages the fixed
the cab. The driver manually locks and unlocks the wheel tooth clutch.
differential pneumatically by engaging a mechanical clutch • The sliding clutch is splined to the axle shaft (extended
and unlocks the wheel differential to function normally. splined shaft).
Description • The fixed clutch is splined to the differential case hub.
The Wheel Differential Lock consists of three major • Engaging the two clutches locks the wheel differential
assemblies: thus preventing wheel differential action.
• A pneumatic slave cylinder assembly which operates a
Operation - Differential Lock Disengaged:
shift fork & push rod assembly.
• When pneumatic pressure at the shift cylinder is
• A shift fork and push rod assembly which engages and released, a return compression spring (mounted on the
disengages the differential lock straight tooth clutch push-rod) moves the push-rod, shift fork and sliding
assembly. clutch as an assembly. The sliding tooth clutch moves out
• A straight tooth clutch assembly which consists of a of engagement with the fixed clutch.
sliding clutch splined to an extended splined axle shaft • The Wheel differential is unlocked and operates normally.
and a fixed clutch which is splined to the differential case
hub
46-02
46
DIFFERENTIAL LOCK - HYDRAULIC
Lever
actuation
Differential lock
mechanism
In operation, it positively locks the wheel differential, to • When the differential carrier operates in the locked
provide improved traction under adverse road conditions. position, there is no differential action between the
Conventional differentials transmit all ring gear torque only wheel.
through the differential gears to the axle shafts; there is a • When the differential carrier is operated in the unlocked
loss of torque to the wheels if just one wheel begins to slip. position, there is normal differential action between the
With full differential lock, direct power flow is available wheels all the time.
from the differential case to each axle shaft through a Differential Lock Engagement Indicator
combination of fixed & sliding clutch arrangement, which The Differential Lock also includes a switch (electric) in the
creates better vehicle control under adverse driving lever actuation, differential lock which senses clutch
conditions. engagement and sends an electrical signal to a cab
This control is most useful in wheel spin situations, such as mounted room lamp
when a wheel leaves the ground, crosses the patch of ice,
Operation - Differential Lock Engaged:
or is on an unusually bumpy road. In situations of unequal
• Hydraulic fluid pressure applied to the slave cylinder
traction where both wheels slip, the differential lock
moves the piston, push rod, shift fork and sliding tooth
utilizes all traction available at both the wheels.
clutch as an assembly. The sliding tooth clutch engages
The differential lock is Direct Driver controlled system the fixed tooth clutch.
through a mechanical actuation lever device mounted in
• The sliding clutch is splined to the axle shaft (extended
the cab. The driver manually locks and unlocks the wheel
splined shaft).
differential hydraulically by engaging a mechanical clutch
and unlocks the wheel differential to function normally. • The fixed clutch is splined to the differential case hub.
Description • Engaging the two clutches locks the wheel differential
The Wheel Differential Lock consists of three major thus preventing wheel differential action.
assemblies: Operation - Differential Lock Disengaged:
• A hydraulic slave cylinder assembly which operates a shift • When Hydraulic fluid pressure at the shift cylinder is
fork & push rod assembly. released, a return compression spring (mounted on the
• A shift fork and push rod assembly which engages and push-rod) moves the push-rod, shift fork and sliding
disengages the differential lock straight tooth clutch clutch as an assembly. The sliding tooth clutch moves out
assembly. of engagement with the fixed clutch.
• A straight tooth clutch assembly which consists of a • The Wheel differential is unlocked and operates normally.
sliding clutch splined to an extended splined axle shaft
and a fixed clutch which is splined to the differential case
hub
46-03
46
REAR AXLE IDENTIFICATION NUMBER (From May 2011) FINAL REDUCTION RATIO (GEAR RATIO) NUMBER
B F XXXX L
Model range identification

L: LMD models
H: HD models
Number of teeth on
crown wheel
Month wise running serial
number of rear axle
Rear axle production Number of teeth on

month code (A to M) pinion (Final drive)
A = Jan. and M = Dec.
Note : "I" is omitted
Rear axle production

year code
(2010 = A, 2011 = B, 2012 = C, etc...)
Note : "I" is omitted * These codes are punched on a rear axle housing.
Axle No. Date Gear Ra o Shi

H E L 29/08/14 6.428 [07 X 45] B Shi [refer Table 6]
No. of Teeth on Crown Wheel
No. of Teeth on Pinion
Gear Ra o
Date in DD/MM/20 Format
RA Code - RAXXX
Model Range [L-LMD, H-HD]
Month Wise Running

Serial No. of Rear Axle
Year of Manufacturing
Month of Manufacturing
Table - 6
First Shift A
Second Shift B
Third Shift C
46-04
46
Axle No. Date Gear Ra o Shi
L J XXXXX L RA325 22/09/20 7 X 37 5.28 A
Shi [refer Table 6]
Gear Ra o
No. of Teeth on Crown Wheel
No. of Teeth on Pinion
Date in DD/MM/20 Format
RA Code - RAXXX
Model Range [L-LMD, H-HD]
Month Wise Running

Serial No. of Rear Axle
Year of Manufacturing
Month of Manufacturing
Table - 6
First Shift A
Second Shift B
Third Shift C
46-05
46
Schematic wiring circuit - Pro 2065 LHD Export
1
2 BF 24
Diff 3
Lock 4
5 BF 1
SW. 6
Diff Lock I/C To Diff Lock

Switch Pigtail I/C To Cabin
Harness-1 Instrument
1 1 Cluster B
Pin 18 PIN 30
2 2
Diff Lock 3
Solenoid I/C To Cabin 85 86
4 Harness-1
1 87 30
Pin 31 Diff Lock
2 Solenoid Relay
BF 24
46-06
46
2110, 3012, 2112, Pro 2110XP, Pro 2114XP,
10.50, 10.55, 10.59, 10.60G, 10.70, 10.80XP, 10.90G 11.10, 11.12 6016 Pro 2059, Pro 2114LX /S 3014,
Applicable Vehicle Models 10.59XP, 10.60, 10.60E 10.75, 10.90 10.95 11.12XP, 11.14
Pro 2059XP, Pro 2075 Pro 3015, Pro 3016
Pro 2095XP, Pro 2110 2075 Bus, 2090 Bus,
Pro 2095XP/+ Pro 2114XPS, Pro 2109 6016 Bus
Rear Axle Type Banjo fully floating
Reduction
Type Single Reduction
Ratio 6.166 6.571 6.5 6.857 5.286 / 5.857 6.428 / 5.857
Tooth Shape Hypoid gear
Differential Tooth Straight bevel gear
Shape
Hypoid gear oil (lit.) 4.0±0.2 5.0 ± 0.2 7.0 8.0
Wheel Greasing
Grease Type Lithium base NLGI2
Pro 1049, Pro 1049 (BSIV), Pro 1050, Pro 1075, Pro 1075 (BSIV),
Pro 1050 (BSIV), Pro 1055, Pro 1055 T, Pro 1075 (CNG), Pro 1080, Pro 1075 Kenya,
Pro 1055 T (BSIV), Pro 1059, Pro 1090, Pro 1090 (BSIV), Pro 1095 T,
Pro 1080 (BSIV), Pro 1095,
Applicable Vehicle Models Pro 1059 (BSIV), Pro 1059 (CNG), Pro 1095 (BSIV), Pro 1095 T (BSIV)
Pro 1059XP, Pro 1059XP (BSIV), Pro 1095 (CNG), Pro 1095XP,
Pro 1059XP (CNG) Pro 1095XP (CNG) Pro 1095XP (BSIV)
Rear Axle Type Banjo type, Hypoid gears, Bevel gear differential
Reduction
Type Single Reduaction
Ratio 3.46 / 5.285 4.7 / 6.5 4.3 6.166 & 6.14
Tooth Shape Hypoid Gear
Crown wheel/ Pinion teeth 45/13 47/10 43/10 37/6
Differential Tooth Shape Straight Bevel Gear
Rear Axle Oil Qty (Ltrs.) 4.5 5 4.5
Rear Axle Oil Type SAE 85W140
Wheel Greasing
Grease Type Servo plex NLGI-2
Pro 1110XP T, Pro 1112XP T,

Pro 1080XP, Pro 1080XP T & Pro 1110C, Pro 1110XP, Pro 1112XP, Pro 2110, Pro 2110XP / XP+
Applicable Vehicle Models Pro 1110
Pro 1080XP T, Pro 2080XP Pro 1114 & Pro 1114XP, Pro 2118 Pro 2110XPT
Rear Axle Type Banjo type, Hypoid gears, Bevel gear differential Banjo Fully Floating
Reduction
Ratio 6.5 & 5.57 6.166 5.857 6.166
Crown wheel/ Pinion teeth 39/6 37/6 41/7
Rear Axle Oil Qty (Ltrs.) 5 8 12.5
Rear Axle Oil Type SAE 85W140
Wheel Greasing
46-05
46
Pro 1114XP, Pro 3009 Bus, Pro 3010 Bus
Applicable Vehicle Models Pro 3008 Bus
Pro 1110XP Pro 3011 Bus, 2112 Bus
Banjo type, Hypoid gears, Banjo fully floating
Rear Axle Type
Bevel gear differential
Reduction
Ratio 6.428 4.33 4.88/*4.33
Crown wheel/ Pinion teeth 41/7 39/9 48/10
Rear Axle Oil Qty (Ltrs.) 8 4.5
Rear Axle Oil Type SAE 85W140 API GL-5 SAE 85W140
Wheel Greasing
Pro 3008 (RHD) Pro 3008 Pro 3009 Pro 3012,

Applicable Vehicle Models Pro 3015 KUZER - RKE150
KUZER - RKE150 (LHD) (RHD) Pro 3013
Rear Axle Type Banjo type, Hypoid gear, Bevel gear differential
Reduction
Type Single Reduction
Ratio 4.8 4.3 6.428 4.8
Crown wheel/ Pinion teeth 41/7 39/9 41/7 45/7 41/7

Rear Axle Oil Qty (Ltrs.) 4.5 8 7
Rear Axle Oil Type API GL-5 SAE 85W140
Wheel Greasing
Grease Type Lithium - NLGI 2
Pro 2049, Pro 2050, Pro 2055, Pro 2080XP, Pro 2095 /
Pro 2049 Pro 2055T, Pro 2059, Pro 2075 Pro 2080XPT /
Applicable Vehicle Models Pro 2050 Bus Pro 2060, Pro 2070,
Pro 2059 XP
Pro 2090
2095XP, KUZER RKE150
Pro 2095XPT
6019 Bus
Pro 2075, Pro 2090 6019 Bus
Rear Axle Type Banjo type, Hypoid gears, Bevel gear differential
Reduction
(4.3 / Opt. 4.8 /
Ratio 3.46 4.3/4.7 3.9 4.3 4.8 5.57
Opt. 5.286)
Rear Axle Oil Qty (Ltrs.) 4.5 7.0 17.0
Rear Axle Oil Type
Wheel Greasing
Grease Type
46-06
46
Item Specification
Differential lock Type Manually operated, Hydraulic
Engagement Type Straight tooth, case lock
Brake oil quantity (liters) 0.5 (dry filling)
Gear Set (Reduction) Model 10.70 LHD Differential Lock
Item Specification
Differential lock Type Manually operated, Vaccum
Engagement Type Straight tooth, case lock
Gear Set (Reduction) Model Pro-2065/2070- 12/14/16FT Truck LHD Differential Lock
Gear Backlash value
DH FDR BACKLASH VALUE

305 3.46 0.18-0.23
305 4.3 0.18-0.23
305 4.7 0.18-0.23
305 5.286 0.18-0.23
305 5.857 0.20-0.28
305 6.571 0.20-0.28
320 4.33 0.20-0.28
320 4.8 0.20-0.28
320 6.166 0.20-0.28
320 6.5 0.20-0.28
340 5.286 0.2-0.3
370 4.88 0.25-0.35
370 5.857 0.25-0.33
370 5.286 0.25-0.33
370 6.428 0.20-0.28
395 6.166 0.25-0.33
395 5.286 0.3-0.41
395 5.857 0.25-0.30
395 5.286 0.3-0.41
440 6.428 0.25-0.33
440 6.833 0.3-0.41
440 5.857 0.3-0.41
440 6.166 0.3-0.41
458 4.8 0.25-0.33
458 5.286 0.3-0.41
458 5.857 0.3-0.41
432 All FDR 0.2-0.32
46-07
46
Correction and
Description Model / Type Nominal Value Limit
remarks
Rear Axle
At shaft center 2 4 Correct or replace

Rear axle shaft bend
At flange 0.03 0.05 Correct or replace
Rear axle shaft and differential gear spline
0.05 to 0.15 0.5 Replace
play in turning direction
Adjust with
0.18-0.23 0.5
differential gear
Backlash between differential gear spacer (replace as
and differential pinion differential gear set
0.2 - 0.28 0.5 in case of poor tooth
contact )
0.18 - 0.23 0.5
Backlash between final drive gear
and final drive pinion 0.25 - 0.33 Adjust
0.5
0.20 - 0.28
Backlash between differential spider and

0.17 - 0.27 0.5 Correct or replace
differential bevel pinion
Back face run out 0.1 or Less 0.5 Adjust
195 to 295 N cm
(20 to 30 Kgf Cm) 0.5
Final drive pinion starting (without installing Adjust with shim
oil seal) torque N cm (kgf cm) (When new) 110 to 350 N cm or coller
0.5
(11 to 35 Kgf Cm)
150 to 235 N cm
0.5
Final drive pinion starting (without installing (16 to 24 Kgf Cm)
Adjust
oil seal) torque N cm (kgf cm) (When used) 100 to 300 N Cm
0.5
(10 to 30 Kgf Cm)
Rear wheel hub starting torque N cm

(kgf cm) (without installing outer oil 195 to 390 (20 to 40) _ Adjust
seal and axle shaft)
0.02 to 0.06 _
Rear wheel hub end play Adjust with shim
Play between fixed tooth clutch spline and RH case - 0.02 Replace
differential spline in turning direction
Play between rear axle shaft and sliding tooth clutch 0.05 0.1 Replace
in turning direction
0.17 - 0.27 0.5 Replace

Differential pinion to spider clearance
Push rod to shifting fork clearance 0.04 - 0.15 0.2 Replace
Push rod to plug support cylinder clearance 0.04 - 0.05 0.5 Replace
46-08
46
Thead size Nm (Kgfm) Tightening torque

Part to be tightened Model / Type
O.D. x pitch (mm) Nm (Kgfm)
Rear Axle
Propeller shaft joint assembly attaching nut M 26 X 1.5 370 to 470 (38 to 48)
M14 X 1.5 225 to 265 (23 to 27)

Final drive gear to differential case
attaching bolt M14 X 1 225 to 265 (23 to 27)
Bearing cap tightening bolt M 16 X 1.5 175 to 200 (18 to 21)
Side bearing nut fixing lock plate

M8 X 1.25 20 to 26 (2.0 to 2.7)
attaching nut
Differential carrier assembly attaching nut M10 X 1.25 80 to 100 (8 to 10)
Bearing retainer mounting bolt M12 X 1.25 67 to 90 (6.8 to 9.2)
M10 X 1.25 58 to 78 (6 to 8)
M12 X 1.25 83 to 112 (8.5 to 11.5)
M26 X 1.5 372 to 470 (38 to 48)

Pinion Nut
M36 X 1.5 735 to 892 (75 to 91)
Rear axle flange bolt M16 X 2 260 to 300 (26 to 30)
Rear brake assembly attaching bolt M14 X 1.5 98 to 135 (10 to 14)
Rear wheel hub to rear brake drum
attaching nut (after tightening, lock using M19 X 1.5 305 to 380 (31 to 39)
triangular or quadrangular pyramid punch)
Wheel bearing inner lock nut tightening 98.1 to 127.53

Primary
(wheel bearing pre load adjustment) M52 X 1.5 (10 to 13)
29.43 to 39.24
Secondary M52 X 1.5
Wheel bearing inner lock nut tightening (3 to 4)
(wheel bearing pre load adjustment) Backing out
- 60O (1/6 turn)
angle
Wheel bearing outer lock nut M 52 X 1.5 69 to 125 (7 to 13)
Wheel bearing lock nut tightening (wheel
M 60 X 1.5 290 to 340 (30 to 35)
bearing pre load adjustment)
Rear axle shaft attaching bolts M 12 X 1.0 155 to 190 (15.5 to 19)
Oil filter plug M 18 X 1.5 59 to 78 (6 to 8)
Drain plug M 18 X 1.5 59 to 78 (6 to 8)
Wheel bearing locknut screw M 6 X 1.0 10 to 15 (1 to 1.5)
Diff. lock housing block bolt M 10 X 1.25 35 to 50 (3.5 to 5)
Diff. lock push rod assy. bolt M 8 X 1.25 35 to 50 (3.5 to 5)
Oil seal cover bkt. socket head screw - 4 to 6 (0.4 to 0.6)
Diff. lock plug, support & Vaccum cylinder bracket bolt M 8 X 1.25 20 to 30 (2 to 3)
46-09
46
Tools Name Part no. Shape Use
Inner oil seal dolly

Inner oil sea dolly ST227109
Cylinder gauge 153164 Cylinder gauge
Gradability adopter 153724 Gradability adopter
Dust cover installer 202705 Dust cover installer (MD)
Lock nut wrench 153043 Removal & installation of rear wheel

bearing nut
Removal of rear and front wheel hub

Kit-Front and rear hub puller ST000017 In Combination with child parts:
Hub Puller-0230002 & Adaptor -0032720
46-08
46
Installation of rear wheel hub

Rear hub bearing installer 152994
bearing and out race
Lock nut wrench 153614 Removal and installation of

rear wheel hub nut
Removal and installation of rear wheel

Hub Lock nut wrench ST000213M hub lock nut
Commonised against 172704, 0032709
Removal of wheel Hub

Kit Hub Puller ST000015 In Combination with below child parts:
Hub Puller- 153053 & Adaptor-0032720
Hub Puller ST126581 For removing of wheel Hub

(Applicable for 6 bolts hub)
Pinion height gauge 153173 Pinion height gauge-used to calculate C error
46-09
46
Installation of side bearing race

Differential side bearing 152984
installer
Oil seal installer 153725 Installation of bearing retainer oil seal
Tightening of differential bearing nut

Differential side bearing 153728
adjusting tool
Rear hub Inner & outer oil seal installer

Rear hub Inner & outer 202701
oil seal installer
Rear hub inner & outer 1002704 Rear hub inner & outer oil seal installer
oil seal instiller
Oil seal spacer installer 202702 Oil seal spacer installer
46-10
46
Bearing installer 305 Ø /320 Ø

Pinion bearing installer 152974
Outer oil seal dolly ST227110 Outer oil seal dolly
Pinion height gauge-used to calculate C error
Commonised against below tool

0032717 replaced by ST000212-1, 0032724
Rear axle shim selection ST000212M replaced by ST000212-2,
gauge 153726 replaced by ST000212-3, 0032725
replaced by ST000212-4, 1202725
replaced by ST000212-5, St127382
replaced by ST000212-6
Checking the pressure of pressure

Pressure cheking gauge ST111532 limiting valve of lift axle
Companion flange puller ST000209M Removal of companion flange
Kit-Removal of differential bearings and

propeller shaft centre bearing removal
Kit-Differential and In Combination with below child parts: ST000004

Propeller shaft bearing puller ST000007 Differential Bearing puller 152424
Adaptor - 0032720, Adaptor - 202602 -
Adaptor ST000007 is commonised against - 0032726,
0032701,152893, 0032704,153020,153727, St027297,
ST027301, 0052702, 0052703, 0052704, 0062708,
152424, 0032720, 202602)
46-11
46
Installation of bearing race
Commonised against 0032707, 0032708, 0202703,

1002701, 1002702, 202704, 153010, 0052717,
Bearing race installer ST622500 0052718, 0032723, 0032722, St027279, 0052705,
0052706, 0062704, 0062705, 0062716, 0062717,
0032606, 0032607, 1002601, 1002602
Wheel bearing inner cone ST227107 To press inner cone wheel bearing
pressing tool Tractor Trailor
Wheel bearing outer cone ST227108

To press outer cone wheel bearing
pressing tool Tractor Trailor
Flange Locking tool ST127616 Flange locking of TM and differential
Hub bearing greaser ST626491 Greasing of hub bearing
Skewness MA setting tool ST126610 Skewness setting of single axle

and multi axle vehicle
46-12
SERVICE PROCEDURES 46
5. SERVICE PROCEDURES
5.1 REAR AXLE NOTES :
5.1.1 Removal Leave the garage jacks in position to support the
Drain Rear Axle Oil housing.
a) Park your vehicle on a level surface. Apply parking
brake. WARNING :
b) Unscrew the drain plug from the center of the Vehicles on jacks can fall, causing serious personal injury
differential. Position the oil drain pan under the or property damage.
differential. Allow all the oil to drain out.
Never work under a vehicle supported by a jack without
supporting the vehicle with stands and blocking the
wheels.
NOTES :
Use MY-T-SIL 968 Black Neutral RTV Silicone Sealant
Drain plug
BLACK
59 to 78 Nm
968
(6 to 8 kgfm)
E1238D
Apply Chocks and Lift Up Rear Axle.

a) Apply chocks in front and behind the front tires then lift
up the rear axle housing using garage jacks and support
the frame by a rigid stand.
2 3
E1239D
1. Tire chock 2. Rigid rack 3. Garage jack
46-10
46 SERVICE PROCEDURES
Removal of Rear Axle (Hydraulic Brake)
Brake pipe
Shock absorber
U - bolts
Tire
Propeller shaft
E1240D
a) Park the vehicle on a level surface. Block the wheels to

prevent the vehicle from moving. Loosen wheel nuts. NOTES :
b) Raise the rear axle using garage jacks until the tires are Plug disconnected pipe to prevent entry of dirt, dust etc.
off the floor. Support frame by rigid stands.
c) Remove wheel nut and take out tires of rear axle.
d) Disconnect brake pipe connections.
e) Loosen and remove shock absorber mounting nuts and
U-bolt nuts.
f) Loosen and remove propeller shaft mounting nuts.
(Differential side)
g) Remove rear axle assy. by using jib crane and lifting
chain.
46-11
Removal of Rear Axle (Air Brake)
Tire section
Spring shackle
section
Propeller shaft
section
Spring brake
actuator
U - bolt section
E1241D
a) Park the vehicle on a level surface. Block the wheels to

prevent the vehicle from moving. Loosen wheel nuts. NOTES :
b) Raise the rear axle using garage jacks until the tires are Plug disconnected pipe to prevent entry of dirt, dust etc.
off the floor. Support frame by rigid stands.
c) Remove wheel nut and take out tires of rear axle.
d) Disconnect brake pipe connections. Loosen and
remove service brake actuator.
e) Loosen and remove shock absorber mounting nuts and
U-bolt nuts.
f) Loosen and remove propeller shaft mounting nuts.
(Differential side)
g) Remove rear axle by using jib crane and lifting chain.
46-12
5.1.2 Re-fitment
Re-fitment of Rear Axle (Hydraulic Brake)
Brake pipe
Shock absorber
26 to 33 Nm
(2.7 to 3.4 kgfm)
26 to 33 Nm
(2.7 to 3.3 kgfm)
U - bolts
115 to 155 Nm
(12 to 16 kgfm)
Tire
440 to 480 Nm
(44 to 48 kgfm)
Propeller shaft
E1242D
a) Install rear axle by using jib crane and lifting chain.

b) Re-fit propeller shaft mounting nuts (Differential side).
c) Re-fit shock absorber mounting nuts and U-bolt nuts.
d) Connect brake pipe connections.
e) Re-fit rear tires and tighten wheel nuts.
f) Take out rigid stands and slowly lower down rear axle.
46-13
Re-fitment of Rear Axle (Air Brake)
Tire section
440 to 480 Nm
(44 to 48 kgfm)
Spring shackle
section
40 to 55 Nm
(4 to 5.5 kgm)
Propeller shaft
section
59 to 74 Nm
(6.0 to 7.5 kgfm)
Spring brake
actuator
U - bolt section
40 to 55 Nm 200 to 240 Nm
(4 to 5.5 kgm) (20 to 24 kgfm) E1243D
a) Install rear axle by using jib crane and lifting chain.

b) Re-fit propeller shaft mounting nuts (Differential side).
c) Re-fit shock absorber mounting nuts and U-bolt nuts.
d) Re-fit service brake actuator and connect brake pipe
connections.
e) Re-fit rear tires and tighten wheel nuts.
f) Take out rigid stands and slowly lift down rear axle.
46-14
5.2 WHEEL HUB AND BRAKE DRUM (LD) b) Removal of wheel bearing nut
5.2.1 Removal 2
a) Removal of rear axle shaft
1
Tool Name Part No.
Rear hub
bearing locking 153043
E1246D nut wrench
Bolt holes for
disassembly 1. Rear hub bearing locking nut wrench 153043
2. Wheel bearing nut
E1244D
3. Internal washer
Remove all bolts attaching the shaft, then remove the rear Straighten the bent internal washer and use the special tool
axle shaft by screwing evenly two of the removed bolts into (Rear hub bearing locking nut wrench) to remove the wheel
the bolt holes provided in the flange for disassembly bearing nuts.
purpose.
NOTES :
For 1080XP
Do not reuse the removed internal washer.
With Shim Pack

5 Removal of lock washer.
4
6 3
2
1
E1245D
1. Nut 4. Rear axle shaft

2. Spring washer 5. Stud
3. Taper sleeve nut 6. Rear wheel hub
Remove all nuts, spring washer and tapper sleeve nuts then E1247D
remove the axle shaft. by screwing evenly two of the
removed bolts into the bolt holes provided in the flange for Remove the outer oil seal by uniformly pulling its outside
disassembly purpose. protrusion using pliers or similar tool.
Removal of wheel bearing lock nut.
Tool Name Part No.
Lock nut
adjusting tool ST000213M
E1248D
46-15
Removal of outer oil seal.
E1249D
c) Removal of wheel hub and brake drum
Tool Name Part No.
Hub puller LD 153053
E1250D
For hub removal, use rear axle shaft attaching bolt.
NOTES :
Remove in cross squence to prevent damage to the oil
seal.
d) Remove Outer/Inner bearing race from hub using
special tool (ST622500) and press with the help up
hydraulic press machine.
Bearing Race puller

ST622500
E0405E
46-16
5.2.2 Disassembly
Wheel Hub and Brake Drum (Without Shim Pack)
15
10
11
9
14
5
4
7 2
8 1
Runout 12
Item NV L
Shaft center 2 4
13
Flange 0.03 0.05
6
NV .... Nominal Value
3
L ..... Limit
E1252D
Disassembly Sequence
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1. Bolt 6. Outer bearing 11. Rear wheel hub

2. Rear axle shaft 7. Inner oil seal 12. Inner bearing outer race
3. Wheel bearing nut 8. Inner bearing 13. Outer bearing outer race
4. Internal washer 9. Hub bolt 14. Dust cover
5. Wheel bearing nut 10. Rear brake drum 15. Rear brake assembly
46-17
Wheel Hub and Brake Drum (With Shim Pack)
23
24
18
19
20
21
13
12
11
10
22 14
17 9
8 15
16 7
6
5
4
3
1
E1253D
c) Clean and inspect the wheel bearings, race spindle
1 2 3 4 5 6 7 8 9 10 11 12 13
bearing journals and hub. Bearings should be cleaned
14 15 16 17 18 19 20 21 22 23 24 with compressed air. Ensure that the air line is moisture
1. Rear axle shaft bolt 13. Hub bolt free.
2. Axle shaft 14. Dust cover
d) Replace all wheel studs that have damaged or
3. Gasket 15. Rear brake drum
distorted threads, are broken or bent, or are badly
4. Bolt 16. Dowel pin
5. Lock washer 17. Rear wheel hub corroded.
6. Lock nut 18. Oil seal e) Inspect bearing for excessive play, roller and bearing
7. Spacer seal outer 19. Bearing grease retainer race wear out. Replace with new one if required.
8. Oil seal rear hub outer 20. Inner bearing
f) Replace all rubber parts like oil seals.
9. Outer bearing inner race 21. Inner bearing outer race
10. Shim 22. Outer bearing outer race g) Replace gaskets.
11. Spacer bearing 23. Brake assembly h) Inspect wheel hub and axle shaft for any crack or
12. Hub nut 24. Spacer seal inner
excessive wear. Replace if required.
5.2.3 Inspection
a) Use a cleaning solvent to clean the hub and bearings.
Caution :
Kerosene or diesel fuel can be used for this purpose. Do not spin dry bearings as the rollers may score due to
b) Thoroughly clean the hub cavity. The cavity must be lack of lubricant.
free of any contaminants.
46-18
5.2.4 Assembly
Wheel Hub and Brake Drum (Without Shim Pack)
After tightening lock

by caulking with a
trigonal or tetragonal
punch
305 to 380 Nm
(31 to 39 kgfm)
8
7
6 14
13 98 to 135 Nm
(10 to 14 kfgm)
10
1
12
2 9
3
4
5
11
Primary tightening
Tighten to 98 to 127 Nm
(10 to 13 kgfm)
15
Secondary tightening
Tighten to 29 to 39 Nm
(3 to 4 kgfm)
Backing out angle 60o
E1254D
Assembly Sequence
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1. Axle shaft 9. Oil seal

2. Lock nut 10. Inner bearing
3. Lock washer 11. Outer bearing outer race
4. Lock nut 12. Inner bearing inner race
5. Outer bearing 13. Hub bolt
6. Hub 14. Dust cover
7. Brake drum 15. Rear brake assembly
8. Hub and brakedrum
46-19
Wheel Hub And Brake Drum (With Shim Pack)
12 After tightening lock

by caulking with a
trigonal or tetragonal
305 to 380 Nm
punch
(31 to 39 kgfm)
9 10 11
18
16
6 17 98 to 135 Nm
(10 to 14 kfgm)
20
1
2
15 13
3 4 7 8 14
19
E1255D
1. Axle shaft 8. Spacer bearing 15. Bearing rear hub inner
2. Lock washer 9. Hub 16. Outer bearing outer race
3. Lock nut 10. Brake drum 17. Inner bearing inner race
4. Oil seal 11. Dust cover 18. Hub bolt
5. Spacer seal outer 12. Hub brake drum & dust cover 19. Rear brake assembly
6. Outer bearing 13. Oil seal 20. Spacer
7. Shim 14. Bearing grease retainer
Assembly Sequence
20 19 12 18 16 17 15 14 13 8 7 6 5 3 2 1
46-20
Greasing at Assembly
Apply wheel
grease to race way
Apply wheel bearing Pack wheel
grease between lips bearing grease
Press fit flush

with hub end face
Pack wheel
bearing grease
Pack wheel Pack wheel bearing
bearing grease grease between lips
E1256D
5.2.5 Re-fitment
Wheel Hub and Brake Drum (Without Shim Pack) b) Installation of inner oil seal.
a) Install Outer/Inner bearing race on hub using special Tool Name Part No.
tool (ST622500) and press with the help up hydraulic Rear hub
press machine. oil seal LD 202701
installer
Bearing Race Puller

ST622500
E1259D
Press - fit with hub end face.
E0409E
46-21
c) Installation of wheel bearing nut and internal washer f) Measurement of rear wheel hub turning torque.
and adjustment of wheel bearing pre load (Turning
torque). Tangential force
d) Installation of wheel bearing nut.
Tool Name Part No.

Rear hub 2
bearing lock 153043
nut wrench
Radius
E1262D
Using a balancer, measure the tangential force when the

1 wheel hub rotation is stabilized. Obtain the using a
E1260D balancer, measure the tangential force when the wheel
hub rotation is stabilized. Obtain the distance between the
1. Rear hub bearing locking nut wrench
2. Wheel bearing nut outer end of the bolt, on which tangential force was
measured, and the center of wheel hub (radius) to calculate
Turn the wheel hub and brake drum while the wheel
the turning torque.
bearing nut is tightened to 69 to125 Nm (7 to13 kgfm).
Then tighten it fully. Again turn the wheel hub and brake 145 to 430 N m
Turning torque
drum while the wheel bearing nut is loosened fully and (15 to 44 kgfm)
then tightened to 20 to 29 Nm (2 to 3 kgfm). Then back it off Turning torque = Tangential force x Radius
60° + 15°.
e) Installation of internal washer and wheel bearing nut. NOTES :
Tool Name Part No. Projection Be sure to install inner oil seal.
Rear hub Do not install rear shaft.
bearing lock 153043
nut wrench
When measuring turning torque, make sure that there is
no drag between the brake and brake drum.
2
3
1
E1261D
1. Lock nut wrench 3. Internal washer

2. Wheel bearing nut
Install the internal washer with its internal projection

directed outward and aligned with the notch in the spindle
of the rear axle housing. Tighten the wheel bearing nut to
69 to 125 Nm (7 to 13 kgfm) and bend the upper part of the
internal washer outward and its lower part inward to lock
the wheel bearing nuts.
NOTES :
Always use new internal washer.
46-22
Wheel Hub and Brake Drum (With Shim Pack) c) Installation of rear wheel hub
a) Installation of inner oil seal spacer by using oil
Tool Name Part No.
seal spacer installer.
Rear hub
Tool Name Part No. oil seal spacer LD 100 27 03
installer
Rear hub
oil seal spacer LD 100 27 03
installer
E1266D
Insert distance piece and shims.

E1263D Fit the outer bearing and inner (without grease), washer
and slotted nut.
Caution : d) Installation of lock nut.
The chamfer on the outer circumference should face oil Tool Name Part No.
seal side.
Lock nut
ST000213M
adjusting tool
b) Install Outer/Inner bearing race on hub using special
tool (ST622500) and press with the help up hydraulic
press machine.
Torque wrench
Bearing Race Puller
ST622500 E1267D
For lock nut Installation, tighten the lock nut to 33 to 35

kgfm while turning the wheel hub.
Caution :
Shim selection for bearing pre loading should be done
without fitment of oil seal and grease on bearings.
e) Adjustment of end play.

E0409E
E1268D
To check the end play mount the dial gauge base on the hub
flange and pointer on the lock nut surface.
Shake the hub axially and read the deflection as shown in
dial gauge.
46-23
The end play should be 0.02-0.06 Correct by adjusting
Caution :
shims. In case the reading is less and on shims and vice-a-
versa. The lock nut must be tightened to specification. Check
Types of shim. for free rotation of the hub.
Thickness (mm) The chamfer on outer diameter of outer oil seal spacer
0.10, 0.15, 0.20, 0.25, 0.30, 0.50,1.00 should face oil seal side.
h) Installation of rear axle shaft.
Remove nut, washer, outer bearing, hub and inner bearing.
Install of bearing grease retainer, rear oil seal, dust cover.
Pack up grease on bearings and hub.
f) Installation of rear wheel hub and outer oil seal.
Knock
pin
Align knock
pin with this hole
E1271D
E1269D
For 1080XP
After correct shim selection install the outer oil seal in the
illustrated direction with the special tool, Rear wheel hub
oil seal installer.
5
NOTES :
4
Always use a new outer oil seal.
6 3
g) Installation lock washer. 2
1
E1272D
1. Nut 4. Rear axle shaft

2. Spring washer 5. Stud
3. Taper sleeve 6. Rear wheel hub
Re-fit axle shaft and than taper sleeeve, spring washer, and
nut.Tighten as per specified torque value.
E1270D
For lock washer installation, insert the lock washer into the
rear axle housing, with its flat portion in the spindle notch.
Then use two screws (M6 x 1.0) diagonally across the lock
nut to secure the lock washer in position. If bolt holes are
not liver up, turn in the loosening direction until they are
lined up.
46-24
5.3 WHEEL HUB AND BRAKE DRUM (MD) d) Removal of wheel bearing nut.
5.3.1 Removal
Tool Name Part No.
a) Removal of rear axle shaft Lock nut
adjusting tool ST000213M
E1276D
Bolt holes for
disassembly
e) Removal of outer oil seal.
E1273D
Remove all bolts attaching the shaft, then remove the rear
axle shaft by screwing evenly two of the removed bolts into
the bolt holes provided in the flange for disassembly
purpose.
b) Removal of wheel drum.
E1277D
f) Removal of wheel bearing hub.
Tool Name Part No.

Hub puller MD 023 00 02
E1274D
c) Removal of wheel bearing lock washer.
E1278D
E1275D
Loosen the two bolts and remove the lock washer.
46-25
g) Removal of Inner bearing and inner oil seal spacer.
E1279D
To remove the inner bearing along with the inner oil

seal use gear puller (standard tool) along with the
adapter.
h) Removal of dust cover
E1280D
Insert a appropriate thin rod from the opposite side of the

hub and tap it gently with a hammer.
I) Remove Outer/Inner bearing race from hub using
special tool (ST622500) and press with the help up
hydraulic press machine.
Bearing Race puller

ST622500
E0405E
46-26
5.3.2 Disassembly
Wheel Hub and Brake Drum (MD)
21
22
16
17
18
19
15
14
13
12
10
9
7
5
3
11 2
20 1
8
6
4
E1282D
Disassembly Sequence 5.3.3 Inspection

1 2 3 4 5 6 7 8 9 10 11 12 13
a) Thoroughly clean the hub cavity. The cavity must be
14 15 16 17 18 19 20 21 22 free of any contaminants. Kerosene or diesel fuel can
1. Drum brake 12. Dowel pin be used for this purpose.
2. Rear axle shaft 13. Rear wheel hub
b) Clean and inspect the wheel bearings, race spindle
3. Gasket 14. Bolt
bearing journals and hub. Bearings should be cleaned
4. Bolt 15. Dust cover rear wheel hub
5. Lock washer rear hub 16. Oil seal rear wheel hub inner
with compressed air. Do not spin dry bearings as the
6. Lock nut, wheel bearing 17. Bearing grease retainer rollers may score due to lack of lubricant. Ensure that
7. Spacer seal outer 18. Inner bearing the air line is moisture free.
8. Oil seal rear wheel hub 19. Inner bearing outer race c) Replace all wheel studs that have damaged or
outer 20. Outer bearing outer race
distorted threads, are broken or bent, or are badly
9. Outer bearing inner race 21. Rear brake assembly
10. Shim rear wheel hub 22. Spacer seal inner
corroded.
11. Spacer bearing d) Inspect bearing for excessive play, balls and bearing
race wear out. Replace with new one if required.
Replace parts like oil seals, gaskets.
e) Inspect wheel hub and axle shaft for any crack or
excessive wear. Replace if required.
46-27
5.3.4 Assembly
20
1
380 to 450 Nm
(38 to 45 Kgfm)
14 15
Gasket
11
150 to 185 Nm
(15.5 to 19 Kgfm) 12 16
2 9 10
4
8 260 to 300 Nm
(26 to 30 Kgfm)
20 to 30 Nm
(2 to 2.7 Kgfm)
17
6
16
7
400 to 450 Nm
(40 to 45 Kgfm) 13
21
19 Rear Wheel Hub End Play

18 NV : 0.02 - 0.06
NV : Nominal Value
E1283D L : Limit
Assembly Sequence
17 21 15 16 20 19 18 13 14
12 11 10 9 8 7 6 4 3 2 1
1. Brake drum 13. Rear wheel hub

2. Axle shaft bolt 14. Hub bolt
3. Axle shaft 15. Dust cover
4. Gasket 16. Oil seal rear hub inner
5. Bolt 17. Spacer
6. Lock washer 18. Inner bearing outer race
7. Lock nut wheel bearing 19. Inner bearing inner race
8. Spacer, seal outer 20. Bearing grease retainer
9. Oil seal rear hub outer 21. Rear brake assembly
10. Outer bearing inner race
11. Shims rear wheel hub
12. Spacer, seal inner
46-28
Greasing at Assembly
Pack wheel
Apply wheel bearing
bearing grease
grease to race way
Pack wheel
Press-fit flush with
bearing grease
hub end face
Apply wheel bearing Pack wheel

grease between lips bearing grease
E1284D
5.3.5 Re-fitment
a) Installation of Inner oil seal spacer by using oil b) Install Outer/Inner bearing race on hub using special
seal spacer installer. tool (ST622500) and press with the help up hydraulic
press machine.
Tool Name Part No.

Oil seal
MD 100 27 03 Bearing Race Puller
spacer installer
ST622500
E0409E
E1285D
Caution :
The chamfer on the outer circumference should face oil
seal side.
46-29
c) Installation of rear wheel hub & adjustment of rear
wheel hub end play.
Installation of rear wheel hub.
E1290D
Type of Shim
Thickness (mm)
E1288D
0.10, 0.15, 0.20, 0.25, 0.30, 0.50,1.00
Insert distance piece and shims. Remove nut, washer, outer bearing, hub and inner bearing.
Fit the outer bearing (without grease), washer and slotted
d) Installation of inner oil seal.
nut.
Installation of lock nut.
Tool Name Part No.

Lock nut
adjusting tool ST000213M Tool Name Part No.
Oil seal
MD 202701
installer
Torque
wrench
E1291D
E1289D Using a oil seal installer (Special Tool) press fit - with hub
end face Install of bearing grease retainer, rear oil seal, Pack
For lock nut Installation, tighten the lock nut to 33 to 35
up grease on bearings and hub.
kgfm while turning the wheel hub.
e) Install the dust cover using the special tool.
Caution : (Dust cover installer)
Shim selection for bearing pre loading should be done

without fitment of oil seal and grease on bearings.
Adjustment of end play.
To check the end play mount the dial gauge base on the hub Tool Name Part No.
flange and pointer on the lock nut surface. Dust cover

MD 202705
installer
Shake the hub axially and read the deflection as shown in
dial gauge.
The end play should be 0.02 - 0.06 mm corrected by
adjusting shims. In case the reading is less add on shims and E1292D
vice-a-versa.
46-30
f) Installation of outer oil seal. h) Installation of rear axle shaft.
Knock
pin
Align knock
Tool Name Part No. pin with this hole
Hub oil seal
MD 202701
installer
E1293D
After correct shim selection install the outer oil seal in the
illustrated direction with the special tool, rear wheel hub
E1295D
oil seal installer
At installation, align the knock pin driven into the wheel
NOTES : hub with the hole at the protrusion of the axle shaft flange
Always use a new outer oil seal. surface.
I) Installation of brake drum.
g) Installation of lock washer.
15 to 20 Nm
(1.5 to 2.5 Kgfm)
E1296D
E1294D
Fit the countersunk screw with a torque (50 to 60 Nm) 5
For lock washer installation, insert the lock washer into the kgfm.
rear axle housing, with its flat portion in the spindle notch. j) Correction and installation of axle shaft.
Then use two screws (M6 x 1.0) diagonally across the lock Rear axle shaft bend check.
nut to secure the lock washer in position. If bolt holes are
not liver up, turn in the loosening direction until they are
lined up.
Caution :
The lock nut must be tightened to specification. Check
for free rotation of the hub.
The chamfer on outer diameter of outer oil seal spacer
should face oil seal side.
E1297D
46-31
5.4 DIFFERENTIAL CARRIER ASSEMBLY Inspection Before Disassembly
5.4.1 Removal a) Backlash between the differential gear and differential
a) Removal of differential carrier assembly. pinion.
Garage jack E1298D E1300D
Measure the final drive gear circumference at about three

NOTES : points.
Remove sealant completely from the rear axle housing b) Run out on the back of the final drive gear.
and carrier mounting surface.
b) Setting the differential carrier assembly on the
working base (special tool).
Tool Name Part No.

Differential
working
base 003 27 21
assembly E1301D
Measure at the maximum diameter position.

c) Final drive tooth contact.
E1299D
Paper
E1302D
Apply a light coat of lead on three or four teeth and turn the
gear several turns and check tooth contact using paper.
46-32
5.4.2 Disassembly
5.4.2.1 Differential (305 Ø) (LD)
(Unit : mm)
Item Nominal value Limit
Play between rear axle shaft
and differential gear splines in 0.05 to 0.15 0.5
turning direction
Backlash between differential
0.19 to 0.25 0.5
gear and differential pinion
10
6
7
Differential pinion to differential
spider clearance (mm)
9 Rotating
Nominal value Limit 13
8 condition
0.17 to 0. 27 0.5
5
11 4 3
Rotating condition
23 24
28
14 26 25
1
Rotating 12
15 Deformation, wear,
condition
cracks, damage
27 2 * Run out on back
19 21 surface(mm)
17 * Backlash (mm)
Nominal value
29 Nominal value Limit
22 0.20 to 0.28 0.5 0.1 or less
20
18
16
E1303D
1 2 3 4 5 6 7 8 9 10
NOTES :
11 12 13 14 15 16 17 18 19 20 Check parts marked * before disassembly.
21 22 23 24 25 26 27 28 29 Put match marks on bearing caps to identify LH and
RH.
1. Lock plate 11. Differential gear spacer 21. Front bearing inner race
2. Side bearing cap * Final drive gear
12. 22. Collar
3. Adjusting nut 13. Differential case LH 23. Rear bearing inner race
4. Side bearing outer race 14. Differential carrier 24. Lock ring
5. Side bearing inner race 15. Shim 25. Pinion pilot bearing
6. Differential case RH 16. Lock nut 26. Final drive pinion
7. Differential pinion spacer 17. Companion flange 27. Front bearing outer race
*8. Differential pinion 18. Dust cover 28. Rear bearing outer race
9. Differential spider 19. Oil seal 29. Bearing retainer
10. Differential gear 20. Oil separator
46-33
(Unit : mm)
Item Nominal value Limit Bend (see inspection and
Play between rear axle shaft correction procedures) (mm)
turning direction Item Nominal value Limit
A 0.5 or less 1
gear and differential pinion 0.19 to 0.25 0.5 B1-B2 1.0 or less 5
7 11
Thin wire 6 Rotating
10 12
Differential pinion to differential 13 condition
spider clearance (mm) 9 5 4 3
Nominal value Limit
0.17 to 0. 27 0.5 8
24
23 25
Deformation, wear,
28 26 cracks, damage
* Run out on back
* Backlash (mm) surface(mm)
Nominal value Limit Nominal value
1
0.25 to 0.33 0.5 0.1 or less
2
14
22 15
29
21
19 27
20
18
17
16
E1304D
1 2 3 4 5 6 7 8 9 10
NOTES :
21 22 23 24 25 26 27 28 29 Put match marks on bearing caps to identify LH and RH.
2. Side bearing cap *12. Final drive gear 22. Collar
46-34
5.4.2.3 Differential (320 Ø) (MD)
(Unit : mm) Bend (see inspection and

Item Nominal value Limit correction procedures) (mm)
Play between rear axle shaft Item Nominal value Limit
and differential gear splines in 0.05 to 0.18 0.5 A 0.5 or less 1
turning direction B1-B2 1.0 or less 5
0.2 to 0.25 0.5
gear and differential pinion * Backlash (mm)
Nominal value Limit
0.25 to 0.3 0.5
6
Differential pinion to differential 7
spider clearance (mm) 10
12
Nominal value Limit
9 11 13
0.2 to 0.27 0.5
* Backlash (mm)
5
Nominal value Limit 4 3
0.25 to 0.3 0.5 8
25
23
26
28
1
2
14 15
22
27
21
20 Deformation, wear,
cracks, damage
18
* Run out on back
19
surface(mm)
17 Nominal value
0.1 or less
29
16
E1305D
1 2 3 4 5 6 7 8 9 10
NOTES :
21 22 23 24 25 26 27 28 29
Put match marks on bearing caps to identify LH and RH.
1. Lock plate 11. Differential gear spacer 22. Collar

2. Side bearing cap *12. Final drive gear 23. Rear bearing inner race
3. Adjusting nut 13. Differential case LH 24. Lock ring
4. Side bearing outer race 14. Differential carrier 25. Pinion pilot bearing
5. Side bearing inner race 15. Shim 26. Final drive pinion
6. Differential case RH 17. Companion flange 27. Front bearing outer race
7. Differential pinion spacer 18. Dust cover 28. Rear bearing outer race
* 8. Differential pinion 19. Oil seal 29. Bearing retainer
9. Differential spider 20. Oil separator
10. Differential gear 21. Front bearing inner race
46-35
5.4.2.4 Differential (340Ø & 370 Ø) (MD)
(Unit : mm)
Item Nominal value Limit Bend (see inspection and
Play between rear axle shaft correction procedures) (mm)
turning direction Item Nominal value Limit
Backlash between differential A 0.5 or less 1
0.22 to 0.27 0.5 B-B 1.0 or less 5
gear and differential pinion 1 2
* Backlash (mm)
7
Differential pinion to differential 11 0.25 to 0.33 0.5
spider clearance (mm)
12
13
0.22 to 0. 28 0.5
* Backlash (mm)
8 3
0.25 to 0.33 0.5
25
200 to 250 Nm 23
30 (20 to 25 kgfm) 26
31
28
1
2
14 15 Deformation, wear,
22 cracks, damage
27 * Runout on back
21 surface(mm)
20 Nominal value
18 0.15 or less
19
17
29
16 E1306D
1 2 3 4 5 6 7 8 9 10
NOTES :
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 Check parts marked * before disassembly.
Put match marks on bearing caps to identify LH and RH.
1. Lock plate 11. Differential gear spacer 22. Collar

2. Side bearing cap * 12. Final drive gear 23. Rear bearing inner race
3 . Adjusting nut 13. Differential case LH 24. Lock ring
4. Side bearing outer race 14. Differential carrier 25. Pinion pilot bearing
5 . Side bearing inner race 15. Shim 26. Final drive pinion
6 . Differential case RH 17. Companion flange 27. Front bearing outer race
7. Differential pinion spacer 18. Dust cover 28. Rear bearing outer race
* 8. Differential pinion 19. Oil seal 29. Bearing retainer
9. Differential spider 20. Oil separator 30. Thrust bolt
10. Differential gear 21. Front bearing inner race 31. Thrust nut
46-36
Disassembly d) Removal of final drive pinion.

a) Removal of bearing inner race.
2
Tool Name Part No.

Universal Diff. & Prop. sha 1
ST000004 3
bearing puller
E1310D
E1307D
1. Bearing retainer 3. Final drive pinion
b) Removal of bearing inner race. 2. Press 4. Guide
Using an appropriate cylinder as a guide, drive out the final

drive pinion with a press.
1080XP
e) Removal of pinion pilot bearing.
2 To jaw
puller
E1308D
3
c) Removal of bearing retainer.
E1311D
1. Lock ring 2. Pinion pilot bearing 3. Final drive pinion
First remove the lock ring and then remove the bearing
using the special tool, gear puller.
f) Removal of rear bearing inner race.
2 Holes
Provided for Tool Name Part No.
removal of retainer E1309D Universal Diff. & Prop. sha ST000004
bearing puller
Screw M12 x 1.25 mm bolts uniformly into the two holes
provided for disassembly of the bearing retainer and
remove the retainer.
E1312D
Set the special tool (Pinion bearing remover) and remove

the inner race using a press.
46-37
g) Removal of front and rear bearing outer races. j) Removal of differential gears.
2
Notches
3
6
Bearing
retainer
Front bearing
outer race Rear bearing 4
outer race 5
E1313D
Apply a bar to each of the three notches provided inside of

the bearing retainer and strike uniformly to drive out outer
E1316D
race.
h) Removal of wire from case diff. bolts. 1. Differential gear washer 4. Differential case RH
2. Differential bevel gear 5. Differential pinion washer
3. Differential spider 6. Differential bevel pinion
1080 XP
NOTES :
Keep LH and RH differential gear spacer separately so
that correct ones may be used on correct side during
reassembly
E1314D
I) Removal of case LH and RH.
Differential
Mating case L.H.
marks
Differential
Case R.H.
E1315D
Loosen the differential case bolt to separate case LH and

RH.
Caution :
Before disassembly, be sure to put alignment marks on
cases LH and RH, if they are without such marks.
46-38
5.4.3 Inspection
Bend inspection and correction (mm)
a) Rear axle shaft and differential gear spline play in
turning direction. Item Nominal value Limit
A 0.5 or less 1
B1-B2 1.0 or less 5
c) Backlash between differential gear differential pinion.

Rear axle
shaft
Play
E1317D
b) Rear axle housing bend.
E1319D
A A
V-block
B1 or B2
Square
Measuring point
E1318D
Support horizontally the housing spindle at the inner

bearing engagement section at both ends by V-blocks.
For measurement of A, apply a dial gauge to the outer
bearing engagement section and turn through 360
degrees.
For measurement of B1 and B2 use a square to position the
housing squarely and measure B1 . Then, turn through 180
degrees and measure B2 .
Replace if the measured value exceeds the limit, in case of
bend of spindle section (measurement of A) the spring seat
of the housing may be corrected by a hydraulic press.
46-39
5.4.4 Assembly
Back surface run out Starting torque

Nominal value Nominal value Tangential force
0.1 or less 195 to 295 N cm 34 to 52 N
Apply LOCTITE (3.4 to 5.2 kgf)
(20 to 30 kgf cm)
(LOCTITE 271 : red
or equivalent)
83 to 110 Nm
(8.5 to 11.5 kgfm)
175 to 200 Nm
(18 to 21 kgfm)
1
12
11 3 Backlash
26
Backlash 5
0.20 to 0.28 0.5
4
0.18 to 0.23 0.5
8 13
30 Apply sealent
7
(THREEBOND 1215
or equivalent)
9 34 to 44 Nm
(3.5 to 4.5 kgfm)
27
Apply LOCTITE 25 21
(LOCTITE 601 : green 15
or equivalent) 24
29
14 28 20
23
67 to 90 Nm 19
(6.8 to 9.2 kgfm)
18
Starting torque 22 17
Item Nominal value Limit 16
Apply grease to lps
When new 195 to 295 N cm Tangential force 370 to 470 Nm (Wheel bearing grease
(20 to 30 kgf cm) 34 to 52 N (38 to 48 kgfm) or equivalent)
(3.4 to 5.2 kgf)
When reused 150 to 235 N cm Tangential force
(16 to 24 kgf cm) 27 to 41 N
(2.7 to 4.1 kgf) E1320D
Assembly Sequence
27 29 28 22 21 25 24 20 19 18 17 16 15 14 4 3 2 1 30
15 14 5 6 11 10
9 8 7
When following parts are to be replaced be sure to
12 13 5 replaced as a set.
Set name Set composition Remarks
Gear set Final drive gear Use parts of
and final drive same mating
pinion serial numbers
Carrier Carrier and
assembly bearing cap
Bearing Inner race and
outer race
Differential Differential Make sure that
gear pinion and all gears are of
differential gear same make
46-40

Back surface runout
Nominal value
Apply LOCTITE 0.1 or less Starting torque
(LOCTITE 271: red
or equivalent) Nominal value Tangential force
12
195 to 295 N cm 32 to 48 N
13 (20 to 30 kgf cm) (3.2 to 4.8 kgf)
11
6 20 to 26 N m
4 14 (2.0 to 2.7 kgf m)
Backlash 5 2
Nominal value Limit
3 Apply sealant
0.18 to 0.23 0.5 10
9 ( THREEBOND 1215
8 or equivalent)
7
30
24
25
34 to 44 Nm
14 (3.5 to 4.5 kgfm)
28
67 to 90 Nm
(6.8 to 9.2 kgfm) 23
15
22
21 27
29 20
Backlash 19
26 Apply Grease to lips
Nominal value Limit 18 (Wheel bearing grease or equivalent)
0.25 to 0.33 0.5
17
Starting torque
Item Nomial value Limit 16
When new 195 to 295 N cm Tangential force 370 to 470N m
(20 to 30 kgf cm) 32 to 48 N (38 to 48 kgfm)
(3.2 to 4.8 kgf)
(16 to 24 kgf cm) 25 to 38 N
(2.5 to 3.8 kgf) E1321D
Assembly Sequence
27 29 28 22 21 25 24 20 19 18 17 16 15 14 4 3 2 1 30
23 26 5 6 11 10
9 8 7
12 13 5
10. Differential gear 20. Oil separator 30. Rear axle housing
46-41
Back surface run out Starting torque

Nominal value Nominal value Tangential force
0.1 or less 195 to 295 N cm 34 to 52 N
Apply LOCTITE (20 to 30 kgf cm) (3.4 to 5.2 kgf)
(LOCTITE 271 : red
or equivalent)
83 to 110 Nm
(8.5 to 11.5 kgfm)
175 to 200 Nm
(18 to 21 kgfm)
1
12
11 3 Backlash
26
2 5 Nominal value Limit
Backlash
0.20 to 0.28 0.5
4
0.18 to 0.23 0.5
8 13
30
7 Apply sealent
(THREEBOND 1215
or equivalent)
9 34 to 44 Nm
(3.5 to 4.5 kgfm)
27
Apply LOCTITE 25 21
(LOCTITE 601 : green 15
or equivalent) 24
29
14 28 20
23
67 to 90 Nm 19
(6.8 to 9.2 kgfm)
18
Starting torque 22 17
Item Nominal value Limit 16

Apply grease to lps
When new 195 to 295 N cm Tangential force 370 to 470 Nm (Wheel bearing grease
(20 to 30 kgf cm) 34 to 52 N (38 to 48 kgfm) or equivalent)
(3.4 to 5.2 kgf)
(16 to 24 kgf cm) 27 to 41 N
(2.7 to 4.1 kgf) E1322D
Assembly Sequence
27 29 28 22 21 25 24 20 19 18 17 16 15 14 4 3 2 1 30
15 14 5 6 11 10
9 8 7
12 13 5
2. Side bearing cap * 12. Final drive gear 22. Collar
* 8. Differential pinion 18. Dust cover 28. Rear bearing outer race
46-42

Back surface runout
Nominal value
Apply LOCTITE 0.1 or less Starting torque
(LOCTITE 271: red
or equivalent) Nominal value Tangential force
12
110 to 350 N cm 14.7 to 46.7 kgf
13 (11 to 35 kgf cm) (1.5 to 4.6 kgf)
11
6 20 to 26 N m
4 14 (2.0 to 2.7 kgf m)
Backlash 5 2
Nominal value Limit
3 Apply sealant
0.18 to 0.23 0.5 10
9 ( THREEBOND 1215
8 or equivalent)
7
30
24
200 to 250 Nm 25
34 to 44 Nm
(20 to 25 kgfm)
14 (3.5 to 4.5 kgfm)
28
67 to 90 Nm
(6.8 to 9.2 kgfm) 23
15
22
21 27
29 20
Backlash 19
26 Apply Grease to lips
Nominal value Limit 18 (Wheel bearing grease or equivalent)
0.25 to 0.33 0.5
17
Starting torque
Item Nomial value Limit 16
When new 110 to 350 N cm Tangential f orce 370 to 470N m
(11 to 35 kgf cm) 14.7 to 46.7 N (38 to 48 kgfm)
(1.5 to 4.7 kgf)
When reused 100 to 300 N cm Tangential f orce
(10 to 30 kgf cm) 13 to 40 N
(1.3 to 4kgf) E1323D
Assembly Sequence
27 29 28 22 21 25 24 20 19 18 17 16 15 14 4 3 2 1 30
23 26 5 6 11 10
9 8 7
12 13 5
10. Differential gear 20. Oil separator 30. Rear axle housing
46-43
Assembly of Reduction Assembly c) After fitting the collar, install the front bearing inner
a) Reduction assembly race to the final drive pinion using the special tool,
Assembly of bearing retainer. pinion bearing installer.
Pinion bearing installer Pinion bearing installer
Installer punch 305 Ø 152974 305 Ø / 320 Ø 152324
123 00 01 320 Ø 202702 370 Ø 003 27 10
370 Ø ST622500
Bearing retainer Pinion pilot bearing
Rear bearing Final drive pinion
outer race
Front bearing
outer race Pinion bearing installer
305 Ø 152974
320 Ø 202702
Installer punch 370 Ø ST622500
123 00 01
E1324D E1327D
Using the special tools, two pinion bearing installers, install d) Using the special tools, pinion pilot bearing installer,
the outer races in the bearing retainer. install the pinion pilot bearing to the final drive pinion.
Pinion bearing installer Companion flange

305 Ø / 320 Ø 152974
370 Ø 003 27 11 To be secured
370 to 470 Nm
Rear bearing Tangential force (38 to 48 kgfm)
inner race
Wind wire here

Bearing retainer
Final drive
pinion E1328D
E1325D
e) Tighten the lock nut to specified torque and check that
b) Using the special tools, pinion bearing installer, install
the tangential force is as specified below. If out of
the rear bearing inner race to the final drive pinion.
standard, adjust for standard tangential force by
selecting an appropriate adjusting collar from the table
Pinion bearing installer below.
305 Ø / 320 Ø 152974
370 Ø 003 27 11 Adjusting collar
Collar thickness
T = 15.2 to 15.8 (25 types in 0.025 mm increments)
Rear bearing
Collar
inner race NOTES :
Final drive
When measuring the starting torque, be sure to fit the
pinion oil separator.
E1326D
Measure starting torque without oil seal installed.
When New When Used
Tangential Force Starting Torque Tangential Force Starting Torque
N (Kgf) N Cm (Kgf Cm) N (Kgf) N Cm (Kgf Cm)
305 Dia LD 34 - 52 (3.4 - 5.2) 195 to 295 (20 to 30) 27 - 41 (2.8 - 4.1) 150 to 235 (16 to 24)
320 Dia MD 34 - 52 (3.4 - 5.2) 195 to 295 (20 to 30) 27 - 41 (2.8 - 4.1) 150 to 235 (16 to 24)
320 Dia LD 32 - 48 (3.2 - 4.8) 195 to 295 (20 to 30) 24.4 - 38.2 (2.49 - 3.89) 150 to 235 (16 to 24)
370 Dia MD 14.7 - 46.7 (1.5 - 4.76) 110 to 350 (11 to 35) 13.33 - 40 (1.36 - 4.08) 100 to 300 (10 to 30)
46-44
Equation
Oil seal installer Shim Thickness D = (0.5 - a) + b + c
305 Ø / 320 Ø 153725
370 Ø 003 27 13 Where, a = Error with respect to Nominal dimension A
® Diff. Carrier Case error
Oil seal b = Error with respect to Nominal dimension B
® Drive Pinion error
Oil separator c = Error with respect to Nominal dimension C
® Assembly error
Bearing retainer
How To Calculate Errors :
Error On Dimension A - Differential Carrier
E1329D
- If Error punched on Diff. Carrier is '+1' then, a = 0.1
f) Using the special tool, oil seal installer, install the oil - If Error punched on Diff. Carrier is '0' then, a = 0
seal in the bearing retainer. - If Error punched on Diff. Carrier is '-1' then, a = - 0.1
Selection of the final drive pinion mounting adjusting Error On Dimension B - Drive Pinion
shim (pinion height adjustment) - If Error punched on Drive pinion tip is ' + 1' then, b = 0.1
- If Error punched on Drive pinion tip is '00' then, b = 0
- If Error punched on Drive pinion tip is ' - 1' then, b = -0.1
1
Error On Dimension C - Assembly Error
2 Read the following procedure to calculate C error
1
2
Number
3
stamped 4
here
E1330D
1. Differential carrier 2. Final drive pinion 5
To achieve nominal dimensions at reassembly, based on

6
the stamped sizes of the final drive pinion and differential
E1332D
gear carrier, calculate the thickness of shims by the
following equation and choose shims. 1. Companion flange 4. Bearing retainer
2. Lock nut 5. Front bearing
3. Rear bearing 6. Pinion height gauge
Tool Name Part No.

Pinion height ST000212M
D gauge
C
Mount the illustrated parts to pinion gauge for straddle
mounted differential and tighten the lock nut until nominal
A starting torque (as per service standard table) is obtained.
B
NOTES :
E1331D
Do not mount any part other than parts shown in the
illustration.
46-45
Insert a right thickness of feeler gauge in between the pin Installation of bearing retainer.
of special tool and the surface of the bearing retainer (as
shown in above figure) rotate the retainer and check at 2
more points and take the average of three readings.
Then 'C' error = Feeler Gauge thickness - 0.5 mm.
Shim Selection
On calculation of all the errors, viz., a, b & c, substitute the
Apply LOCTITE all around
respective error values in the Equation and obtain required (LOCTITE 601 : green or equivalent) E1333D
shim thickness, D.
Apply LOCTITE to the surface of the differential carrier on
Shim Thickness, D = (0.5 - a) + b + c which the pinion pilot bearing is to be installed. After
application of LOCTITE leave it alone for 30 minutes to 2
hours. Allow three hours, preferably 24 hours, before
In order to choose the shim of thickness D, please use an
actual operation of the vehicle.
one or combination of the following shim sizes.
0.5, 0.2, 0.1 mm.
Example :
Consider the following case procedure for shim selection is
4
explained as follows.
Let,
5
1. Error punched on Diff. carrier face is = '+1'
2. Error punched on Drive pinion tip is = '0.0'
6
3. Error punched on Pinion gauge = '+0.1' 3
2
(i.e, Feeler gauge thickness = 0.6, 1
E2173D
hence, c = 0.6 - 0.5 = + 0.1)
1. Final drive pinion 4. Embossed match marks
\Shim thickness, D = (0.5 - a) + b + c
2. Shims 5. Bearing retainer
In this case, as given above, a = + 0.1 3. Differential carrier 6. Companion flange
b=0
Install the final drive pinion to the differential carrier.
and c = + 0.1
therefore, D = (0.5 - 0.1) + 0 + 0.1
D = 0.5 NOTES :
Hence a shim with 0.5 thickness needs to be selected for Line up embossed match marks on the bearing retainer
use. and differential carrier.
46-46
46
Backlash Table
Sr. No.
1 305 3.46 0.18-0.23
2 305 4.3 0.18-0.23
3 305 4.7 0.18-0.23
4 305 5.286 0.18-0.23
5 305 5.857 0.20-0.28
6 305 6.571 0.20-0.28
7 320 4.33 0.20-0.28
8 320 4.8 0.20-0.28
9 320 6.166 0.20-0.28
10 320 6.5 0.20-0.28
11 340 5.286 0.2-0.3
12 370 4.88 0.25-0.35
13 370 5.857 0.25-0.33
14 370 5.286 0.25-0.33
15 370 6.428 0.20-0.28
46-44
46
5.4.3 Differential Lock - Disassembly & Assembly
Apply Sealant
All around
20 to 30 Nm
(2 to 3 kgf m)
1
2
4 to 6 Nm 22
13 (0.4 to 0.6 kgf m)
7 8
9
14
Apply locktite 16
Apply Sealant Disassembly Sequence
All around 21
on thread 6 Deformation, wear, 1. Vaccum cylinder mtg. bracket bolt
15
cracks, damage 2. Vaccum cylinder mtg. bracket
11 3. Diff. lock plug support bolt
12 4. Diff. lock plug support
5 5. Diff. lock return spring
18 20
10 17 4 Grease nipple
6. Spring support
35 to 50 Nm 20 to 30 Nm 3 7. Oil seal cover bracket socket head screw
4 to 6 Nm 20 to 30 Nm
(3.5 to 5kgf m) (2 to 3kgf m) (0.4 to 0.6 kgf m) 8. Oil seal cover bracket
19 (2 to 3 kgf m)
Apply locktite 35 to 50 Nm 9. Oil seal
on thread (3.5 to 5kgf m)
10. Diff. lock push rod mtg. nut
11. Collar linkage bush
12. Washer plain
13. Diff. lock push rod assy.
14. Snap pin
15. Collar pin
16. Diff. lock linkage bracket
17. Backup lamp switch
18. Gasket
19. Diff. lock housing block bolt
20. Diff. lock housing block
21. Diff. lock sliding tooth clutch
22. Diff. lock fork
Assembly Sequence
22 21 6 20 19 5 4 3 9 8 7 13
16 15 14 12 11 10 18 17 2 1
46-45
46
Pinion height shim selection matrix for Straddle Mounted Differential
Shim Thickness = 'D' = (0.5 - a) + b + c
Feeler
gauge B = '+0.1' B = '0.0' B = '-0.1'
thickness A = '+1' A = '0' A = -1' A = '+1' A = '0' A = '-1' A = '+1' A = '0' A = '-1'
0.1 0.1 0.2 0.3 0.1 0.1 0.2 0.1 0.1 0.1
0.2 0.2 0.3 0.4 0.1 0.2 0.3 0.1 0.1 0.2
0.3 0.3 0.4 0.5 0.2 0.3 0.4 0.1 0.2 0.3
0.4 0.4 0.5 0.6 0.3 0.4 0.5 0.2 0.3 0.4
0.5 0.5 0.6 0.7 0.4 0.5 0.6 0.3 0.4 0.5
0.6 0.6 0.7 0.8 0.5 0.6 0.7 0.4 0.5 0.6
0.7 0.7 0.8 0.9 0.6 0.7 0.8 0.5 0.6 0.7
0.8 0.8 0.9 1.0 0.7 0.8 0.9 0.6 0.7 0.8
0.9 0.9 1.0 1.1 0.8 0.9 1.0 0.7 0.8 0.9
1.0 1.0 1.1 1.2 0.9 1.0 1.1 0.8 0.9 1.0
1.1 1.1 1.2 1.3 1.0 1.1 1.2 0.9 1.0 1.1
1.2 1.2 1.3 1.4 1.1 1.2 1.3 1.0 1.1 1.2
1.3 1.3 1.4 1.5 1.2 1.3 1.4 1.1 1.2 1.3
1.4 1.4 1.5 1.6 1.3 1.4 1.5 1.2 1.3 1.4
1.5 1.5 1.6 1.7 1.4 1.5 1.6 1.3 1.4 1.5
"A" = Error mark punched on differential carrier
"B" = Error itched on drive pinion tip
= Min. shim thickness to be kept
E1335D E1336D
1.41+0.01, 1.44+0.01, 1.47+0.01, 1.50+0.01, 1.53+0.01, 1.56+0.01,

1.59+0.01, 1.62+0.01, 1.65+0.01, 1.30+0.01,
46-46
46
g) Reassembly of differential assembly (305 ø)
Differential
case L.H.
Mating
Side bearing marks
inner race
Differential
Case R.H.
E1337D E1340D
Insert wire in the bolts of differential case assembly and

lock the wire by twisting.
3
6
E1341D
4
5
Run out on the back of final drive gear .
E1338D
1. Differential gear washer

2. Differential bevel gear 5. Differential pinion washer
3. Differential spider 6. Differential bevel pinion
Adjustment of backlash between differential gear and

differential pinion.
E1342D
Measure run out at the maximum diameter position.
E1339D
46-47
46
Tooth contact adjustment of final drive gear.
E1343D
Apply a light coat of red lead to three or four teeth and turn
the gear several times to check tooth contact.
If the tooth contact is excessively out of position adjust by
adding or removing final drive pinion mounting adjusting
shims and increasing or decreasing the backlash.
When the gear has to be replaced because of badly worn
teeth, make sure that the final drive gear and final drive
pinion are replaced as a set.
Abnormal Final Drive Gear Tooth Contact and Its Cause.
Face contact Flank contact Toe Contact Heel contact

Correct contact
Too large Backlash, Incorrect pinion Incorrect pinion
Too small Backlash
worn gear height height
Correct Contact
70 - 80 % Toe Biased Center Contact
46-48
46
5.4.5 Re-fitment
260 to 300 Nm
a) Sealant application. (26 to 30 Kgfm)
(8 places at upper
and lower points)
260 to 300 Nm
(26 to 30 Kgfm)
Apply sealant to Differential carrier
outer side of notch base at 4 places
(2 places) E1345D
c) Lubrication after Re-fitment.
Sealant
(Three bond 3 to 4
1215 or
equivalent)
Section B-B E1344D Oil filler plug

59 to 78 Nm
b) Installation. (6 to 8 kgfm)
Use Differential carrier base for installation.

Center the assembly so that the mounting stud threads of E1346D
the rear axle housing may not be damaged.
After parts installation, bleed the brake system.
For bleeding procedures, see group 52 Hydraulic brake.
46-49
46
46-50

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46

Reduction gear Reduction Pinion

Differential pinion Differential gear

Axle shaft (LH) Axle shaft (RH)

Vaccum - Diff. lock rear

In operation, it positively locks the wheel differential, to

Model range identification

Rear axle production Number of teeth on

Rear axle production

Axle No. Date Gear Ra o Shi

No. of Teeth on Crown Wheel

No. of Teeth on Pinion

Date in DD/MM/20 Format

Model Range [L-LMD, H-HD]

Month Wise Running

Shi [refer Table 6]

No. of Teeth on Crown Wheel

No. of Teeth on Pinion

Date in DD/MM/20 Format

Model Range [L-LMD, H-HD]

Month Wise Running

Diﬀ Lock I/C To Diff Lock

Pro 1110XP T, Pro 1112XP T,

Pro 3008 (RHD) Pro 3008 Pro 3009 Pro 3012,

Ratio 4.8 4.3 6.428 4.8

Tooth Shape Hypoid Gear

Crown wheel/ Pinion teeth 41/7 39/9 41/7 45/7 41/7

Grease Type Lithium - NLGI 2

Gear Backlash value

DH FDR BACKLASH VALUE

At shaft center 2 4 Correct or replace

Backlash between differential spider and

Back face run out 0.1 or Less 0.5 Adjust

Rear wheel hub starting torque N cm

0.17 - 0.27 0.5 Replace

Push rod to shifting fork clearance 0.04 - 0.15 0.2 Replace

Thead size Nm (Kgfm) Tightening torque

M14 X 1.5 225 to 265 (23 to 27)

Bearing cap tightening bolt M 16 X 1.5 175 to 200 (18 to 21)

Side bearing nut fixing lock plate

Differential carrier assembly attaching nut M10 X 1.25 80 to 100 (8 to 10)

Bearing retainer mounting bolt M12 X 1.25 67 to 90 (6.8 to 9.2)

M12 X 1.25 83 to 112 (8.5 to 11.5)

M26 X 1.5 372 to 470 (38 to 48)

Wheel bearing inner lock nut tightening 98.1 to 127.53

Tools Name Part no. Shape Use

Inner oil seal dolly

Cylinder gauge 153164 Cylinder gauge

Gradability adopter 153724 Gradability adopter

Dust cover installer 202705 Dust cover installer (MD)

Lock nut wrench 153043 Removal & installation of rear wheel

Removal of rear and front wheel hub

Tools Name Part no. Shape Use

Installation of rear wheel hub

Lock nut wrench 153614 Removal and installation of

Removal and installation of rear wheel

Removal of wheel Hub

Hub Puller ST126581 For removing of wheel Hub

Pinion height gauge 153173 Pinion height gauge-used to calculate C error