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HYSTER K007 (H12XM-6 Europe) Forklift Service Repair Manual

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HYSTER K007 (H12XM-6 Europe) Forklift Service Repair Manual

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  1. SERVICE REPAIR H8XM-6 H9XM-6 H10XM-6 H10XMS-6 H12XM-6 Europe [K007] PART NO. 1652525 8000 SRM 1320

  2. 8000 SRM 1596 Counterweight Weights Counterweight Weights Unit Main Counterweight H170HD 2900 kg (6393 lb) H190HD/H8.00XM 3070 kg (6768 lb) H210HD/H9.00XM 3385 kg (7463 lb) H230HD/H10.00XM-6 4295 kg (9469 lb) H250HD 4470 kg (9855 lb) H280HD/H12.00XM 5150 kg (11,354 lb) H300HD/H13.00XM 5360 kg (11,817 lb) H330HD/H14.00XM/H10.00XM-12EC 5995 kg (13,217 lb) H360HD/H16.00XM-6/H12.00XM-12EC/ H360HD-EC 7050 kg (15,543 lb) Table 1. Counterweight Weights Model Weight H8XM-6 (H190HD2) 3,070 kg (6,768 lb) H9XM-6 (H210HD2) 3,385 kg (7,463 lb) H10XM-6 (H230HD2) 4,295 kg (9,469 lb) H10XMS (H250HD2/H230HD2S) 4,470 kg (9,855 lb) H12XM-6 (H280HD2) 5,150 kg (11,354 lb) H13XM-6 (H300HD2) 5,360 kg (11,817 lb) H14XM-6/H10XM-EC (H330HD2) 5,995 kg (13,217 lb) H16XM-6/H12XM-EC (H360HD2 H360HD2-EC) 7,050 kg (15,543 lb) 1

  3. Lift Truck Weights 8000 SRM 1596 Lift Truck Weights Table 2. Basic Truck Model "MIN" Weight "MAX" Weight H190HD2 H8-12XM 9,400 kg (20,723 lb) 10,150 kg (22,376 lb) H210HD2 H8-12XM 9,700 kg (21,384 lb) 10,450 kg (23,038 lb) H230HD2 H8-12XM 10,700 kg (23,589 lb) 11,450 kg (25,242 lb) H250HD2 H8-12XM 10,900 kg (24,030 lb) 11,600 kg (25,573 lb) H280HD2 H8-12XM 11,550 kg (25,463 lb) 12,300 kg (27,116 lb) H300HD2 H13-14XM 12,500 kg (27,557 lb) 13,700 kg (30,203 lb) H330HD2 H13-14XM 13,200 kg (29,101 lb) 14,350 kg (31,636 lb) H360HD2 H16XM-6 14,250 kg (31,415 lb) 15,400 kg (33,951 lb) NOTE: Add 90 kg (198.4 lb) for a completely topped off fuel tank. NOTE: The minimum weight indicates the weight for trucks with an open cab and pneumatic tires. The maximum weight indicates the weight for trucks with an open cab and solid tires. To calculate the total weight of the basic truck include the weight of following options: • Add 200 kg (440.9 lb) for a closed cab. • Add 50 kg (110 lb) for air conditioning. • Add 90 kg (198.4 lb) for a completely topped up fuel tank. 2

  4. 8000 SRM 1596 Capacities Capacities Item Quantity Engine Oil, Tier 3, QSB6.7L 16 liter (16.9 qt) Engine Oil, Tier 4, QSB4.5L 10.5 liter (11.0 qt) Engine Oil, Tier 4, QSB6.7L 14.5 liter (15.3 qt) Cooling System 25.5 liter (27 qt) Hydraulic Tank (FULL mark) 125 liter (33 gal) Hydraulic System (Total Capacity) 160 liter (42.3 gal) Transmission ZF 20 liter (21.1 qt) Drive Axle and Differential 8 to 12 ton 19 liter (5 gal) 12 to 16 ton 21 liter (5.5 gal) Planetary Gears 8 to 12 ton 2.8 liter (2.95 qt) 12 to 16 ton 2.4 liter (2.5 qt) Fuel Tank 128 liter (33.8 gal) 3

  5. Engine Specifications 8000 SRM 1596 Engine Specifications Table 3. Cummins QSB4.5 Item Specification Type Cummins QSB4.5 4 Number of Cylinders 1-3-2-4 Firing Order Bore 107 mm (4.2 in.) Stroke 120 mm (4.7 in.) 4.5 liter (275 in.3) Displacement 17.2:1 Compression Ratio Oil Pressure (Minimum, at Low Idle) 52 kPa (7.5 psi) Oil Pressure (At low idle) 69 kPa (10 psi) Governed Speed (Full power at Normal Operating Temperature) 2450 rpm with load ± 50 rpm no load 800 rpm ±2% Idle Speed Stall Speed (Broken-in Engine) 2016 + 100/-50 rpm Thermostat Begin to open 82°C (179°F) Fully open 91°C (196°F) Valve Clearance (Cold) Intake 0.25 mm (0.01 in.) Exhaust 0.51 mm (0.02 in.) 120 rpm Minimum Cranking Speed Weight (Dry) 371 kg (818 lb) 4

  6. 8000 SRM 1596 Engine Specifications Table 4. Cummins QSB6.7 Item Specification Type Cummins QSB6.7 6 Number of Cylinders 1-5-3-6-2-4 Firing Order Bore 102 mm (4.02 in.) Stroke 120 mm (4.62 in.) 6.7 liter (409 in.3) Displacement 17.2:1 Compression Ratio Oil Pressure (Minimum, at 2500 rpm and normal operating temperature) 345 kPa (50 psi) Oil Pressure (At low idle) 69 kPa (10 psi) Governed Speed (Full power at Normal Operating Temperature) 2300 rpm with load 2450 ±30 no load 800 rpm ±2% Idle Speed 1950 to 2100 rpm Stall Speed (Broken-in Engine) Thermostat Begin to open 83°C (181°F) Fully open 91°C (196°F) Valve Clearance (Cold) Intake 0.25 mm (0.01 in.) Exhaust 0.51 mm (0.02 in.) 125 rpm Minimum Cranking Speed Weight (Dry) 485 kg (1069 lb) 5

  7. Tire Sizes 8000 SRM 1596 Hydraulic System Item Quantity Cummins Diesel Hydraulic Pump Capacity @ 2300 rpm 90 cc (3 oz) 196 liter/min (51.7 gal/min) 120 cc (4 oz) 262 liter/min (69.2 gal/min) 25 cc (0.8 oz) Wet Brake Cooling Pump 57 liter/min (15.0 gal/min) Relief Pressures * Main Control Valve 22.5 MPa (3262.5 psi) Steering Circuit 16 ±1 MPa (2320 ±145 psi) *Oil temperature 60°C (140°F) Electrical System All Models 24 Volt, Negative Ground Alternator Output at 24°C (75°F) 21 amps at 750 rpm All Engines 76 amps at 2200 rpm Tire Sizes NOTE: Refer to Truck Nameplate for correct tire pressure. Model Tire Size Tire Pressure H8.00-9.00XM-6 (H170-210HD2) 9.00 × 20-14 ply 900 kPa (130 psi) H10.00-12.00XM-6 (H230-280HD2) 10.00 × 20-16 ply 900 kPa (130 psi) H10.00-12.00XM-EC (H360HD2-EC) 12.00 × 20-16 ply 1000 kPa (145 psi) H13-14XM-6 (H300-330HD2); H16XM-6 (H360HD2) 12.00 × 20-16 ply 1000 kPa (145 psi) All Michelin XZM Radial Tires 1000 kPa (145 psi) 6

  8. 8000 SRM 1596 Mast Speeds Mast Speeds Lifting and Lowering Speeds 120 cc/Rev @2050 rpm 90cc/Rev @2050 rpm Unit m/ sec ft/ min m/ sec ft/ min Rated Load Rated Load H190HD2 0.46 90.5 0.55 108 2 STG NFL H8XM 3 STG FFL (2ND/FREE) 0.33/0.30 65/59 0.37/0.32 72.8/63 H210HD2 0.46 90.5 0.55 108 2 STG NFL H9XM 3 STG FFL (2ND/FREE) 0.33/0.30 65/59 0.37/0.32 72.8/63 H230HD2 0.35 69 0.42 82.7 2 STG NFL H10XM 3 STG FFL (2ND/FREE) 0.32/0.28 63/55 0.39/0.34 77/67 H250HD2 0.35 69 0.42 82.7 2 STG NFL 3 STG FFL (2ND/FREE) 0.32/0.28 63/55 0.39/0.34 77/67 H280HD2 0.35 69 0.42 82.7 2 STG NFL H12XM 3 STG FFL (2ND/FREE) 0.32/0.28 63/55 0.39/0.34 77/67 H300HD2 0.28 55 0.33 65 2 STG NFL 3 STG FFL (2ND/FREE) 0.25/0.24 49.2/47.2 0.30/0.29 59/57 H13XM 0.28 55 0.33 65 2 STG NFL 3 STG FFL (2ND/FREE) 0.25/0.24 49.2/47.2 0.30/0.29 59/57 H330HD2 0.28 55 0.33 65 2 STG NFL 3 STG FFL (2ND/FREE) 0.25/0.24 49.2/47.2 0.30/0.29 59/57 H14XM 0.28 55 0.33 65 2 STG NFL 3 STG FFL (2ND/FREE) 0.25/0.24 49.2/47.2 0.30/0.29 59/57 H360HD2 0.28 55 0.33 65 2 STG NFL 3 STG FFL (2ND/FREE) 0.25/0.24 49.2/47.2 0.30/0.29 59/57 H16XM 0.28 55 0.33 65 2 STG NFL 3 STG FFL (2ND/FREE) 0.25/0.24 49.2/47.2 0.30/0.29 59/57 7

  9. Torque Specifications, General 8000 SRM 1596 Torque Specifications, Cummins Diesel LUBRICATION SYSTEM All other Torque Specifications are found in Cum- mins Engine Manual. Contact Cummins Engine for any torque specifications not listed for this engine. Plug, Oil Sump, Steel Oil Pan 80 N•m (59 lbf ft) Torque Specifications, General TRANSMISSION ZF Capscrews, Hydraulic Pumps to Transmission 25 N•m (18 lbf ft) Nuts, Locking System Pressure Tubes Into Rear Transmission Cover 42 N•m (31 lbf ft) See the sectionTransmission, Repair (ZF-WG161) 1300 SRM 1456 for other torque values. Screw, Holding Segment on Pressure Tubes 23 N•m (17 lbf ft) DRIVELINE AND AXLE Capscrews, Universal Yoke 50 N•m (37 lbf ft) Capscrews, Screen Into Front Trans- mission Cover 23 N•m (17 lbf ft) Bolts, Axle to Frame 920 N•m (679 lbf ft) Capscrews, Tubes and Suction Tube Into Front Transmission Cover 23 N•m (17 lbf ft) COUNTERWEIGHT Top Capscrews 1500 N•m (1106 lbf ft) Capscrews, Rear Transmission Cover to Front Transmission Cover 4 N•m (34 lbf ft) Rear Capscrews 1500 N•m (1106 lbf ft) Capscrews, Output Flange to Trans- mission Housing 34 N•m (25 lbf ft) DIFFERENTIAL See the section Differential 1400 SRM 46 . Capscrews, Torque Converter Bell Housing to Transmission Housing 46 N•m (34 lbf ft) BRAKES - WET See the sections Planetary Drive Axle, (Wet Sys- tem) 1400 SRM 944 and Brake and Hydraulic Cooling System 1800 SRM 1498 . Oil Fill Tube with Dipstick and Oil Drain Plug 80 N•m (59 lbf ft) Capscrews, Torque Converter Bell Housing to Transmission Housing 46 N•m (34 lbf ft) STEERING Nut, Steering Wheel 68 N•m (50 lbf ft) Capscrews, Transmission Oil Filter Head 23 N•m (21 lbf ft) Capscrews, Steer Cylinder Mount 435 N•m (321 lbf ft) Capscrews, Torque Converter Housing to Flywheel Housing 46 N•m (34 lbf ft) Capscrews, Bearing Cap 75 N•m (55 lbf ft) 8

  10. 8000 SRM 1596 Torque Specifications, General Lift Pressure Selector Valve (B) 35 to 40 N•m (26 to 30 lbf ft) Nut, Wheel Bearing Initial 203 N•m (150 lbf ft) Final 34 N•m (25 lbf ft) Coil Retaining Nut for Lift Pressure Selector Valve (B) 4 to 6 N•m (35 to 53 lbf in) Note: Torque lock nut to Initial torque while rotating wheel hub. Back offlock nut until wheel hub turns freely with no end play. (Torque at this point should be less than 27 N•m (20 lbf ft)). Retorque to Final torque and lock in place at first alignment position which occurs at or above final torque spec. Solenoid Capscrews 6.3 N•m (56 lbf in) Mount Capscrews 14 N•m (124 lbf in) Capscrews, Steer Axle Mount 270 N•m (199 lbf ft) Pump Flangehead Screws 46 to 49 N•m (34 to 36 lbf ft) WHEEL NUTS Pump to Motor Capscrews 25 N•m (221 lbf in) Drive Wheels (Final Torque Value) 615 to 710 N•m (454 to 524 lbf ft) Suction Hose Adapter to Hydraulic Pump 91 to 100 N•m (67 to 74 lbf ft) Steer Wheels (Final Torque Value) 615 to 710 N•m (454 to 524 lbf ft) Pressure Line Fitting to Hydraulic Pump 49 to 59 N•m (36 to 44 lbf ft) HYDRAULIC SYSTEM Priority Valve (A) 217to 231 N•m (160 to 170 lbf ft) Counterbalance Valves 60 N•m (44.3 lbf ft) Check Valve (K) 27 to 34 N•m (20 to 25 lbf ft) MAST Capscrews, Pivot Pin 435 N•m (321 lbf ft) Check Valve (L) 122 to 136 N•m (90 to 100 lbf ft) Capscrew, Bearing Block 9 N•m (7 lbf ft) Check Valve (Q) 9 to 12 N•m (7 to 9 lbf ft) Capscrews, Bearing Block Bracket 44 N•m (32 lbf ft) Shuttle Valves 26 to 30 N•m (34 to 40 lbf ft) Nuts, Wear Plate 53 N•m (39 lbf ft) Full Flow Relief Valve (C) and (G) 217to 231 N•m (160 to 170 lbf ft) Retainer, Lift Cylinder H8-9XM-6 (H170-210HD2) 400 to 475 N•m (295 to 350 lbf ft) H10-12XM-6 (H230-280HD2) 475 to 550 N•m (350 to 406 lbf ft) H13-14XM-6 (H300-330HD2); H16XM-6 (H360HD2); H10-12XM-12EC (H360HD2-EC) 550 to 625 N•m (406 to 461 lbf ft) Pilot Supply Valve (F) 45 to 50 N•m (33 to 37 lbf ft) Load Sense Selector Valve (D) 35 to 40 N•m (26 to 30 lbf ft) Coil Retaining Nut for Load Sense Selector Valve (D) 4 to 6 N•m (35 to 53 lbf in) 9

  11. Torque Specifications, General 8000 SRM 1596 CARRIAGE Lock Nut, Rod End 66 N•m (49 lbf ft) Capscrew, Bearing Block 9 N•m (7 lbf ft) Capscrew, Pin Anchor 165 N•m (122 lbf ft) Capscrews, Bearing Block Bracket 44 N•m (32 lbf ft) WIPER ARMS, FRONT Nut, Sideshift Cylinder Rod 675 N•m (498 lbf ft) Capscrews, Bracket to Cab 20 to 25 N•m (14.7 to 18.4 lbf ft) TILT CYLINDERS Capscrews, Arm to Bracket 22 to 27 N•m (16.2 to 19.9 lbf ft) Nut, Cylinder Rod H13-14XM-6 (H300-330HD2); H16XM-6 (H360HD2); H10-12XM-12EC (H360HD2-EC) 949 to 983 N•m (700 to 725 lbf ft) H13-16XM-6 (H300-360HD2) 1105 to 1140 N•m (815 to 841 lbf ft) Capscrews, Blade to Arm 8 to 10 N•m (6 to 7.4 lbf ft) Capscrew, Arm Set 35 to 45 N•m (25.8 to 33.2 lbf ft) Retainer H8-12XM-6 (H170-280HD2) 542 to 610 N•m (400 to 450 lbf ft) H13-14XM-6 (H300-330HD2); H16XM-6 (H360HD2); H10-12XM-12EC (H360HD2-EC) 610 to 675 N•m (450 to 498 lbf ft) 10

  12. 1400 SRM 0046 General General This section contains description and repair procedures for the differential. There is a Specifications section and a Troubleshooting section at the end of this section. Description This differential is fastened to the drive axle hous- ing of the lift truck. The differential provides a sin- gle-speed reduction for an increase in torque to the drive wheels. There is a housing, a ring and pinion gear set, and the differential assembly. The ring gear transfers power from the pinion through the differential assembly to the axles. The differential assembly permits the drive wheels to rotate at dif- ferent speeds during a turn. See Figure 1. 1

  13. Description 1400 SRM 0046 Figure 1. Typical Differential Assembly 2

  14. 1400 SRM 0046 Description Legend for Figure 1 NOTE: *SOME AXLES DO NOT HAVE THE PARTS DESCRIBED. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. CAPSCREW 11. SIDE GEAR 12. THRUST WASHER 13. CASE HALF 14. BEARING CONE 15. BEARING CUP 16. PINION 17. SPIDER PINION NUT WASHER* INPUT YOKE* DEFLECTOR TRIPLE-LIP OIL SEAL DIFFERENTIAL CARRIER FILL PLUG ADJUSTMENT RING LOCK PLATE 18. CAPSCREW OR RIVET* 19. RING GEAR 20. CASE HALF, FLANGE 21. NUT* 22. NUT 23. WASHER 24. THRUST BLOCK* 25. BEARING CAP 26. COTTER PIN (ADJUSTING RING)* 27. JAM NUT* 28. THRUST SCREW* 29. RETAINING RING 30. WASHER 31. SPIGOT BEARING 32. PINION 33. SPACER 34. SHIM 35. PINION CARRIER 36. COVER 37. BOLT 38. SHIFT FORK 39. SPRING 40. SHIFT SHAFT 41. PIN 42. AIR CYLINDER TUBE 43. SCREW IN DIFFERENTIAL LOCK CYLINDER 44. CYLINDER COVER 45. GASKET 46. PLUG 47. SHIFT COLLAR 48. PISTON 49. O-RING 3

  15. Differential Repair 1400 SRM 0046 Differential Repair REMOVE WARNING Block the wheels to prevent the lift truck from moving. Support the lift truck with safety stands. DO NOT work under a lift truck supported only by jacks. Jacks can slip and fall over. Serious per- sonal injury can result. NOTE: The repair procedures cover all units unless otherwise indicated. Differential Carrier From Axle Housing, Remove NOTE: The differential assembly can normally be removed without removing the drive axle. On some trucks, including the H7.00-12.50H (H150-275H), the drive axle must be removed to remove the dif- ferential assembly. If removal of the drive axle is necessary, see the Drive Axle service manual for your lift truck model. 3. Place jack stands under each spring seat of the axle, to hold the lift truck in the raised position. 4. Remove plug from the bottom of the axle hous- ing and drain the oil from the axle assembly. 5. Disconnect the drive shaft at the differential. If a speed reducer or gear box is installed, remove the speed reducer or gear box. 1. Remove the mast. See the Mast service manual for your lift truck model for the removal proce- dures. 6. Some units have a drum or disc brake attached to the output yoke. Disconnect any brake link- age or brake lines. See the Brake manual for your unit. 2. Raise the end of the vehicle where the axle is mounted. Use a jack or other lifting tool, and place safety stands under each side of the axle. See Figure 2. 7. Disconnect the driveline universal joint from the pinion input yoke or flange on the differen- tial carrier. See Figure 3. 1. SAFETY STANDS Figure 2. Lift Truck Support 4

  16. 1400 SRM 0046 Differential Repair 1. 2. 3. BEARING CUPS END YOKE YOKE SADDLE 4. 5. 6. WELD YOKE BEARING STRAP CAPSCREWS 7. 8. 9. U-JOINT CROSS SLIP YOKE TUBING Figure 3. Typical Driveline Universal Joint 5

  17. Differential Repair 1400 SRM 0046 8. Remove the axle shafts from the axle housing. See the Drive Axle manual for your model of lift truck for the procedures. 10. Remove all but the top two differential carrier housing capscrews. See Figure 4. 11. Loosen the top two differential carrier housing capscrews and leave them attached to the as- sembly. The capscrews will hold the differential carrier in the housing. a. On Straddle Trucks™, disconnect the drive axle universal joints at the differential yokes. Remove the capscrews that fasten the bearing retainers to the differential housing. Pull the yoke, stub shaft and bearing re- tainer from the housing. 12. Loosen the differential carrier in the axle hous- ing. Use a leather mallet to hit the mounting flange of the differential carrier at several points. 9. Place a transmission jack under the differential carrier for support. See Figure 4. 13. After the differential carrier is loosened, re- move the top two capscrews. CAUTION When using a pry bar, be careful not to damage the differential carrier or housing flange. Damage to these surfaces will cause oil leaks. 14. Remove the differential carrier from the axle housing. Use a pry bar with a round end, to help remove differential carrier from housing. 15. Remove the differential carrier assembly from under the lift truck. 16. Use a lifting device and lift the differential car- rier by the input yoke or flange and place the assembly on a repair stand. See Figure 5. 1. 2. 3. WOOD BLOCK TRANSMISSION JACK CAPSCREWS Figure 4. Differential Carrier Support 6

  18. 1400 SRM 0046 Differential Repair NOTE: Before working on the differential carrier, inspect the hypoid gear set for damage. If inspec- tion shows no damage, the same gear set can be used again. Measure the backlash of the gear set and make a record of the dimension. See the section Ring Gear Backlash, Adjust. During differential re- assembly, adjust the backlash to the original recor- ded dimension when the gear set is installed into the differential carrier. 1. Loosen the jam nuts on the thrust screw. 2. Remove the thrust screw and jam nut from the differential carrier. See Figure 6. 1. 2. DIFFERENTIAL CARRIER REPAIR STAND Figure 5. Differential Carrier Stand Differential and Ring Gear From Differential Carrier, Remove NOTE: Some of the parts described below are not found on some differential carrier models. See Fig- ure 1. Figure 6. Thrust Screw and Jam Nut Removal 7

  19. Differential Repair 1400 SRM 0046 3. Rotate the differential carrier until the ring gear is at the top of the assembly. 6. Remove capscrews and washers holding the two bearing caps on the differential carrier. See Figure 8. 4. Mark one differential carrier leg and bearing cap to correctly match the parts during differ- ential carrier assembly. Mark the parts using a center punch and hammer. See Figure 7. 1. 2. 3. BEARING CAP DIFFERENTIAL CARRIER LEG MATCHMARKS Figure 7. Mark Differential Carrier Leg and Bearing Cap 1. 2. COTTER PIN LOCK PLATE 5. Remove the cotter pins that hold the bearing adjusting rings in position. Some differential carrier models have dowel pins or lock plates holding the bearing adjusting rings in position. Each lock plate is held in position by two cap- screws. See Figure 8. Figure 8. Bearing Adjusting Ring Removal 7. Remove the bearing caps and bearing adjusting rings from the differential carrier. See Figure 9. 8

  20. 1400 SRM 0046 Differential Repair Legend for Figure 10 1. 2. 3. 4. BEARING CUP DIFFERENTIAL CARRIER BEARING BORE PUT ADHESIVE HERE (INSTALLATION ONLY) Drive Pinion and Pinion Carrier From Differential Carrier, Remove NOTE: Some of the parts described below are not found on some differential carrier models. See Fig- ure 1. 1. Fasten a yoke or flange bar to the input yoke or flange. When the nut is removed, the bar will hold the drive pinion in position. See Figure 11. 1. 2. BEARING CAP BEARING ADJUSTING RING Figure 9. Bearing Cap Removal 2. Remove the nut and washer from the drive pin- ion. 8. Use a lifting device and lift the main differen- tial and ring gear assembly from the differen- tial carrier. See Figure 10. 3. Remove the yoke or flange bar. Figure 10. Main Differential and Ring Gear Assembly Removal 1. FLANGE BAR 2. YOKE BAR Figure 11. Flange and Yoke Bar 9

  21. Differential Repair 1400 SRM 0046 5. Remove the capscrews and washers that hold the pinion carrier in the differential carrier. See Figure 13. CAUTION Do not use a hammer or mallet to loosen and re- move the yoke or flange. A hammer or mallet can damage the parts and cause driveline runout or driveline imbalance problems after carrier to driveline assembly. 4. Remove the yoke or flange from the drive pin- ion. If the yoke or flange is tight on the pinion, use a puller for removal. See Figure 12. 1. 2. 3. DRIVE PINION AND PINION CARRIER SHIMS CAPSCREWS Figure 13. Pinion Carrier Removal WARNING Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. CAUTION Do not use a pry bar to remove the pinion carrier from the carrier. A pry bar can damage the bear- ing case, shims, and differential carrier. A. YOKE PULLER B. FLANGE PULLER Figure 12. Yoke and Flange Puller Tools 10

  22. 1400 SRM 0046 Differential Repair 6. Remove the drive pinion, pinion carrier, and shims from the differential carrier. See Fig- ure 13. If the pinion carrier is tight on the dif- ferential carrier, hit the pinion carrier at sev- eral points around the flange area with a leather, plastic or rubber mallet. 7. Inspect the shims. If they are in good condition, keep the shims together for use during differen- tial carrier assembly. 8. If the shims are to be replaced, first measure the total thickness of the pack. Make a note of the dimension. The dimension will be needed to calculate the depth of the drive pinion in the differential carrier when the gear set is instal- led. DISASSEMBLE Differential and Ring Gear Assembly, Disassemble NOTE: Some of the parts described below are not found on some differential carrier models. See Fig- ure 1. 1. 2. 3. THRUST WASHER SIDE GEAR SPIDER, PINIONS, AND THRUST WASHERS Figure 14. Ring Gear Disassembly NOTE: Make sure there are matching marks on the case halves of the differential assembly. See Step 4 in the section Differential and Ring Gear From Differential Carrier, Remove. See Figure 7. 3. If the ring gear needs to be replaced, remove bolts, nuts, and washers holding the ring gear to the flange case half. WARNING Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. CAUTION Do not remove the rivets or rivet heads with a chisel and hammer. Using a flat edge tool can cause damage to the flange case. See Figure 15. 1. Remove the capscrews and washers that hold the case halves together and separate the case halves. If necessary, use a brass, plastic, or leather mallet to loosen the parts. 4. If your differential model uses rivets to hold the ring gear to the flange case half, remove the rivets as follows: a. Center punch each rivet head in the center, on the ring gear side of the assembly. 2. Remove the differential spider, four pinion gears, two side gears, and six thrust washers from inside the case halves. See Figure 14. 11

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  24. Differential Repair 1400 SRM 0046 b. Drill each rivet head on the ring gear side of the assembly to a depth equal to the thick- ness of one rivet head. Use a drill bit that is 1/32 of an inch smaller than the body diame- ter of the rivets. See Figure 15. c. Press the rivets through holes in the ring gear and flange case half. Press from the drilled rivet head. 1. 2. CASE HALF PRESS 3. 4. PLATE SUPPORTS Figure 16. Case Half and Ring Gear Separation 6. If the differential bearings need to be replaced, remove the bearing cones from the case halves. Use a bearing puller or press. See Figure 17. A. CORRECT DRILLING RIVETS FROM HEAD B. WRONG CHISELING RIVETS FROM HEAD Figure 15. Rivet Removal WARNING Observe all warnings and cautions provided by the press manufacturer to avoid damage to com- ponents and serious personal injury. 5. Separate the case half and ring gear using a press. Support the assembly under the ring gear with metal or wood blocks and press the case half through the gear. See Figure 16. A. PULLER B. PRESS Figure 17. Differential Bearings Replacement 12

  25. 1400 SRM 0046 Differential Repair NOTE: The inner bearing cone and bearing spacer will remain on the pinion shaft. See Figure 19. Drive Pinion and Pinion Carrier, Disassemble WARNING Observe all warnings and cautions provided by the press manufacturer to avoid damage to com- ponents and serious personal injury. 3. If a press is not available, use a leather, plastic or rubber mallet to drive the pinion through the pinion carrier. CAUTION When removing the oil seal, Do not damage the wall of the bore. Damage to the bore wall can re- sult in oil leaks. NOTE: Some of the parts described below are not found on some differential carrier models. See Fig- ure 1. 1. Place drive pinion and pinion carrier in a press. The pinion shaft must be toward the top of the assembly. Add supports for the pinion carrier under the flange area. See Figure 18. NOTE: Always replace the oil seal with a new seal during reassembly. 4. Remove the oil seal from the pinion carrier. See Figure 19. 2. Press the drive pinion through the pinion car- rier. See Figure 18. 1. 2. 3. 4. PRESS DRIVE PINION OIL SEAL PINION CARRIER 5. 6. 7. SUPPORT SPIGOT BEARING FLANGE SUPPORT 1. 2. 3. 4. 5. 6. 7. DRIVE PINION OIL SEAL OUTER BEARING (CUP AND CONE) INNER BEARING (CUP AND CONE) SPIGOT BEARING SNAP RING BEARING SPACER Figure 18. Drive Pinion Disassembly WARNING Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. Figure 19. Drive Pinion 13

  26. Differential Repair 1400 SRM 0046 5. Inspect the pinion bearings and replace if nec- essary. If the pinion bearings need to be re- placed, perform the following: a. Remove the inner and outer bearing cups from the inside of the cage. Use either a press and sleeve, bearing puller, or a small drift pin. See Figure 17 and Figure 20. If a press is used, provide support for the pinion carrier under the flange area with metal or wood blocks. 1. 2. 3. 4. 5. PRESS DRIVE PINION BEARING PULLER SUPPORTS INNER BEARING CONE Figure 21. Pinion Bearing Replacement 6. If the spigot bearing needs to be replaced, place the drive pinion in a vise. Install a soft metal cover over each vise jaw to protect the drive pinion. 7. Remove the snap ring from the end of the drive pinion. See Figure 22. A. BEARING DRIVER B. BEARING PULLER Figure 20. Pinion Bearing Replacement CAUTION The puller must fit under the inner race of the cone to remove the cone correctly without dam- age. b. Remove the inner bearing cone from the drive pinion with a press or bearing puller. See Figure 21. 1. SPIGOT BEARING 2. SNAP RING Figure 22. Snap Ring Removal 14

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