W563-005XE axle

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					                                                                 Publication No. W563-0053E




                   Service Manual
                                                 03
                                    Driving Axle
                                            20135 (SHP-S24.0)
                                    Model
                                            20136 (SHP-S24.0N)
                    W563-0053E




c
◯2006
PRINTED IN JAPAN
0612 E
                                                   Foreword


Foreword

This service manual explains the disassembly and
reassembly procedures for the driving axles used in
the Tadano rough terrain cranes. This manual
applies to the models listed below.
Before starting repair work, check the model No. in the
nameplate on the unit.
Read the applicable parts catalog, crane service
manual and other reference documents for additional
indispensable information on the crane besides this
manual to carry out correct repair and maintenance.


1. Applicable Crane Model
The table below shows the relationship between the
crane models and the models of axle used.


    Crane model           Model No.            Applicable            Axle model
•TR-600XL-4
•TR-600XXL-4         20135                Front                   SHP-S24.0
•TR-800XXL-4
•GR-700EXL-1         20136                Rear (with No-spin)     SHP-S24.0N
•GR-550EX-1




[NOTICE]
  There is a case that the appearance and so on
  differ from the parts for this crane. Although there
  is not so much difference in functions and
  disassembly procedures, make sure of the serial
  number of this crane and the part sales unit
  described in the parts catalog before starting
  disassembling operations.




                                                              Please note that, for product Improvement, some
                                                              changes may have been incorporated in the machine
                                                              that are not covered in this manual.


                                                          1       W563-0053E
                                                                      Foreword


2. Contents
                                                                                   Axle Assembly ................................................ 27
Foreword          ....................................................... 1         1. Disassembly ....................................................27
  1. Applicable Crane Model.................................... 1                     1.1 Axle assy...................................................27
  2. Contents............................................................ 2           1.2 Draining gear oil........................................27
                                                                                      1.3 Disc brake assy.........................................27
Structure         ....................................................... 4           1.4 Removing planetary gear spider assy ......27
  1. Structure............................................................ 4          1.5 Planetary gear spider assy .......................27
    1.1 Differential section...................................... 4                  1.6 Removing internal gear hub assy .............28
    1.2 Center brake section .................................. 5                     1.7 Internal gear hub assy ..............................28
    1.3 Exploded view ............................................ 6                  1.8 Removing wheel hub assy ........................28
    1.4 Differential section...................................... 7                  1.9 Wheel hub assy ........................................29
    1.5 Exploded view ............................................ 8                  1.10 Tie rod assy ..............................................29
    1.6 Housing, speed reducer and brake .......... 10                                1.11 Knuckle assy.............................................29
    1.7 Housing, speed reducer and                                                    1.12 Knuckle assy.............................................29
             brake (Rear) ....................................... 11                  1.13 Ball joint assy ............................................30
    1.8 Oil plug ..................................................... 11             1.14 Axle housing assy .....................................30
    1.9 Ball joint .................................................... 12            1.15 Differential assy ........................................31
    1.10 Exploded view .......................................... 13                2. Cleaning...........................................................31
    1.11 Tightening torque ..................................... 15                 3. Inspection ........................................................31
  2. General ........................................................... 16           3.1 Gear and spline.........................................31
    2.1 Reduction gearing .................................... 16                     3.2 Planetary gear and planetary pin..............31
    2.2 Differential ................................................ 16              3.3 Oil seal ......................................................31
    2.3 Planetary speed reducer .......................... 17                         3.4 Axle shaft ..................................................31
    2.4 Ball joint assembly (assy)......................... 17                        3.5 King pin bushing .......................................31
    2.5 Disc brake................................................. 18                3.6 Boot...........................................................31
                                                                                      3.7 Bearing......................................................31
Differential ..................................................... 20                 3.8 Ball joint assy ............................................31
  1. Standard differential ........................................ 20                3.9 Service brake ............................................32
    1.1. Operating principle of                                                     4. Reassembly .....................................................32
            standard differential............................ 21                      4.1 Differential assy ........................................32
  2. No-spin type differential .................................. 22                  4.2 Axle housing assy .....................................32
    2.1 Structure and configuration of No-spin type                                   4.3 Knuckle assy.............................................33
            differential........................................... 22                4.4 Ball joint assy ............................................34
    2.2 Spider assy............................................... 23                 4.5 Assembling tie rod assy ............................35
    2.3 Driven clutch assy .................................... 24                    4.6 Assembling wheel hub assy .....................35
    2.4 Spring ....................................................... 24             4.7 Internal gear hub assy ..............................35
    2.5 Side gear .................................................. 24               4.8 Assembling planetary gear spider assy ....36
    2.6 Operating explanation (propeller driving in a                                 4.9 Installing knuckle assy ..............................36
            straight-forward) ................................. 24                    4.10 Installing wheel hub assy ..........................37
    2.7 Operating explanation (propeller driving in                                   4.11 Installing internal gear hub assy ...............37
            forward turn) ....................................... 25                  4.12 Planetary gear spider assy .......................38
                                                                                      4.13 Tie rod assy ..............................................38
                                                                                      4.14 Disc brake assy.........................................39
                                                                                      4.15 Lubrication ................................................39




                                                                               2          W563-0053E
                                                                      Foreword



Differential Assembly ...................................... 40
  1. Dismounting .................................................... 40
  2. Disassembly.................................................... 40
    2.1 Differential carrier assy............................. 40
    2.2 Differential case assy
             (Standard differential)......................... 42
    2.3 Differential case assy
             (No-spin differential)........................... 42
    2.4 Drive pinion assy (front axle).................... 43
    2.5 Drive pinion assy (rear axle)..................... 43
    2.6 Removing drive pinion and bearing.......... 44
  3. Cleaning .......................................................... 45
  4. Inspection........................................................ 45
  5. Reassembly .................................................... 46
    5.1 Drive pinion assy ...................................... 46
    5.2 Differential case assy
             (standard differential) ......................... 47
    5.3 No-spin differential case assy .................. 48
    5.4 Differential carrier assy............................. 48
    5.5 Drive pinion assy ...................................... 50
    5.6 Installing differential case assy................. 50
    5.7 Inspection and
             adjustment of tooth contact pattern.... 50
    5.8 Parking brake assy................................... 52
    5.9 Differential carrier assy............................. 52
    5.10 Lubrication ................................................ 53

Adjustment ..................................................... 54
  1. Steering angle ................................................. 54

Trouble shooting ............................................. 55
  1. Noise ........................................................... 55
  2. Oil leak ........................................................... 55
  3. Defective steering and turning
              operations........................................... 55
  4. Insufficient braking .......................................... 56
  5. Brake drag....................................................... 56

Test for No-spin differential ............................. 57
  1.Test with wheels jacked up................................ 57
  2.Test by traveling ................................................ 58
  3.Abnormal conditions during traveling................ 58




                                                                               3   W563-0053E
                                                    Structure


Structure
1. Structure
   The axle transmits the driving force from the             [NOTICE]
   engine to the right and left driving wheels as well        For tightening torque of each bolt and nut, refer to
   as it supports the weight of the vehicle. As it is         the tightening torque table on page15.
   designed as a steering drive axle, it is equipped
   with steering mechanism such as ball joints and a
   tie rod for steering operation.

1.1 Differential section

                                               T1
                                               24                           18                 40      T6
                                                                                               41
                 39                                                                            21
                                                                                               29      T2
                 32                                                                            30

                27                                                                            28
                26                                                                            7
                 1                                                                            20
              16-A                                                                            19
                25                                                                            4
                31                                                                            5
         T3      51                                                                           6        T7
                 52
                                                                                              45
                 53
                                                                                               15
                 12
                 13                                                                           2
                8-D                                                                           3
                 15
                                                                                               1-C
                           8-B                                                                 1-A     T4
                T5                                                                             1-B
                           8-A
                                                                                               17      T9
                                 11
                                      9                                                        8-C
                                          10                                                   16-B
                                                                                              IW563-0052E01




                                                         4       W563-0053E
                                           Structure

1.2 Center brake section

                                         38

                                                            33
                                 35
                           T11   34                           36




                                                              43    T8
                                                              44
                                                              42

                                      View - A




                   T10     37


                                 A




                                                                    IW563-0052E02




                                                 5     W563-0053E
                                                               Structure

1.3 Exploded view
     Front • rear
                                                                                                   1-A
                                                                                                         1-B
                                                                                                                       1     2

                                                                                                   8-A 14

                                                                      11                     8-D
                                                           11                       13
                                                                10             12
                                                                                                                                  3
                                               16-B                                                                    8-B
                                                           13
                                                                                    9 11
                                    8-C                                                                                53 51
      1-A                 15                                                                                              52
            1-B
                                                                12                  10
                                                                                    11

                                                                                                                                           16-A
                                                                                         4
                                                                                    5

                                                                                                                                 31
                                                      7                                                                               25
                               17                                                            6                1
                          3                                    26
                      1                                                                                                45
             2                                                            19
                                                                               20
                                                                                        20
                  7                                                                                28
                          26                                                                                  21
                                     19                                                                                      30
                                          20                                                                                      29
                                               27                                                                                           24
                                                               Final (for rear)
                                                          28
                                                                34
                                                                      35
                                                                               21                                      32
                                                                                         38             30                   18
                                                                                                             29
                                                                                                 33

                                                                                                                  18
                                    Final (for front)


                                                                                                                                                24
                                                    42
                                                                44
                                                                     43
                                                                                                             37


                                                                                                         36
                                                                                                                                      39
                                                                                                                                           41
                                                                                                                                                40
                                                                                                                                       IW563-0052E03



                                                                      6             W563-0053E
                                      Structure

1.4 Differential section

                                      T1
                                      24                       18   21
                 32                                                 29       T2
                                                                    30
                 27                                                 28
                26                                                  7
                 1                                                  20
              16-A                                                  19
                25                                                  4
                31                                                  5
         T3      51                                                 6        T7
                 52
                                                                    45
                 53
                                                                    15

                                                                    2
               8-D                                                  3
                 15
                                                                    1-C
                           8-B                                      1-A      T4
               T5                                                   1-B
                           8-A
                                                                    17       T9
                                 55
                                                                    8-C
                                                                    16-B
                                                                    IW563-0052E04




                                           7      W563-0053E
                                                Structure

1.5 Exploded view
     Nospin diff

                                                                                            1-A
                                                                                                  1-B
                                                                                                            1
                                                                                                                   2

                                                                                             8-A 14
                                                                                      8-D



                                                               55                                                       3
                                                                                                            8-B



                                     16-B

                               8-C                                                   53 51
                     15                                                                 52
     1-A
           1-B


                                                                                                     16-A
                                                               4
                                                          5

                                            7                                              31
                                                                                                25
                          17                    26                 6        1
                     3
                 1                                   19                              45
           2                                              20
                                                               27
                                                                       28
                                                                                21
                                                                                           30
                                                                                                29
                                                                                                          24




                                                                                      32
                                                                                            18          IW563-0052E05




                                                     8         W563-0053E
                                             Structure


1. Carrier cage      8-D.Gear case(2)              21.Bearing cage cover     37.Nut
1-A.Bolt             9. Spider                     24.Nut                    38.Shim
1-B.Spring washer   10. Differential side pinion   25.Roller beating         39.Disc center brake
1-C.Bearing cap     11. Thrust washer (pinion)     26.Taper roller bearing   40.Bolt
2. Ring nut         12. Differential side gear     27.Taper roller bearing   41.Spring washer
3. Lock pin         13. Thrust washer (gear)       28.Packing                42.Chamber bracket
4. Thrust plug      14. Taper roller bearing       29.Bolt                   43.Bolt
5. Thrust bolt      15. Taper roller bearing       30.Spring washer          44.Spring washer
6. Nut              16-A.Hypoid pinion             31.Snap ring              45.Grommet
7. Shim             16-B.Hypoid gear               32.Oil seal               51.Bolt
8. Gear case set    17. Bolt                       33.Center brake support   52.Bolt
8-A.Bolt            18. Companion flange           34.Bolt                   53.Spring washer
8-B.Bolt            19. Pinion bearing cage        35.Spring washer          55.No-spin differential assy
8-C.Gear case(1)    20. Distance piece             36.Center brake assy




                                                   9       W563-0053E
                                       Structure

1.6 Housing, speed reducer and brake




                                          10       W563-0053E
                                         Structure

1.7 Housing, speed reducer and brake (Rear)

                                                     T20       T25

                                                     201
                                                     202       200

                                                                                      T23

                                                                                      139
                                                                               199    140     138




                                                       198    141 137        136       IW563-0052E07



1.8 Oil plug

                                          104




                                              106                    105
                                                                     IW563-0021E08E




                                                11         W563-0053E
                        Structure

1.9 Ball joint

                 212    214        213




                       211          148      147
                                                  IW563-0051E03E




                              12     W563-0053E
                                        Structure

1.10 Exploded view
     Housing, speed reducer and brake




                                           13       W563-0053E
                                                        Structure


101.Axle housing                 126.Rubber boot holding plate    156.Planetary gear shaft   183.Oil seal
102.Kingpin bushing              127.Bolt                         157.Thrust washer          185.Spcer
104.Air breather                 129.Stopper bolt                 159.Gear spider cover      186.Snap ring
105.Plug                         130.Nut                          160.O-ring                 187.-----
106.Plug                         133.Tie rod                      161.Bolt                   188.Disc
107.Bushing                      134.Tie rod end (R)              162.Spring washer          189.Bolt
108.Retainer                     135.Tie rod end (L)              163.Bolt                   190.Spring washer
109.O-ring                       136.Bushing                      164.Spring washer          193.Caliper assy
110.Oil seal                     137.Pin                          166.Plug                   194.Caliper assy
112.Knuckle(1)                   138.Lock plate                   167.Plug                   195.Retainer
113.Knuckle(2)                   139.Bolt                         168.O-ring                 196.Oil seal
114.Knuckle spindle              140.Spring washer                169.Thrust washer          197.Pin
115.Bolt                         141.Snap ring                    170.Needle bearing         198.Oil seal
116.-----                        143.Bolt                         172.Internal gear          199.Grease nipple
117.Bearing                      144.Nut                          173.Internal gear hub      200.Bolt
118.King pin : upper             145.Spring washer                174.Stop wire              201.Bolt
119.Thrust washer                147.Axle shaft                   175.Bearing nut            202.Spring washer
120.king pin : lower             148.Shaft collar                 176.Lock plate             204.Connector
121.Thrust bearing               150.Boll joint                   177.Bolt                   204-AO-ring
122.Shim                         151.Bearing spacer               178.Wheel hub              211.Inner race
123.Grease nipple                152.Shaft stopper                179.Hub bolt               212.Cage
124.Bolt                         153.Sun gear                     180.Hub nut                213.Steel ball
125.Rubber boot                  154.Planetary gear spider        181.Taper roller bearing   214.Outer race
125-A.Rubber boot retaining ring 155.Planetary gear               182.Taper roller bearing




                                                                 14       W563-0053E
                                              Structure

1.11 Tightening torque

                                               Tightening torque
                   Place
                                   N・m               ft・lbf           kgf・m
                     T-1         490±49            361±36              50±5
                     T-2         108±20             80±15              11±2
                    #T-3         206±29             152±21             21±3
                   (*)T-4        481±70            355±52             49±7.1
                   (*)T-5         113±18            83±13            11.5±1.8
                   (*)T-6        108±20             80±15              11±2
                    #T-7         147±29            108±21              15±3
                   (*)T-8        270±41            199±30            27.5±4.2
                   (*)T-9        314±20            232±15              32±2
                    T-10         4.4±0.5            3.2±0.4         0.45±0.05
                  (*)T-11        255±29             188±21             26±3
                  (*)T-12        422±29             311±22             43±3
                  (*)T-13        539±49            389±36              55±5
                    T-14         127±20             94±15              13±2
                  (*)T-15         49±10              36±7              5±1
                   #T-16          49±10              36±7              5±1
                    T-18          2.9±1            2.1±0.7            0.3±0.1
                  (*)T-19        932±49            687±36              95±5
                    T-20         588±29            434±21              60±3
                    T-21         392±49            289±36              40±5
                  (*)T-22        206±29            152±21              21±3
                    T-23          24.5±5            18±3.6            2.5±0.5
                    T-25          2.9±1            2.1±0.7            0.3±0.1

                (*) : Apply screw locking agent (Three Bond 1360k or equivalents)
                 # : Apply sealing agent (Three Bond 1215k or equivalents)




                                                    15        W563-0053E
                                                      Structure


2. General

2.1 Reduction gearing

   The reduction gearing consists of the drive pinion
   and the ring gear bolted to the differential case.
   It transmits the driving force from the propeller
   shaft to the axle shafts while changing the force
   direction 90 degrees and reducing the speed to
   give increased torque.

2.2 Differential

 1. The differential is an arrangement of gears that
   allows the right and left driving wheels to turn at
   different speeds when the vehicle makes turns
   and the two wheels have to travel different
   distances. It prevents the tires from dragging.

 2. There are two types of differential; one is the
   standard type used in ordinary vehicles and the
   other is the no-spin type that can automatically
   adjust the torque distributed to the right and left
   driving wheels.

              Drive pinion                                                     Ring gear


                                                                               Spider

            Thrust washer
                                                                               Differential pinion


            Thrust washer
                                                                               Side gear



                                                                               Axle shaft




                                                                               Differential case



                                                                                    IW563-0010J011E




                                                         16       W563-0053E
                                                       Structure

2.3 Planetary speed reducer                                                   Wheel hub

 1. The planetary speed reducer consists of the sun                       Planetary gear

   gear, planetary gears, internal gear and planetary                       Planetary pin

   gear spider. The planetary gears, fixed to the                   Planetary gear spider
   planetary gear spider with the planetary pins,
                                                                                Sun gear
   mesh with the external gear teeth of the sun gear
   and the internal gear teeth of the internal gear.
                                                                            Internal gear
 2. The planetary gear spider is fixed to the wheel
    hub with bolts. The internal gear is fixed on the
    axle housing.
    Under this condition, the sun gear on the input
    shaft meshes with the planetary gears and cannot                      Planetary gear

    rotate.
                                                                           Planetary pin
 3. The planetary gears both revolve around the sun
                                                                           Internal gear
   gear along the internal gear and rotate on their
   own axes. And the driving force from the sun
   gear is transmitted to the planetary gear spider
   (wheel hub) to rotate the tire fitted on the wheel
                                                                                Sun gear
   hub. The rotational direction is the same as that
   of the sun gear.


                                                                                                          IW563-0010J019E


2.4 Ball joint assembly (assy)

 1. The ball joint consists of the inner race, outer race,     2. This joint is of the constant velocity type and it can
   cage and balls. Even when the joint turns at an             transmit the rotational speed and the torque of the
   angle with the axle shaft, the balls retained by the        driving shaft to the driven shaft regardless of change
   cage roll within the grooves on the outer race and
                                                               in the joint operation angle during steering operation.
   inner race. The cage holds the balls in the
   prescribed positions while sliding on the
   corresponding surfaces of the inner and outer
   races.
         Outer race   Inner race   X    Ball    Cage




                                                                                                  X-X
                                   X
                                                                                                  IW563-0021E39E
                                   Axle shaft




                                                          17         W563-0053E
                                                                Structure

2.5 Disc brake                                                          Tightening torque

 1. This is an opposed piston type Disc brake. This                                              Tightening torque
    brake has two pad assy on both sides of the disc                      Place
                                                                                       N•m            ft • lbf           kgf • m
    plate, and they pinch the disc plate when braking
                                                                           T-26       23 - 28         17 - 21           2.3 - 2.9
    is applied.
                                                                           T-27        52 ± 3       38.4 ± 2.2          5.3 ± 0.3
 2. When brake pressure is applied, the pistons built                      T-28       306 ± 15       226 ± 11          31.2 ± 1.5
    in the torque plates push the pad assy at their tips                   T-29       207 ± 10      153 ± 7.4          21.1 ± 1.0
    against the disc plate from both sides to create                       T-30        52 ± 3       38.4 ± 2.2          5.3 ± 0.3
    braking force.

 3. The piston seal keeps a constant clearance
    between the pad assy and the disc plate.

                                              T26                                                      Pad thickness check
             Disc plate          1             2 19                       C                            hole (2 places)
                                                            6
                                                                                                                 4,5


    10
    B                                             A
    11                                                                            C
                                                                                  View A
                                                                               T28
                        8            7       13     3                           18                    T29
                            C-C                    T27                                                 9
                                              T30
                                              17




                                                                                  View B

           21      12       15       16     14         3
                                                      T27                                                   IW563-0010J021E




1.Torque plate                       6.Torque pin (thin)            11.Piston plug                 16.Back up ring
2.Bleeder valve                      7.Pad assy                     12.Cap seal                    17.Bolt
3.Bolt                               8.Pad assy                     13.Pistpn                      18.Cap bolt
4.Torque pin (thick)                 9.Cap bolt                     14.Scraper ring                19.Cap
5.O-ring                             10.Cover plate                 15.Piston seal                 21.Back up ring




                                                                   18         W563-0053E
                                                Structure

 Principle of operation                                      The simple check method of pad assy is shown as
                                                             follows:
 1. When hydraulic pressure is applied                          Check the pad thickness by inserting a check gauge
                                                                as shown below in the check holes in the torque
   The pistons exert force to the pad assy by                   plate.




                                                                                                                5.5
   deforming the piston seals. (Fig. 2)                                                       0.
                                                                                                 2
                                                                                             R




                                                             9




                                                                                                              C
                                                                                                     60±0.2




                                                                                                               0.
                                                                                                                  5
                                                                                      90                              IW577-017201

                                                                         Unit: mm (1mm=0.039inch)

                                                             [NOTICE]
                                                               When one of the pad assy is found to have worn to
                                                               the use limit, all the other ones are also worn to the
                                                               same limit in most cases.
                                                               Replace the pad assy for the right and the left
 2. When hydraulic pressure is removed                         wheels or even for all the four wheels
                                                               simultaneously.
   The seals recover the original shape to push the            Thickness of the brake lining of the Pad assy
   pistons back, creating clearance between the disc                               Thickness of the brake lining
   plate and the pad assy. (Fig. 3 )                               New parts             14 mm (0.56in)
                                                                   Use limit              4 mm (0.16in)
                                                               The regular check is necessary to prevent from
                                                               deteriorating brake function and from the brake
                                                               damage since the thickness of the brake lining
                                                               exceeding the limit results in serious damage.

                                                                                            Check gauge



 3. When pad assy wears

   The piston displacement distance increases
   beyond the seal deformation limit, and the pistons                                  Replace the pad assy when this
                                                                                       distance becomes zero.
   slip relative to the seals, but when the hydraulic                        Piston
                                                                             Back plate       Pad assy
   pressure is removed, the pistons are pulled back                          Brake lining
   by the seals through the same distance as before                          Disc plate                       IW577-0190E02

   the occurance of wear, giving the same
   clearances.

                                                             ● Checking the disc plate
● Checking the pad assy
                                                                 Check the disc plate for the thickness and
[NOTICE]                                                         damage. If it is excessively damaged or the
 The brake calliper must be disassembled to check                thickness is below 17.5 mm (0.689 in), replace the
 the remainded pad thickness. However, the check                 disc plate. (Thickness of new disc plate: 20 mm
 gauge may use to check.                                         (0.787 in))




                                                        19        W563-0053E
                                                   Differential


Differential

1. Standard differential

              Drive pinion                                                  Ring gear


                                                                            Spider

           Thrust washer
                                                                            Differential pinion


           Thrust washer
                                                                            Side gear



                                                                            Axle shaft




                                                                            Differential case



                                                                                 IW563-0010J011E




   In the differential cases, four differential pinions
   placed around a spider whose ends are supported
   by the differential cases are in mesh with two side
   gears that are splined to the end of the axle shafts.
   The differential pinions and side gears can rotate
   freely.




                                                          20   W563-0053E
                                                 Differential

1.1. Operating explantion of standard differential

 1. The following figures show the comparison of the
   operating conditions, one for traveling straight and
   the other for turning.

                          Drive pinion    Ring gear


                                            Spider

                                            Differential pinion


                                             Side gear              Outside                Inside




     When traveling                              Axle shaft          When turning
     straight

                                                                                    IW563-0010J012E




 2. As shown above, when the vehicle turns a corner,
   the differential pinions rotate on their own axes to
   absorb the speed difference between the right and
   left axle shafts, providing a smooth cornering.

 3. This standard differential, however, cannot
    provide a straight traveling when the road surface
    conditions are different between the right and left
    tires.

 4. Especially when one of the wheels gets stuck in
   the mud or runs on a frozen road surface, etc., it
   may slip, leaving the vehicle stranded.
   Additionally when the vehicle drives on a bumpy
   road, the driving wheel free of the ground will race
   at a high speed and produce impulsive high
   driving force when it touches the road surface
   again. This may lead to the tail sway
   phenomenon.




                                                          21      W563-0053E
                                                              Differential


2 No-spin type differential
                                                                             5. The raised wheel rotation is the same as the
 1. The no-spin type differential compensates weak                               wheel on ground, and consequently, the tail sway
   points of the ordinary.                                                       phenomenon does not occur easily.

 2. The driving force from the engine is evenly divided
    on the right and left wheels when going straight.

 3. At the turning, the outside wheel is disconnected
   from the power line, and the inside wheel is drived
   by all engine torque with the no-spin type
   differential function.

 4. When the one side wheel loses surface resistance,
   the wheel slips, the other side wheel is drived by
   all engine torque, and the vehicle can propell
   consequently.



2.1 Structure and configuration of No-spin type differential
                                                                                                        Drive pinion

                                                                                                        Ring gear
                  Center cam              Spider

                                              Retaining ring
                                                     Holdout ring                                    No-spin differential assy
            Driven clutch
                                                        Spring
           Side gear




                                                                                                       Axle shaft
                        No-spin differential assy
                                                                                                    Differential case

                                                                                                                    IW563-0052E09




                                                                                     Spider


                                                                    Retaining ring

                                                            Center cam

                                                Holdout ring

                                     Driven clutch

                            Spring

                Side gear




                                                                                                            IW563-0052E10



                                                                       22            W563-0053E
                                                           Differential

2.2 Spider assy
                                                                          3. The spider has a key, in the spider inner
 1. Spider assy is composed of a spider, a center                           circumference, to limit the rotation of the center
    cam, and retaining rings.                                               cam and holdout ring.

              Retaning ring                      Trunnion                 4. The center cam is held with a retaining ring by the
                                                                            spider. Therefor, the center cam is of structure
  Driven cluch                                   Spider
                                                                            that allows the center cam to rotate in the
                                                                            backlash between the spider key and center cam
                                                                            flute.

                                                                          5. The center cam has three flutes in outer, and
                                                                             spider's key enters into the one flute and the
                                                                             projections of the holdout ring enter into the other
                                                                             flutes.

                                                                              Left holdout ring         Right holdout ring
       Clutch teeth     Trapezoid teeth    Center cam
                                                   IW563-0052E11


  The illustration shows the left driven clutch and
  holdout ring are got out from the center cam
  flute.                                                                    Projections of
                                                                          the holdout ring
  When driving straight ahead, the left driven
  clutch and holdout ring are in the center cam                                                                     Center cam flute

  flute.

 2. The spider has radial square teeth on both sides
    as a clutch. The spider has four trunnions on outer
    circumference as shown.

                                 The rotation of the center cam is
                                 limitted by the spider key.                                       Center cam           IW563-0052E13
                                 The center cam is allowed to
                                 rotate within this flute.
         Key                                                              The illustration shows the state of the left
 (Only one position)
                                            Square teeth                  holdout ring came out.
                                                                          When driving straight ahead, the left holdout ring
                                                                          is in the flute of the center cam, too.

                                                                          6. The center cam has trapezoid teeth of the same
                          Trapezoid
                                                                            number as the square teeth on both sides of the
                            teeth                                           spider.




Center cam flute

                                          Retaining ring
           Center cam
                                                 IW563-0052E12




                                                                     23       W563-0053E
                                                              Differential

2.3 Driven clutch assy                                                     2.4 Spring
                     Square teeth
                                                                              Springs are installed between the outside of the
  Driven clutch                       Holdout ring                            driven clutch and the side gear flange. Springs
                                                                              ensure the biting each other of the driven clutch
                                                   Projection of              with the spider.
                                                   the holdout ring

                                                                           2.5 Side gear
                     Square teeth                                             The outside spline bites each other to the internal
                                                                              diameter spline of a driven clutch, and the internal
                                                                              diameter spline bites each other to the axle shaft.

                                                                           2.6 Operating explanation (propeller driving in a
                                                                                     straight-forward)
                                                     IW563-0052E14

            Retaning ring                           Trunnion                1. The clutch teeth of the right and left driven clutch
                                                                               bite each other to the spider's clutch teeth, and
  Driven cluch                                      Spider
                                                                               the cam teeth bite each other to the cam teeth of
                                                                               the center cam, too.




                                                                              Backlash



                                                                                                                         Backlash



      Clutch teeth      Trapezoid teeth    Center cam
                                                      IW563-0052E11


 1. The driven clutch assy is composed of two driven
    clutches and a holdout ring. The holdout ring is
                                                                               Rotating at the same speed           IW563-0052E16
    inlaid into the flute of the driven clutch ,and it may
    only rotate relatively.                                                 2. Under this condition, the driving force is
                                                                              transmitted to the right and left wheel by the
 2. The driven clutch has square teeth of same
                                                                              following route:
   number as the spider, their teeth bite each other.
                                                                              Drive pinion →Ring gear → Differential case →
   Inside square teeth bite each other to trapezoid
                                                                              spider → driven clutch → side gear → axle
   teeth of the center cam.
                                                                              shaft.
 3. The internal diameter spline of the driven clutch
   bite each other to the outside diameter spline of
   the side gear.
         Clutch teeth     Cam teeth

                                    Holdout ring




        Driven clutch
                                             IW563-0052E15



                                                                      24        W563-0053E
                                                       Differential

           Retaning ring                    Trunnion                cam (the left side clutch is disengaged), and thus
                                                                    the left wheel runs faster than the right and the
  Driven cluch                              Spider
                                                                    vehicle can consequntly turn the corner smoothly.

                                                                  Left driben clutch            Right driven clutch




     Clutch teeth   Trapezoid teeth   Center cam
                                             IW563-0052E11




2.7 Operating explanation (propeller driving in
           forward turn)                                                                   Center cam
                                                                                                           IW563-0052E18

 1. When turning, the rotating speed of the right and
   left wheels should be different because the
   mileage of the inside and outside wheel is
   different.

 2. When the spider is driving the driven clutch, it is
    impossible the driven clutch turns later than the
    spider, but the driven clutch can turn faster to the
    backlash direction.
         Rotating at a
         faster speed




       Rotating at the same speed      IW563-0052E17


 3. In propeller driving in forward-right turn, the spider
    transmit the driven-right (inside) clutch the torque
    of 100% with the spider engaging completlly with
    the driven-right (inside) clutch.

 4. Under this condition, the gear right (inside)
   propellers vehicle forward, being recieved the
   same rotation as the ring gear. However, in the
   left(outer) side, the friction force from the ground
   rises the drive clutch on the incline of the center

                                                             25       W563-0053E
                                                     Differential

          Retaning ring                    Trunnion

 Driven cluch                              Spider
                                                                   Backlash



                                                                                                      Backlash




                                                                    Rotating at the same speed   IW563-0052E16
     Clutch teeth   Trapezoid teeth   Center cam
                                            IW563-0052E11



5. When the clutch teeth are disengaged, the left
  holdout ring contacts the spider key, the
  protruding portions of the left holdout ring coming
  out from the flutes of the center cam and being
  held on the center cam.
  The left holdout ring consequntly prevents the
  driven clutch from engaging while the driven
  clutch rotates faster than the spider.
    Left holdout ring           Right holdout ring




  Projections of
the holdout ring

                                         Center cam flute




                           Center cam         IW563-0052E13


6. When turns completely, or it is not necessary to
   differentiate, the no-spin differential returns to the
   same condition as that of straightaway.




                                                              26     W563-0053E
                                                           Axle Assembly


Axle Assembly                                                        1.3 Disc brake assy
                                                                                                             Bolt
1. Disassembly                                                         Disc brake assy

[NOTICE]
  The procedures for the axle assy and the
  differential assy are separated. In some cases the
  illustrated images may differ from the actual parts,
  but the contents of the operation are the same.

1.1 Axle assy

[NOTICE]
                                                                                                                    IW563-0021E11E
  The planetary gear block and the brake block can
  be disassembled without removing the axle assy
                                                                      1. Remove bolts, and remove disc brake assy.
  from the crane.
  Disassemble both the right and left components in
  the same procedure. Be sure not to erroneously                     1.4 Removing planetary gear spider assy
  mix the right and left parts when disassembling the
                                                                      1.Put matchmarks on planetary gear spider and
  right and left components at the same time.
                                                                        wheel hub. Then remove bolts and remove
                                                                        planetary gear spider assy with tapped extractor
1.2 Draining gear oil
                                                                        holes.
 1. Remove drain plug, and drain gear oil from axle
                                                                                            Wheel hub assy
   housing. (approx. 24 L)
                                                                         Planetary gear spider

                                                                         Bolt




                                                                                                     Matchmarks
                    Drain plug               IW563-0010J022E
                                                                                                                    IW563-0021E12E




 2. Remove plug B, and drain gear oil from wheel hub.
                                                                     1.5 Planetary gear spider assy
    (approx. 5 L)
                                 Plug A                               1. Remove bolts, and remove cover.

                                                                      2. Remove planetary pins by pushing out from the
                                                                        inside with a press.

                                                                      3. Remove planetary gears, thrust washers and
                                                                         needle bearings from planetary gear spider.




           Plug B                         IW563-0051E05E




                                                                27        W563-0053E
                                                                     Axle Assembly

                                                              Bolt
                          Cover
                                                                                   [NOTICE]
                                                                     Bolt           The unit of marked figures is millimeter. Then if the
                                                                                    measurement is conducted in “inch”, dimensions
                                                                                    have to be converted into “mm” by
      Press                                                                         1mm = 0.03937in

                                                                                   1.7 Internal gear hub assy
                                                          Planetary gear
                                                          spider assy              [NOTICE]
                                                      Threst washer
                                                                                    Do not remove taper roller bearings unless the
                                                                                    replacement of those parts is necessary.
                                                      Planetary gear
                                                                                    1. Remove stop wires to pull out internal gear hub.
  Planetary pin
                                                      Needle roller bearing
                                                                                    2. Remove inner race of taper roller bearing from
                                                      Threst washer                   internal gear hub.
                                                             IW563-0021E13E
                                                                                     Tapered roller bearing A
                                                                                                  (Inner race)
                                                                                                                           Stop wires
1.6 Removing internal gear hub assy                                                     Internal gear hub

 1. Remove snap ring, and pull out sun gear and
   spacer.
                                                                                              Internal gear
 2. Remove bolts and lock plate.

 3. Remove bearing nut and internal gear hub assy.

                                                                                                                           IW563-0010J029E
                 Bearing nut
        Spacer
  Sun gear
                                                                                   1.8 Removing wheel hub assy

                                                                                    1. While being careful not to damage oil seal,
                                                                                      remove wheel hub assy by lifting it up with a
                                                                                      crane.
                                                Wheel hub assy
                                 Internal hub gear assy
                          Lock plate                                                          Wheel hub assy
                  Bolt
         Snap ring                                          IW563-0021E14E




             Tool to tighten / loosen bearing nut
                                                170




                     35             140
           80
                55




                               50




                                                                                                                          IW563-0021E16E
                                           40
    26
                     10    100            65
                                 175                           140

                                                            IW563-0051E06E




                                                                              28        W563-0053E
                                                            Axle Assembly

1.9 Wheel hub assy                                                          1.11 Knuckle assy

[NOTICE]                                                                       King pin (upper)                Axle

  Do not remove disc plate and taper roller bearings
                                                                                            Shim
  unless the replacement of those parts is necessary.
                                                                                 Threst washer

 1. Remove oil seal, spacer and retainer.                                        Knuckle assy
    Then remove inner race of taper roller bearing.                                                                               Bolt
                                                                                                                          Plate
 2. Remove outer races of taper roller bearings A and                                                                 Boot
   B.                                                                                                          Ball joint assy
                                                                                 Threst bearing                and axle shaft
 3. Remove bolts, and remove disc plate.
                                                                                            Shim
                                 Taper roller bearing A (outer)                 King pin (lower)
                                                                                                                  IW563-0021E19E
    Taper roller bearing B



                                                                             1. Remove bolts, and take off boot covering knuckle.

                                                                             2. While holding knuckle assy with a crane, remove
                                                                               king pins with tapped extractor holes.

                                                                            [NOTICE]
                                                                             To prevent ball joint assy and axle shaft from
                                                                             accidentally slipping off, be sure to pull out them
                                                     Brake disc
                                                                             cautiously and slowly.

    Bolt   Spacer         Retainer      Oil seal
                                                                             3. Dismount knuckle assy from axle housing.
                                                      IW563-0051E07E

                                                                            1.12 Knuckle assy
                                                                                                               Axle shaft
                                                                                             Knuckle assy
1.10 Tie rod assy

 1. Remove lock plate and snap ring, and pull out tie                                        Ball joint assy
   rod end pin.
                                                                                  Knuckle spindle
 2. Remove tie rod assy from knuckle.

                  Bolt                                                                                             Oil seal

              Washer
           Lock Plate                     Tie rod

                                                                                     Bolt
                    Pin
                                                                                                                  IW563-0021E20E



                                                                            [NOTICE]
                                                                             Do not remove knuckle spindles unless the
                                         Rod end
                                                                             replacement of those parts is necessary.
           Knuckle                     Snap ring
                                                   IW563-0021E18E
                                                                             1. Remove axle shaft and ball joint assy.

                                                                             2. Remove bolts and knuckle spindles.

                                                                             3. Remove oil seal from knuckle spindle.

                                                                       29        W563-0053E
                                                        Axle Assembly

1.13 Ball joint assy
                                                                       3. Rotate inner race and cage 90 degrees as a unit.
        Cage       Outer race      Steel ball                            Then turn cage until its larger opening is located
                                                                         to align with two spherical recesses of outer race,
                                                                         and remove inner race and cage.

                                                                       4. Rotate inner race 90 degrees in cage. Take out
                                                                         inner race after putting its protruding portion into
                                                                         larger opening of cage.

                                                                           Inner race




                                                                               Cage                                  Larger opening
                   Inner rase    Shaft      Axle shaft
                                                IW563-0021E21E
                                                                                                                          IW563-0010J040E




 1. Pull out shaft from inner race.
                                                                      1.14 Axle housing assy
[NOTICE]
                                                                      [NOTICE]
  When it is difficult to separate parts, lightly tap parts
  with a plastic hammer.                                               Do not remove king pin bushings and housing
                                                                       bushings unless the replacement of those parts is
  Rotate shaft stopper by half a pitch to align the                    necessary.
  shaft spline tooth portion with the stopper spline
  space portion.
                                                                       1. Pull out king pin bushings and plates.
 2. Push the end face of cage, and take out steel
                                                                      [NOTICE]
    balls.
                                                                       Remove king pin bushings by striking them towards
                                                                       the outside from the inside of axle housing.
[NOTICE]
  Remove steel balls alternately for easy operation.                   2. Pull out retainer and bushing. Then remove
                                                                         O-ring and oil seal from retainer.
                                Inner race and cage
                                   Tilt inner race                                                                           Axle
                                   and cage
                                                                                        King pin bushing

                                 Remove stell ball
                                         Stell ball
          Outer race                                                                             Bushing
                                      IW563-0010J038E                                    Retainer
                                                                               Boot
                                                                       Clamp

    Inner race and cage
                                                                                                                          King pin bushing
                                          Larger opening




                                                                                                               Oil seal
     Outer race
                                                                                                           O-ring               IW563-0021E22E


                                            IW563-0010J039E

                                                                       3. Loosen boot band and remove boot.


                                                                 30        W563-0053E
                                             Axle Assembly

1.15 Differential assy                                       3.6 Boot

 1. Remove bolts, and dismount differential assy from           Check boots for cracks and damages. Replace
   axle housing.                                                defective ones.

                                                             3.7 Bearing
2. Cleaning
                                                              1. Wash bearings in kerosene to thoroughly remove
[NOTICE]
                                                                oil and grease, and check them for the following
  Do not use mineral oil.
                                                                items. If defects are found, replace a bearing as
                                                                a set including inner and outer races.
 1. Metal parts
   Wash metal parts in clean kerosene, and allow              • Noisy, irregular rotation when turned by hand
   them to air dry.
                                                              • Flaw, crack, pitting corrosion, stepped wear on
 2 Rubber parts                                                 outer race
   Clean rubber parts with alcohol or a clean wiper.
                                                              • Flaw, crack, pitting corrosion, partial wear on the
                                                                raceway surface of inner race
3. Inspection
                                                              • Deformation and partial wear of cage
3.1 Gear and spline
                                                              • Discoloration (a sign of seizure) on rollers, inner
   Check gears and splines for wear, pitting, etc.              race and outer race
   Replace defective ones.
                                                              2. If no defect is found, apply a thin coat of grease.
3.2 Planetary gear and planetary pin
                                                             3.8 Ball joint assy
   Check planetary gears and outer diameter of
   planetary pins. Replace defective ones.                      It is difficult to know that the ball joint assy has
                                                                reached its life span by checking only its
3.3 Oil seal                                                    components for their wear condition. Then the
                                                                following can be used as a rule of thumb to judge
   Check sealing lip of oil seal for wear, cut, etc.
                                                                that the ball joint may have ended its life.
   Replace ones having defects that can be felt by
   fingertips.                                                1. Condition of the whole ball joint assy

3.4 Axle shaft                                                • Unusual noise, vibration or heat emission

   Replace ones if their straightness is over the             2. Condition of individual components
   standard value.                                            • In the recesses for balls and the spherical
   Standard value: 0.5mm (0.02 in)                              surfaces of the inner race and the outer race,
                                                                there exist failures such as flaking, pitting, seizure,
3.5 King pin bushing
                                                                galling, etc.
   Replace ones if the clearance between the king
                                                              • Cracks are observed in the recesses for balls and
   pin OD and the king pin bushing ID is over the use
                                                                the spherical surfaces of the inner race and the
   limit.
                                                                outer race or circumferences of the cage
   Standard value: 0-0.08mm (0-0.003 in)
                                                                apertures.
   Use limit: 0.27mm (0.011 in)
                                                              • The corner is broken off at the recesses for balls
                                                                of the inner race and the outer race or the cage.


                                                        31        W563-0053E
                                                         Axle Assembly


 • The recess for the ball is abnormally worn out.                         4. Reassembly
   The wear reaches the shoulder portion of the
   recess for balls (chamfered intersection of the                         [NOTICE]
   recess for ball and the inner diameter).                                  Replace all rubber parts such as O-rings and oil
                                                                             seals as well as packing with new ones. Never
     Cage                  Enlarged view                                     reuse them.
                           Outer race
                                                                             Before press fitting oil seals, completely degrease
                                                                             the fitting surface and apply liquid gasket. When
                                                                             the fitting surface is metal, use liquid gasket
                                                                             THREEBOND No. 1104 or equivalent.
                                Ball                                         For tightening torque of each bolt and nut, refer to
                                                                             the Tightening torque table on page15.
     Inner race

                                        Worn portion                       4.1 Differential assy
                                                  Enlarged view
                                                                            1. Apply THREEBOND No. 1215 or equivalent to the
            Recess ball
                                                                              surface of axle housing where carrier case is to be
  Chamfey is also worn                                                        installed.
                          Chamfey
                                        Inner diameter                      2. Install differential assy on axle housing, and
 *   Same to the inner race                         IW563-0010J043E
                                                                               secure it with bolts and washers.
                                                                               Tightening torque: 206 ± 29 N•m { 152 ± 21 ft•lbf }

3.9 Service brake                                                          4.2 Axle housing assy

 1. Disc plate thickness                                                    1. Press fit housing bushing into axle housing with
     Standard value: 20mm (0.79 in)                                            the grooves positioned as illustrated.
     Use limit: 17.5mm (0.69 in)
                                                                                                                     Axle

 2. Brake pad thickness (thickness of friction material)
     When brand-new: 14mm (0.55 in)
     Use limit: 5mm (0.20 in)
                                                                                                  Bushing
                                                                                           Retainer
                                                                                    Boot
                                                                            Clamp




                                                                                                                        Oil seal
                                                                                                                   O-ring
                                                                                                                       IW563-0021E23E




                                                                            2. Install boot on housing while paying attention to
                                                                               the installation groove.
                                                                               Align bolt positions of knuckle, and fix boot with
                                                                               band fastening tool.




                                                                      32        W563-0053E
                                                                                       Axle Assembly

                                                                                                             4.3 Knuckle assy
[NOTICE]
 The unit of marked figures is millimeter. Then if the                                                        1. Press fit bushing into knuckle. After press fitting,
 measurement is conducted in “inch”, dimensions                                                                 apply grease to bushing bores.
 have to be converted into “mm” by 1mm =
 0.03937in.                                                                                                   2. Press fit oil seal race onto knuckle spindle.

                                                                                                              3. Press fit bushing.

                                                                                                              4. Apply liquid gasket to the outside surface of oil
                                                                                                                seal, and press fit it into knuckle spindle.
                                                                                                                After press fitting, apply grease to the lip of oil
     Oil seal                                  Oil seal press fitting tool A                                    seal.

   Retainer                                          Oil seal press ditting tool B                                                     Spindle

                                                                                                                               Oil seal race
                                                                          IW563-0010J046E


                                                                     100
                                                              +0.1
                                                               90 +0.2




                                                                                                                                       Bushing
                                      -0.046
                              +0.10
                            30+0.05




                                                                                       -0.05
                                                                                        30-0.10

                                                                                                  110
                                                89
                                       60 0




                90                                                                                                                             Oil seal
                                                                             10


                              2-30
        100          1110                                                         31

 Oil seal press fitting tool A                       Oil seal press fitting tool B
                                                                             IW563-0051F08E



   Press fit king pin bushings into upper and lower
                                                                                                                                                          Knuckle
   holes on axle housing. Then apply lithium base                                                                                       Spindle
                                                                                                                                Bolt
   grease containing MoS2 to the inside surface of                                                                                                 IW563-0021E27E

   bushings.

[NOTICE]                                                                                                     [NOTICE]
 Press fit king pin bushing so that the oil grooves                                                           Apply THREEBOND No. 1360K or equivalent to
 face front and rear of the vehicle.                                                                          bolt threads.
 Turn the step on the outer diameter of bushing to                                                            After insertion into knuckle spindle, wind a tape
 the shaft side, and press fit bushing until it hits                                                          around the tip of the ball joint assy to protect oil seal
 plate.                                                                                                       from damages.

                                                             Axle                                             5. Install knuckle spindle to knuckle with bolts.
           Special tool
                                                                                                                Tightening torque: 539 ± 49 N・m
     King pin bushing                                                                                                             {398 ± 36 ft・lbf }




                                                            Boot


                                                       King pin bushing
                                                                         IW563-0021E25E




                                                                                                        33        W563-0053E
                                                        Axle Assembly

4.4 Ball joint assy                                                       Inner race and cage

                                                                                                                     Larger opening
 1. Apply grease to the following portions.

 • Inner race: ball grooves, outer spherical surfaces
   and spline teeth                                                       Outer race

 • Cage: inner spherical surface, outer spherical
                                                                                                                     IW563-0010J053E
   surface and openings

 • Outer race: inner spherical surfaces and ball
                                                                      5. Set steel balls by tilting inner race and cage.
   grooves
                                                                                    Outer race   Insert ball
 • Axle shaft: spline teeth

         Outer race                                                                                                 Stell ball
                      Cage                                                                                     Tilt inner race
                                                                                                               and cage
                             Inner race
                                     Collar                                                           Inner race and cage
                                                                                                               IW563-0010J054E
                                          Axle shaft



                                                                     [NOTICE]
                                                                       Insert steel balls alternately for easy operation.
                        Steel ball

                                              IW563-0021E28E          6. Pack grease into ball joint.
                                                                        Grease amount: approx. 300g (0.66 lb)

 2. Place inner race at 90 degrees against cage. Fit                  7. Insert shaft and shaft collar into ball joint.
   inner race in cage by placing protrusion into
   longer opening.                                                    8. Other notices

     Inner race                                                       • During disassembly, be careful not to mix the parts
                                                                        (inner race, cage, steel balls and outer race) for
                                                                        one ball joint with parts for other joints.
                                              Larger opning
         Cage
                                                                      • Carefully handle parts not to cause any damages.
                                              IW563-0010J052E           Be sure not to allow foreign materials to enter
                                                                        inside ball joint.

[NOTICE]                                                              9. Applicable grease
  Be sure to place the side of inner race with tapped                    NTN joint grease
  holes to the side of case with smaller inner chamfer.                  MoS2 lithium base grease (black)
                                                                         Packed amount
 4. Place inner race and cage (as a unit) at 90
                                                                         Within ball joint : approx. 350g (0.77lb)
    degrees to outer race with larger opening located
    to align with two spherical recesses of outer race.




                                                                34        W563-0053E
                                                     Axle Assembly




                                                                                                                                   (0.118-0.138in)
4.5 Assembling tie rod assy                                                                                             Oil seal




                                                                                                                                   3-3.5mm
 1. Screw tie rod end until 15mm (0.59in) thread
   remains.

          Tie rod end                          Tie rod
                               15mm (0.59in)
                                                                                                            Special tool
                                                                      Bolt

                                                                Brake disc



                                       IW563-0051E09E



4.6 Assembling wheel hub assy

[NOTICE]
 Before press fit hub bolts, be sure to place cutout
 portion in the head inside.

 1. Press fit the outer races of taper roller bearings A
    and B into wheel hub.                                                        Taper roller bearing B
                                                                                                    Taper roller bearing A (outer)
 2. Place the inner race of taper roller bearing B.                                                                        IW563-0051E10E

   Press fit oil seal into retainer.
   Apply liquid gasket to the outside surface of oil            4.7 Internal gear hub assy
   seal.
                                                                 1. Press fit inner race of taper roller bearing A onto
   Put O-ring in the peripheral groove of retainer.
                                                                    internal gear hub.
   Press fit retainer and oil seal into wheel hub. (Be
   careful of bolt hole positions.)                              2. First put stop wire in the outer groove of internal
                                                                    gear, and install internal gear hub. Then put stop
[NOTICE]
                                                                    wire in the inner groove.
 Apply THREEBOND No. 1360K or equivalent to
 bolt threads.                                                     Tapered roller bearing A
                                                                               (Inner race)
                                                                                                                   Stop wires
 4. Install disc plate with bolts.
                                                                      Internal gear hub
    Tightening torque: 422 ± 29 N・m
                        { 311 ± 22 ft・lbf }

                                                                             Internal gear




                                                                                                                     IW563-0010J058E




                                                           35         W563-0053E
                                                   Axle Assembly

4.8 Assembling planetary gear spider assy                            King pin (upper)              Axle

[NOTICE]                                                                       Shim
  Before press fit planetary pins, be sure to place                   Threst washer
                                                                             (upper)
  cutout portion inside.                                              Knuckle assy
                                                                                                                        Bolt
 1. Within planetary gear spider, put planetary gears,
                                                                                                                Plate
    thrust washers and needle bearings. Then press
                                                                                                          Boot
    fit planetary pins.
                                                                                                   Ball joint assy
                                                                     Threst bearing                and axle shaft
                                                                             (lower)
                           Press                                               Shim
                                                                     King pin (lower)
                           Planetary pin                                                              IW563-0021E31E


                           Planetary gear                         3. For knuckle, axle housing and king pins, each
                           spider assy
                                                                    manufacturing error from nominal dimension is
                                                                    marked at the positions shown below. "1/100
                                                                    mm" (one hundredth millimeter) of the marked
                                   Threst washer                    figure is the error. For example if "-2" is marked,
                                   Planetary gear
                                                                    it means that the error is -0.02mm from the
                                                                    nominal dimension.
                                                                         Knuckle assy               Axle housing
                                   Needle roller bearing
                                                                                A
                                   Threst washer
                                            IW563-0021E30E


                                                                                              C
 2. Put O-ring in the O-ring groove of cover. After
    aligning the matchmarks, install cover with bolts                            B            D
    coated with THREEBOND No. 1215.
    Tightening torque: 49 ± 10 N・m {36 ± 7 ft・lbf }                       king pin (upper)        king pin (lower)
                                                                                                            F
4.9 Installing knuckle assy

[NOTICE]
                                                                                        E             IW563-0021E32E
  Apply lithium base grease containing MoS2 to
  sliding surfaces of king pins and king pin thrust
  washers.                                                        4. Measure the actual dimension of king pin thrust
                                                                    washer (upper) and thrust bearing (lower). Then
 1. When no king pin-related parts have been                        make the errors from the individual nominal
   replaced, re-assemble the same original thrust                   dimensions G and H.
   washer (upper) and shim to king pin (upper) and
                                                                  G: error from the nominal thickness dimension 3.0
   thrust bearing (lower) and shim to king pin (lower)
                                                                    mm (0.118in) of king pin thrust washer
   just before disassembly.
                                                                  H: error from the nominal thickness dimension 18.5
 2. When any parts have been replaced that affect
                                                                    mm (0.728in) of king pin thrust bearing
   king pin function, the shim thickness should be
   calculated according to the following procedure for              (Example) When the actual measured dimension
   each of upper and lower king pin.                                is 3.05mm (0.120 in), G is + 0.05mm (0.002 in).



                                                             36       W563-0053E
                                                         Axle Assembly


[NOTICE]                                                              4.10 Installing wheel hub assy
 The unit of marked figures is millimeter. Then if
 the measurement is conducted in "inch",                             [NOTICE]
 dimensions have to be converted into "mm" by 1mm                    ◆While being careful not to damage oil seal, install
 = 0.03937 in.                                                        wheel hub assy to spindle

 5. Calculation of required shim thickness                            1. Install wheel hub assy to knuckle spindle.
    Upper shim thickness =
      1.0 - A + C + E + G (0 - 0.05)
    Lower shim thickness =                                                      Wheel hub assy
      1.0 - B+ D + F + H (0 - 0.05)
[Example of calculation]

        Part                    code                 marked
  Knuckle                       A (B)                   -10
  Axle housing                  C (D)                   +8
                                                                                                  Spindle
  King pin                      E (F)                   -35
  Thrust washer                 G (H)                    -2                                                        IW563-0021E34E

 The unit of marked figures is millimeter.
   Shim thickness = 1 - (-0.10) + 0.08 + (-0.35) +
   (-0.02) = 0.81 = 0.8mm                                            4.11 Installing internal gear hub assy
   Upper shim thickness = 0.75 - 0.8mm
   Lower shim thickness = 0.75 - 0.8mm                                1. Install internal gear hub assy to knuckle spindle,
                                                                         then tighten bearing nut while turning wheel hub.
 6. Mount knuckle assy to axle housing, and install                      Tighten bearing nut until some resistance is felt
    king pins (Upper and lower) set at the step 1.                       when turning wheel hub. Then back off bearing
                                                                         nut one-half to one turn.
 7. Apply THREEBOND No. 1360K or equivalent to
    bolt threads. Install king pins (upper and lower)                 2. Wind a soft wire around wheel hub and read the
    with bolts.                                                          force A when wheel hub is turning with a spring
    Tightening torque: 932 ± 49 N・m { 687 ± 36 ft・lbf }                  balance. This is mainly the resistance of oil seal.
                                                                         Next tighten bearing nut and read the force B
 8. When the standard cannot be satisfied, make
                                                                         (resistance of bearing and oil seal). Adjust the
    adjustment by equally increase/decrease upper
                                                                         amount of bearing nut tightening to make B - A
    and lower shim thickness by 5/100.
                                                                         within the standard value of:
    Pull to the steering direction, and read the spring
                                                                         when bearing is brand-new: 44 - 64 N (9.9 - 14.4
    balance.
                                                                         lbf)
    Standard value: 50 ± 10N {11.24 ± 2.25 lbf }
                                                                         when bearing is reused: 26 - 39 N (6.0 – 8.8 lbf)
                                Knuckle assy

       Spring balance
               11.24 ± 2.25lb
                                                                            Bearing nut




                                               IW563-0021E33E



 9. Install boot and plate to knuckle with bolts.                                                      Wheel hub assy
   Tightening torque: 2.9 ± 1 N・m { 2.1 ± 0.9 ft・lbf }                                    Internal gear hub assy
                                                                                                            IW563-0021E35E




                                                                37        W563-0053E
                                                     Axle Assembly

      Spring balance                                              4.12 Planetary gear spider assy
                        Wire
                                   Wheel hub assy
                                                                   1. Put O-ring coated with grease in planetary gear
                                                                     spider assy. After aligning the matchmarks,
                                                                     install planetary gear spider assy to wheel hub
                                                                     with bolts.
     Bearing nut
                                                                     Tightening torque: 127 ± 20 N・m { 94 ± 15 ft・lbf }

                                                                                           Wheel hub assy
                                                                       Planetary gear spider


                                                                      Bolt
                      Lock plate
               Bolt                         IW563-0021E36E




[NOTICE]
 Apply THREEBOND No. 1360K or equivalent to
 bolt threads.
 Be sure to place lock plate close to bearing nut for                                              Matchmarks
 better locking performance.                                                                                       IW563-0021E38E



 3. Install lock plate next to bearing nut with bolts.
   Tightening torque: 49 ± 10 N・m                                 4.13 Tie rod assy
                     { 36 ± 7 ft・lbf }
                                                                  [NOTICE]
                                                                    Before driving tie rod end pin, make sure that the
                                                                    holes of tie rod end and knuckle align correctly with
            Spacer                                                  each other. This is necessary to avoid damage to
      Sun gear                                                      the bushing.

                                                                   1. Fit tie rod assy over knuckle, drive tie rod end pin,
                                                                     and install lock plate with bolts.
                                                                     Tightening torque: 24.5 ± 5 N・m {18± 3.6 ft・lbf }

                                                                   2. Put snap ring.

                                                                                    Bolt
        Snap ring                          IW563-0021E37E
                                                                                Washer
                                                                             Lock Plate                 Tie rod
 4. Install spacer and sun gear to shaft of ball joint
   assy, and fix them with snap ring.                                               Pin




                                                                                                       Rod end
                                                                             Knuckle                  Snap ring
                                                                                                                IW563-0021E18E




                                                             38        W563-0053E
                                                    Axle Assembly

4.14 Disc brake assy

 1. Install disc brake assy with bolts so that bleeder
   valve is at the upper side of the vehicle.
   Tightening torque: 588 ± 29 N・m { 434 ± 21 ft・lbf }

4.15 Lubrication

[NOTICE]
  Be sure to use Hypoid Gear Oil A. P. I. Class GL-5
  or higher, SAE90
  Be sure to wind a seal tape on the plug.

 1. Turn wheel hub so that "OIL LEVEL" on the cover
    becomes horizontal. Pour oil from plug B until oil
    comes out from plug A. (approx. 5 L for one side)

                                  Plug A



         Plug B




                                   IW563-0051E11E




                                                         39    W563-0053E
                                                 Differential Assembly


Differential Assembly                                              2. Disassembly

                                                                   2.1 Differential carrier assy
1. Dismounting
                                                                    1. Mount differential carrier assy on a special stand.
                     Differential carrier assy
               Axle housing
                                                                                            Differential carrier assy




                                      Bolt
                    Drain plug               IW563-0021E41E




1. Remove drain plug at the bottom of axle housing                             Stand
  and drain gear oil from axle housing. (approx. 24                                                 IW563-0010J074E

  L)

2. Pull out right and left axle shaft shafts according to           2. Before disassembling differential carrier, measure
  the "disassembly procedure of axle assy".                           the backlash of ring gear, runout at its back, etc.
                                                                      with a dial gauge, and check tooth contact pattern.
3. Remove bolts, and remove differential carrier assy
                                                                      If they are within the required limits, try to restore
   from axle housing.
                                                                      the same conditions during reassembly.

                                                                         Dial gauge                  Ring gear




                                                                                                         IW563-0010J076E




                                                              40        W563-0053E
                                            Differential Assembly

                         Dial gauge
    Ring gear                                                       5. Pull out lock pin, and slightly loosen right and left
                                                                      ring nuts.

                                                                    6. Remove bolts and bearing caps, and remove ring
                                                                      nuts.




                                                                                                                      Bolt



                                                                                                                      Bearing cap



                                            IW563-0010J077E                                                           Ring nut



3. Loosen locknut, and remove thrust bolt.




                 Lock nut                                                                                     IW563-0010J080E

   Thrust bolt

                                                                   [NOTICE]
                                                                    Put marks on ring nuts and taper roller bearing
                                                                    outer races so that erroneous mixture of right and
                                                                    left parts will not be made during reassembly.

           Thrust plug
                                                                    7. Put a bar or a pipe through differential case, and
                                          IW563-0010J078E
                                                                      lift differential case assy with slings. Taper roller
                                                                      bearing outer races will be removed along with the
4. Put matchmarks on bearing caps and carrier                         assembly.
   case.

                                              Ring nut                                       Differential case assy




                                                Lock pin




      Bearing cap          Carrier case
                  Matchmark                 IW563-0010J079E


                                                                                                               IW563-0010J081E




                                                              41        W563-0053E
                                          Differential Assembly

2.2 Differential case assy                                         4. Remove taper roller bearing inner races from
               (Standard differential)
                                                                      differential cases B and C with a pulley puller.
 1. Put matchmarks on differential case B and C.                      Ring gear                        Tapered roller bearing
                                                                                     Bolt

 2. Remove bolts, and separate differential case B
   and C.

                      Bolt




   Differential case set C                                                    Differential case B               Differential case C
                                                                                                                       IW563-0010J084E



   Differential case set B
                                                                  [NOTICE]
                                                                    Do not remove ring gear unless its replacement is
             Matchmark
                                         IW563-0010J082E
                                                                    necessary.

                                                                   5. Remove bolts, and remove ring gear from
 3. Take out differential pinions, side gears, spider                 differential case.
    and thrust washers from differential case B.
                                                                  2.3 Differential case assy
                    Bolt                                                          (No-spin differential)

                                                                  [NOTICE]
 Differential case set C
                                                                    Basically the disassembly procedure is the same as
         Thrust washer                                              that for the standard differential. But be sure to set
                                                                    the special tool shown below to the no-spin
             Side gear                                              differential assy before starting the disassembly so
                                                                    that the differential case should not pop out by the
                                                                    internal spring force.
         Thrust washer
                                                                    The unit of marked figures is millimeter. Then if the
     Differential pinion                                            measurement is conducted in “inch”, dimensions
                                                                    have to be converted into “mm” by 1mm =
                 Spider
                                                                    0.03937in.
     Differential pinion
                                                                                       Spescial tool
         Thrust washer                                                                      M6X10
                                                                                                                0
                                                                                                           55 -1
             Side gear
                                                                                                        t=3.2
                                                                             t=3.2           100                          M6X10
         Thrust washer                                                               230
                                                                                                                    IW563-0051E12E


 Differential case set B



                                           IW563-0010J083E




[NOTICE]
  Do not remove taper roller bearings unless the
  replacement of those parts is necessary.



                                                             42        W563-0053E
                                                  Differential Assembly

                                                      Side gear
                                                                         4. Remove chamber bracket and brake support.
                                             Spring
               Driven cluch assy                                         5. Pull out drive pinion assy.

                                                                         6. For ease of adjustment during reassembly, keep
                                                                           removed shims without bending them.
           Spring
                                                                        2.5 Drive pinion assy (rear axle)
   Side gear



                           Spider and center cam assy
                                                                                                 Shim
                                                 IW563-0010J086E
                                                                                                        Drive pinion assy


2.4 Drive pinion assy (front axle)                                                                                     Packing




                             Shim
                                                                                         Cover
                                    Drive pinion assy                                             Companion flange

                                                                                                              Nut
                                                  Packing



                                                                                                                     IW563-0021E44E
                     Cover

                              Shim
                                                                         1. Undo crimp on nut. While keeping companion
                                     Companion flange
                                                                           flange from turning with a proper tool, loosen nut.
    Chamber                                      Brake disc
     bracket
                                                             Nut         2. Remove bolts, and pull out drive pinion assy.

                                                                         3. For easy adjustment at reassembly, store
                                                                            removed shims without bending them.


                                               Brake support

                                            Center brake



                                                  IW563-0021E43E




 1. Remove bolts, and remove parking brake assy.
   Keep shim set.

 2. Undo crimp on nut. While keeping disc from
    turning with a proper tool, loosen nut.

 3. Remove bolts and disc.



                                                                   43        W563-0053E
                                             Differential Assembly

2.6 Removing drive pinion and bearing                           Drive pinion   Outer race of taper
                                                                               roller bearing
 1. Remove drive pinion from pinion cage with a
   press.

                                                                                            IW563-0031J67E
                                     Drive pinion

       Bearing cage




                                       IW563-0010J089E




                      Inner race of taper
                      roller bearing
                      Spacer
                      Shim
                      Pinion cage



                      Drive pinion




                                          IW563-0031J65E




 2. Remove snap ring, and then remove roller bearing
   inner race with a puller.

 3. Remove taper roller bearing inner race with a
    puller.

                      Inner race of taper
                      roller bearing


                      Drive pinion



                      Roller bearing
                      Snap ring        IW563-0031J66E




 4. Remove taper roller bearing outer races from
   bearing cage.


                                                           44   W563-0053E
                                         Differential Assembly


3. Cleaning
                                                               5. Side gear and differential pinion
[NOTICE]                                                       1. If the tooth surface of a gear is abnormally worn or
  Do not use mineral oil.                                        damaged, replace it with a new one. Check the
                                                                 inside of differential case, thrust washers, spider,
 1. Metal parts
                                                                 etc. If they are abnormally worn or damaged,
   Wash metal parts in clean kerosene, and allow                 replace them.
   them to air dry.                                              Replace side gears and differential pinions in a
                                                                 matched set, together with thrust washers.
 2. Rubber parts
                                                                 Using different combination of side gears and
   Clean rubber parts with alcohol or a clean wiper.             differential pinions that should be used only as a
                                                                 matched set and using old thrust washers
                                                                 together with new ones may cause a premature
4. Inspection
                                                                 failure of those parts.
 1. Differential pinion and spider
                                                               6. Bearing
   Check the clearance between differential pinion ID
                                                                 Wash bearings in kerosene to thoroughly remove
   and spider OD.
                                                                 oil and grease, and check them for the following
   Standard value: 0.1-0.15mm (0.0039 - 0.0059 in)
                                                                 items. If defects are found, replace a bearing as
   Use limit: 0.25mm (0.0098 in)
                                                                 a set including inner and outer races.
 2. Side gear and axle shaft                                     •Noisy, irregular rotation when turned by hand
                                                                 •Flaw, crack, pitting corrosion, stepped wear on
   With axle shaft fixed, measure the spline play in
                                                                   outer race
   the direction of rotation at the outer end of side
                                                                 •Flaw, crack, pitting corrosion, partial wear on the
   gear with a dial gauge.
                                                                   raceway surface of inner race
   Standard value: 0.1-0.31mm (0.0039 - 0.0122 in)
                                                                 •Deformation and partial wear of cage
   Use limit: 0.5mm (0.0197 in)
                                                                 •Discoloration (a sign of seizure) on rollers, inner
 3. Flange and drive pinion                                        race and outer race

   With drive pinion fixed, measure the spline play in           If no defect is found, apply a thin coat of grease.
   the direction of rotation at the outer end of the
                                                               7. Others
   keyway in flange for propeller shaft installation
   with a dial gauge.                                            Replace all parts that are found faulty.
   Standard value: 0-0.27mm (0 - 0.0106 in)
   Use limit: 0.4mm (0.0157 in)

 4. Drive pinion and ring gear

   Check every gear tooth for contact pattern, wear
   and pitting. Slight stepped wear can be repaired
   with an oilstone or a fine file. If tooth surface is
   damaged, replace drive pinion and ring gear in a
   matched set.




                                                          45       W563-0053E
                                           Differential Assembly


5. Reassembly                                                  4. Install snap ring on drive pinion.

[NOTICE]                                                       5. Put snap ring to drive pinion.
 Replace all rubber parts such as O-rings and oil
 seals as well as packing with new ones. Never                                     Inner race of taper
 reuse them.                                                                       roller bearing
 Before press fitting oil seals, completely degrease
 the fitting surface and apply liquid gasket. When                                 Drive pinion
 the fitting surface is metal, use liquid gasket
 THREEBOND No. 1104 or equivalent. For rubber
 fitting surface, use liquid gasket THREEBOND No.
 1212 or equivalent.                                                               Roller bearing
 For tightening torque of each bolt and nut, refer to                              Snap ring          IW563-0031J66E
 the Tightening torque table on page15.

5.1 Drive pinion assy                                          6. Install companion flange to drive pinion and fix it
                                                                 with nut.
[NOTICE]
                                                                 Tightening torque: 490 ± 49 N・m { 361 ± 36 ft・lbf }
 When reusing disassembled bearings, be sure not
 to assemble them in wrong locations.                                                        Nut


 1. Press fit taper roller bearing outer races into
    pinion cage with a press.                                                                Companion flange

      Drive pinion       Outer race of taper
                         roller bearing


                                                                                             Drive pinion assy

                                       IW563-0031J67E




                                                                                                   IW563-0021E46E
                        Special tool



                                                              [NOTICE]
                                                               Do not install cover (brake support) for accurately
                                                               adjust preloads.
                                                               Measure the force needed to turn cage while it is
                                                               turning (not the force when it starts to turn). This
                                                               measured force means the preload applied to the
                                                               bearings.
                                                               Be careful not to grind space more than needed. If
                                                               spacer is ground too much, bearing may be
                                                               damaged when tightening nut.
                                        IW563-0010J093

                                                               7. Apply a small amount of gear oil to bearings.
 2. Press fit taper roller bearing inner race on drive            Wind a wire around bearing cage and measure
    pinion with a press.                                          preload with a spring balance. If the measured
                                                                  force is smaller than the standard value, adjust by
 3. Press fit roller bearing on drive pinion with a
                                                                  gradually grinding spacer.
    press.


                                                         46        W563-0053E
                                          Differential Assembly

                                                                                                  Nut
   On the other hand if the measured force is larger
   than the standard value, replace spacer with new
   one.
                                                                                                  Companion flange
   Standard value
   Bearing (brand new): 14 - 20 N (3.15 - 4.50 lbf)
   Bearing (reused): 7 - 10 N { 1.57 - 2.25 lbf }

                                      Companion flange
                                                                                                  Drive pinion assy
   Spring balance


                                      Bearing cage



                                      Drive pinion                                                      IW563-0021E46E




                                         IW563-0010J096E
                                                                 12.(Front axle)
                                                                   Install packing, cover and companion flange, and
 8. After having adjusted preload to the standard                  tighten nut.
    value, put matchmarks to drive pinion and nut.                 Install parking brake only after differential carrier
                                                                   assy has been assembled.
 9. Remove nut and companion flange.
                                                                5.2 Differential case assy (standard differential)
[NOTICE]
 Before press fitting oil seals, apply liquid gasket to          1. Press fit taper roller bearing inner races to
 the fitting surface.                                              differential case B and C.

 10.Press fit oil seal into cover (brake support).              [NOTICE]
   Apply grease to the lip of oil seal.                           Apply THREEBOND No. 1360K or equivalent to
                                                                  bolt threads.
[NOTICE]
  Be sure to replace packing with new ones.                      2. Install ring gear to differential case with bolts.
                                                                   Tightening torque: 314 ± 20 N・m { 232 ± 15 ft・lbf }
 11.(Rear axle)
   Install packing, cover and companion flange, and                 Ring gear    Bolt              Taper roller bearings

   tighten nut until matchmarks aligns. Then crimp
   nut.




                                                                            Differential case B            Differential case C
                                                                                                               IW563-0010J084E




                                                                [NOTICE]
                                                                  The oil groove of thrust washer should face side
                                                                  gears.

                                                                 3. Install spider, side gears, differential pinions and
                                                                    thrust washers in differential case.


                                                           47        W563-0053E
                                            Differential Assembly

                                                                     The condition which it is set on                      Side gear
 4. Apply THREEBOND No. 1360K or equivalent to
    bolt threads. Align matchmarks on differential                                                               Spring
    cases and tighten with bolts.                                                         Driven cluch assy
    Tightening torque: 113 ± 18 N・m
                      { 83 ± 13 ft・lbf }

                    Bolt                                                         Spring

                                                                       Side gear
 Differential case set C

                                                                                               Spider and center cam assy
         Thrust washer

                                                                                                                         IW563-0010J098E
             Side gear


         Thrust washer
                                                                   [NOTICE]
     Differential pinion                                             The other procedures are just the same as for the
                                                                     standard differential.
                 Spider

     Differential pinion                                           5.4 Differential carrier assy
         Thrust washer                                              1. Put outer races on taper roller bearings at both
             Side gear
                                                                      sides of differential case assy. And place the
                                                                      assembly in carrier cage.
         Thrust washer
                                                                    2. Install right and left adjusting nuts, and place
                                                                       bearing caps according to the matchmarks put
 Differential case set B
                                                                       during disassembly while mating the internal
                                                                       threads of bearing cap with external threads of
                                            IW563-0010J083E
                                                                       adjusting nut.

5.3 No-spin differential case assy                                 [NOTICE]
                                                                     When reusing disassembled parts, be sure not to
   Basically the reassembly procedure is the same                    confuse the bearing outer races and bearing caps
   as that for the standard differential.                            originally located on the right side with those on the
                                                                     left side.
[NOTICE]
  Place no-spin differential assy, still having the
  special tool on it, in differential cases. Then                                               Differential case assy
  remove the special tool while no-spin differential
                                                                                                          Taper roller bearing
  case is in differential cases.
  If the special tool comes off before installing no-spin
  differential assy in differential cases, be sure to
  align the recess of the holdout ring with the spider
  key before installing it.




                                                                                                                    IW563-0010J099E



                                                              48         W563-0053E
                                        Differential Assembly

                                                                                                               Ring nut




                                        Bolt
                                                                 Spring balance


                                        Bearing cap

                                           Ring nut


                                                                                                           IW563-0010J102E




                                                                4. Measuring ring gear runout

                                                               [NOTICE]
                                                               ◆If the runout is larger than the standard value,
                                       IW563-0010J100E          possible causes may be: incorrect tightening of
                                                                adjusting nuts and bolts; dust particles between
                                                                assembled parts. In such a case, repeat
[NOTICE]                                                        disassembling and reassembling.
 Measure the force needed to turn cage while it is             ◆If the runout is still larger than the use limit even
 turning (not the force when it starts to turn).                after repeated reassembling, replace the related
 This measured force means the preload applied to               parts.
 the bearings.
                                                                   Set a dial gauge to make it perpendicular to the
 2. Preload adjustment                                             back of ring gear as shown below. Then
    Apply prescribed preloads by gradually tightening              measure the runout while turning it.
    right and left ring nuts equally. Wind a wire                  Standard value: 1mm (0.004in) or less
    around differential case body (where spider is)                Use limit: 0.2mm (0.008in)
    and measure preload with a spring balance.
                                                                   Dial gauge                  Ring gear
    Standard value
    Bearing (brand new): 26 - 37 N (5.84 - 8.32 lbf)
    Bearing (reused): 14 - 20 N { 3.15 - 4.50 lbf }

[NOTICE]
 At adjustment, align ring nut groove with pin hole of
 bearing cap.
 When installing drive pinion, adjust differential case
 assy to the back side of spiral gear.

                                     Ring nut
                                                                                                         IW563-0031J54E




                                                                4. Put matchmarks right and left portions where ring
                                                                   nut groove aligns with pin hole of bearing cap.

                                                                5. Remove differential case assy from carrier case




                                       IW563-0010J101E




                                                          49         W563-0053E
                                           Differential Assembly

5.5 Drive pinion assy
                                                                 3. To keep the preload to side bearings, if one
[NOTICE]                                                           adjusting nut is loosened, tighten the other
  Correctly match carrier case, shim, bearing cage,                adjusting nut by the same amount.
  packing, bolt holes of cover, lubrication holes before           Standard value: 0.25-0.4mm (0.01 - 0.016 in)
  assembly.
                                                                       Ring gear
 1. When parts are not replaced:
    Among shims that were kept at disassembly,
    apply THREEBOND No. 1104 or equivalent only
                                                                                                       Dial gauge
    to surfaces that touch carrier case and install
    them to bearing cage. Insert drive pinion assy                                                   Adjusting nut
    into carrier case and tighten it with bolts.
    Tightening torque:
    108 ± 20 N・m { 80 ± 15 ft・lbf }

 2. When parts (drive pinion, ring gear, bearing, etc.)
   are replaced:                                                                                          IW563-0031J73E
   Without putting shims, insert drive pinion assy into
   carrier case. Instead of shims, insert thickness
   gauges of the same thickness 0.65 – 1.45mm
                                                                5.7 Inspection and adjustment of tooth contact
                                                                           pattern
   {0.026 - 0.057in} at two or three places and
   temporarily tighten equally space bolts (3 pieces).           1. Temper red lead with spindle oil. Apply it to both
   There are four kinds of shim thickness, 0.10, 0.15,             sides of about 7 to 8 teeth of ring gear.
   0.20 and 0.50mm {0.004in, 0.006in, 0.008in and
                                                                               Ring gear
   0.020in}.
   After completing "tooth contact pattern                          Apply red lead
   adjustment" (described later) and the shim
   amount is determined, install drive pinion assy
   according to the above mentioned "when parts are
   not replaced".

5.6 Installing differential case assy

[NOTICE]
  When installing differential case assy to carrier case,
  align the matchmark on the ring nut put at                                                             IW563-0031J74E

  paragraph 5.4 4 with the pin hole of the bearing cap
  to prevent preload from changing.
  Be sure to check the run-out at the back of the ring           2. Turn ring gear by hand in both directions to press
  gear again.                                                      its tooth flanks against those of pinion gear.

 1. Install differential case assy to carrier case.              3. Check the tooth contact pattern and correct it, if
                                                                   necessary, according to the following table.
 2. The backlash between ring gear and pinion gear
    can be adjusted by turning adjusting nuts at side           [NOTICE]
    bearings, thus making ring gear move.                        At adjustment, move right and left ring nuts by the
                                                                 same amount not to allow preload to change.




                                                           50        W563-0053E
                                              Differential Assembly

                                                                                         Dial gauge
         Tooth contact pattern      Adjustment method
                                                                                     Ring gear
        Good contact pattern     No adjustment required


 1
                                                                                                                   Ring nut




        Wrong contact pattern
        (High bearing)           Use thinner shims to move
                                 drive pinion close to ring
                                 gear, and adjust backlash
 2                               with adjusting nuts.


                                                                                                                  IW563-0010J104E




        Wrong contact pattern                                             If unsatisfactory, repeat the whole assembly
        (Low bearing)            Use thicker shims to move
                                 drive pinion away from ring              procedure or replace parts.
                                 gear, and adjust backlash
 3
                                  with adjusting nuts.
                                                                                                                   Ring nut




                                                IW563-0010J106E




 4. After adjustments, tighten cap bolts of side
     bearing.
     Tightening torque: 481 ± 70 N•m {355 ± 52 ft•lbf}

[NOTICE]
 Apply THREEBOND No.1360k or equivalent to bolt                                 Bearing cap           Lock pin     IW563-0010J107E
 threads.

 5. Recheck the runout at the back of ring gear and                    [NOTICE]
    the backlash.                                                        Be sure to replace lock pin with new one.
       Dial gauge                  Ring gea
                                                                        - If the results are satisfactory, insert lock pin into
                                                                          bearing cap pin hole.

                                                                        - If the results do not meet the standard, conduct
                                                                          assembly again or replace parts.

                                                                        6. Press fit thrust plug on thrust bolt, and screw it
                                                                           into carrier case. After tighten it until it lightly
                                                                           touches the back of ring gear, back off it about 1/8
                                                                           to 1/6 turn and lock it with lock nut.
                                                                           Tightening torque: 147 ± 29 N・m { 108 ± 21 ft・lbf }


                                        IW563-0010J103E




                                                                  51        W563-0053E
                                            Differential Assembly


[NOTICE]                                                             with bolts. Apply THREEBOND #1360K or
 Apply THREEBOND No. 1215 or equivalent to                           equivalent to bolt threads.
 thrust bolt threads.                                                Tightening torque: 108 ± 20 N・m
                                                                                          { 80 ± 15 ft・lbf }

                                                                   3. Install parking brake assy to brake support.
                                                                     Tighten pad carrier bolt nuts.
                                                                     Tightening torque: 4.4 ± 0.5 N・m { 3.2 ± 0.4 ft・lbf }
                  Lock nut                                           After tightening, bend tab washers to the pad
    Thrust bolt                                                      carrier bolt side.

                                                                   4. Adjust the distance between pads to 30.6 ± 0.05
                                                                     mm (1.205 ± 0.002in) with hand brake bolts.

                                                                   5. Install parking brake assy to bearing cage cover
            Thrust plug                                               and fix it with bolts. Adjust clearance between
                                          IW563-0010J078E             pad and disc to the same amount with shims.
                                                                      Apply THREEBOND #1360K or equivalent to bolt
                                                                      threads.
5.8 Parking brake assy
                                                                      Tightening torque: 255 ± 29 N・m {188 ± 21 ft・lbf }
                              Companion flange
                                           Brake disc              6. Adjust clearance between disc plate and pad to
                                                    Nut              0.15 mm (0.006in) for one side with hand brake
                                                                     bolt.
              Packing
                                                                  5.9 Differential carrier assy

                             Cover                                 1. Apply THREEBOND No. 1215 or equivalent to the
                                                                     surface of axle housing where carrier cage is
                                          Shim                       placed. Install differential carrier assy on axle
                                                                     housing with bolts.
              Chamber
               bracket                      Brake support            Tightening torque: 206 ± 29 N•m
                                                                                       {152 ± 21ft•lbf }

                                                                                        Differential carrier assy
                                                                                  Axle housing




                    Center brake            IW563-0021E47E


                                                                                                         Bolt
                                                                                       Drain plug
 1. Install chamber bracket and fix it with bolts.                                                              IW563-0021E41E

   Apply THREEBOND #1360K to bolt threads.
   Tightening torque: 270 ± 41 N・m {199 ± 30 ft・lbf }
                                                                   2. Refer to the axle assy assembly procedure and
 2. Install disc plate to companion flange and fix it                 install right and left axle shafts to complete axle
                                                                      housing assy.

                                                             52        W563-0053E
                                            Differential Assembly

5.10 Lubrication

[NOTICE]
  Be sure to use Hypoid Gear Oil SAE No.90
  (A.P.I –No.GL-5 or higher).
  Be sure to wind a seal tape on the plug.

 1. Tighten drain plug (with washer), and pour gear oil
    into axle housing until oil rises to the oil level plug
    opening. (approx. 24 L)


                                        Plug




                  Drain plug         IW563-0010J112E




                                                              53   W563-0053E
                                                   Adjustment


Adjustment
1. Steering angle
 1. Bleed the steering cylinders of air by operating the
    cylinders in the 4-wheel steer mode 2 or 3 times.

[NOTICE]
 Apply THREEBOND No. 1360k or equivalent to bolt
 threads.

 2. Prior to the adjustment, make sure that the
    amount of tire side slip is within ± 3mm with a side
    slip tester. If the value does not meet this
    condition, adjust the toe-in by loosening the fixing
    bolts of the tie rod end and turning the tie rod.
    Tightening torque: 206 ± 29 N・m {152 ± 21 ft・lbf }

 3. Set the outriggers on a level surface so that the
    clearance between the tires and the road surface
    is equal on both side.

 4. Using a steering angle measuring jig, adjust the
    maximum steering angles in both A and B
    directions by turning stopper bolts A and B
    respectively.

[NOTICE]
 The adjustment angle varies with the crane model
 and the tire size. See the service manual covering
 your model.

    Stopper bolt locknut tightening torque: 392 ± 49
    N・m { 289 ± 36 ft・lbf }

                       Tie rod
         Stopper bolt B        Stopper bolt A
    B                                             A

θ                                                     θ



                                         IW563-0010J113E




    [Reference]
    •King pin angle: 0°
    •Camber: 0°
    •Caster: 0°
    •Toe-in: 0-2mm (0 – 0.079 in)




                                                           54   W563-0053E
                                                              Trouble shooting


Trouble shooting

1. Noise

                                                 Faulty portion and cause                                        Measure
                            Poor tooth contact between drive pinion and ring gear                   Adjust
                            Worn/damaged drive pinion and ring gear                                 Replace
                            Loose/worn taper roller bearing on drive pinion                         Adjust preload, or replace.
          Differential




                            Loose/worn taper roller bearing on differential case                    Adjust tooth contact pattern,
                                                                                                    preload and backlash, or
                                                                                                    replace.
                            Worn side gears, pinions, thrust washers and spider on differential     Replace
                            Damaged no-spin differential                                            Replace
                            Worn spline teeth of drive pinion, side gears and no-spin differential Replace
                            Insufficient/dirty oil                                                  Replenish, or replace oil.
     Planetary speed




                            Worn/damaged bearing                                                    Replace
         reducer




                            Worn/damaged sun gear, planetary gear and internal gear                 Replace
                            Worn spline teeth of ball joint, sun gear, internal gear hub, knuckle   Replace
                            spindle and axle shaft
                            Insufficient/dirty oil                                                  Replenish, or replace oil.




2. Oil leak

                                                 Faulty portion and cause                                        Measure
                            Damaged oil seal and packing                                            Replace
             Differential




                            Loose plug                                                              Re-tighten
                            Loose fixing bolt                                                       Re-tighten
                            Damaged shim                                                            Replace
                            Damaged oil seal and O-ring                                             Replace
   Planetary

   reducer




                            Loose plug                                                              Re-tighten
   speed




                            Loose fixing bolt                                                       Re-tighten




3. Defective steering and turning operations

                                                 Faulty portion and cause                                        Measure
                            Worn/damaged kingpin busing, kingpin thrust washer                      Replace
          Housing




                            Incorrectly installed kingpin                                           Adjust
                            Damaged ball joint                                                      Replace
                            Damaged tie-rod bushing                                                 Replace


                                                                            55     W563-0053E
                                                     Trouble shooting


4. Insufficient braking

                                        Faulty portion and cause                               Measure
                   Deterioration/deformation at pad surface                          Replace
      Brake disc




                   Worn pad beyond use limit                                         Replace
                   Oily material on pad surface                                      Clean
                   Faulty piston operation                                           Replace




5. Brake drag

                                        Faulty portion and cause                               Measure
     Brake disc




                   Faulty piston seal                                                Replace
                   Deflected disc plate (too much run-out)                           Replace
                   Incorrectly installed pad                                         Correct




                                                                   56   W563-0053E
                                     Test for No-spin differential


Test for No-spin differential
                                                                 5. After that, rotate both wheels backward until they
 The no-spin differential function can be checked with             stop and hold the right wheel. Confirm the left
 the right and left wheel movement by the following                wheel is free when the left wheel is rotated
                                                                   forward.
 method.


1. Test with wheels jacked up
 1. Raise the wheels completely from the floor by
   jack-up.

 2. Stop the engine, and lock the propeller shaft.
   (Apply the parking brake under four-wheel drive
                                                                     Example: Right turn with the engine running.
   mode.)

[NOTICE]
 Give measures necessary so that the third party
 cannot start the engine.

 3. Confirm the no-spin differential function of the left
   wheel.
   Rotate both wheels forward until they stop.
   In general, both wheels rotate by 5 to 6 cm (1.97             6. Confirm the no-spin differential function of the
   to 2.36 in) and stop.                                            right wheel.
                                                                    Rotate both wheels forward until they stop.
                                                                    In general, both wheels rotate by 5 to 6 cm (1.97
                                                                    to 2.36 in)and stop.




 4. Hold the right wheel with a forward torque applied.
   Confirm the left wheel is free when the center-cam
   and the left driven clutch are disengaged by
                                                                 7. Hold the left wheel with a torque forward applied.
   rotating the left wheel rearward.
                                                                    Confirm the right wheel is free when the
   Example: Left turn with the engine brake effective.              center-cam and the right driven clutch are
                                                                    disengaged by rotating the right wheel rearward.

                                                                 Example: Right turn with the engine brake effective.




                                                            57       W563-0053E
                                    Test for No-spin differential


 8. After that, rotate both wheels backward until they        2. Test by traveling
    stop and hold the left wheel. Confirm the right
    wheel is free when the right wheel is rotated             [NOTICE]
    forward.                                                   Perform this test on a flat and dry paved road.

                                                               1. Before starting the test, make sure the radii of the
                                                                      right and left tires are equal.

                                                               2. Select the four-wheel drive, front wheel steering
                                                                  mode.

                                                               3. Drive the vehicle slowly in forward gear with the
                                                                 steering wheel kept turned fully to the right.

     Example: Left turn with the engine running.               4. Do the same motion with the steering wheel kept
                                                                    turned fully to the left.

                                                               5. Repeat the same test by driving the vehicle in
                                                                  reverse gear.

                                                              Judgment
                                                               Normal:
                                                               The outer wheel rotates faster than the inner wheel
                                                               when turning a corner.
                                                               Abnormal:
                                                               Loud continuous noise is heard.
Judgment
                                                               Tires drag.
 When the no-spin differential is assembled normally,
 the center-cam and the driven clutch of the rotated
 wheel side are disengaged manually and the wheel
 becomes free.                                                3. Abnormal conditions during traveling
 After that, reverse the wheel rotation or loosen the
 holding wheel , the spider and the driven clutch                 If the following conditions appear, disassemble
 engage each other again.                                           the differential for inspection.
 Then the spider and driven clutch become engaged
 with each other when the wheel rotation is reversed           1. Impulsive noises are frequently heard.
 or the wheel held tight are let loose.
                                                               2. Only one wheel tends to spin.

                                                               3. Vehicle tends to be pulled to one side during
                                                                 traveling straight.

                                                               4. Different feeling between the right turn and the
                                                                   left turn.

                                                               5. Vehicle can not turn a corner or understeers.
                                                                  (A large turning radius is needed)




                                                                                                        363-815-80000   △
                                                                                                                        0

                                                                                                        363-815-90000   △
                                                                                                                        0




                                                         58        W563-0053E
Head Office     Ko-34,Sinden-cho, Takamatsu, Japan


Overseas Service Group
                Tadano Ryogoku Bldg.
                4-12, Kamezawa 2-chome,
                Sumida-ku,
                Tokyo, Japan
                Tel.    81 (3) 3621-7765
                Tel fax 81 (3) 3621-7785




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